Method of coating catalyst on flat or textured substrate

Abstract

According to the invention there is a method of applying a catalyst layer to a surface, the method comprising the steps of providing a donor substrate having opposing first and second surfaces, and providing a catalyst ink disposed as a layer on the second surface, where the catalyst ink comprises a catalyst and a solvent; providing a recipient substrate, wherein the second surface of the donor substrate faces the recipient substrate; and irradiating the catalyst ink with laser radiation at a wavelength absorbed by the catalyst ink to transfer the catalyst ink from the donor substrate to the acceptor substrate.

Description

Technical Field

[0001] This invention relates to a method for preparing a catalyst layer on a flat and / or textured surface, such as a reformer catalyst plate for a solid oxide fuel cell (SOFC). The reformer catalyst interconnect plate converts methane, natural gas, or biofuel into hydrogen, which is then used to generate electricity within the SOFC. The invention also relates to a method for manufacturing a flat and / or textured surface for catalyst coating, and the associated catalyst layer and substrate for the catalyst coating, such as an interconnect plate manufactured using such a method. Background Technology

[0002] Substrates for catalyst coating (such as metal plates) can be used in a variety of applications, including fuel cells and electrolyzers. Conventional methods for catalyst coating include spraying and ultrasonic spraying. However, such methods have limited ability to control coating location and layer thickness, to coat the catalyst in a unique pattern, to coat a flat or textured surface, and they can also lead to catalyst waste through overspraying. With the expanding applications of catalyst-coated plates, it is desirable to correct these shortcomings of conventional coating methods. The method and related products of the present invention address these needs by providing more precise control over coating location, coating layer thickness, coating in a predetermined pattern, coating with enhanced resolution, coating a flat or textured surface, and reducing catalyst waste. Summary of the Invention

[0003] According to some aspects of the invention, a method of applying a catalyst layer to a surface includes the steps of: providing a donor substrate having opposite first and second surfaces; providing a catalyst ink disposed as a layer on the second surface, wherein the catalyst ink comprises a catalyst and a solvent; providing an acceptor substrate, wherein the second surface of the donor substrate faces the acceptor substrate; and irradiating the catalyst ink with laser radiation at a wavelength absorbed by the catalyst ink to transfer the catalyst ink from the donor substrate to the acceptor substrate. The method may further include the step of drying the catalyst ink on the acceptor substrate to substantially remove all solvent. In some aspects, the catalyst comprises a reformer catalyst.

[0004] In some aspects, the receptor substrate includes a non-planar surface, a textured surface, a surface with raised and recessed segments, a surface with pits, and / or a surface with ridges. In some aspects, the receptor substrate includes a flat surface.

[0005] In some respects, the acceptor substrate includes plates for solid oxide fuel cells.

[0006] In some aspects, the catalyst ink is applied to the textured surface with a uniform coating thickness. In some aspects, the catalyst ink is applied to the textured surface with a predetermined non-uniform coating thickness. The catalyst ink can be applied to the acceptor substrate in a predetermined pattern, and in some aspects, it can be applied in a predetermined pattern corresponding to the texture of the acceptor substrate surface. In some aspects, the catalyst layer includes at least one region having a first thickness and at least one region having a second thickness, wherein the first thickness is different from the second thickness.

[0007] In some aspects, the receptor substrate has a textured surface including recessed surfaces and raised surfaces, wherein the catalyst ink is applied to the receptor substrate in a predetermined pattern corresponding to the texture of the receptor substrate surface, such that the recessed surfaces are coated and the raised surfaces are not coated.

[0008] The solvent may have a boiling point of at least 80°C, at least 95°C, at least 100°C, or at least 110°C. The solvent may include, for example, water, ethanol, n-propanol, isopropanol, n-butanol, methanol, ethylene glycol, propylene glycol, dipropylene glycol, poly(ethylene glycol), poly(propylene glycol), ethylene carbonate, propylene carbonate, diethyl carbonate, dimethyl carbonate, or combinations thereof. In some aspects, the solvent is essentially composed of water.

[0009] 19. The method according to any one of the preceding claims, wherein the catalyst ink comprises at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 40% by weight, or at least 50% by weight of the catalyst ink based on the total weight of the catalyst ink.

[0010] In some respects, the catalyst layer has a substantially uniform catalyst loading. In other respects, the catalyst layer may have a substantially non-uniform catalyst loading.

[0011] According to some aspects of the invention, the catalyst layer can be obtained using the methods described herein. According to some aspects of the invention, the catalyst-coated plate can be obtained using the methods described herein. Attached Figure Description

[0012] Figure 1 It is an image showing a flat metal surface with a catalyst layer applied using a LIFT digital printing system (“laser-induced forward transfer”).

[0013] Figure 2It is an image showing a shallowly concave aluminum surface with four catalyst layers applied using the LIFT system.

[0014] Figure 3 It is an image showing a shallowly concave aluminum surface with four catalyst layers applied using the LIFT system.

[0015] Figure 4 It is an image showing the surface of a paper with a catalyst layer applied using the LIFT system.

[0016] Figure 5 It is an image showing a metal surface with a catalyst layer applied using the LIFT system.

[0017] Figure 6 It is an image showing a metal surface with four catalyst layers applied using the LIFT system.

[0018] Figure 7 Four patterns are shown that will be applied as catalyst layers.

[0019] Figure 8 It is an image showing a metal surface with four catalyst layers applied using the LIFT system. Detailed Implementation

[0020] Preferred and / or optional features of the invention will now be set forth. Unless the context otherwise requires, any aspect of the invention may be combined with any other aspect of the invention. Unless the context otherwise requires, any preferred or optional feature of any aspect may be combined with any aspect of the invention, alone or in combination.

[0021] The method of the present invention relates to applying a catalyst layer to a surface. In some aspects, the present invention provides a method for preparing a catalyst layer for use in electrochemical devices such as fuel cells or electrolyzers. In some aspects, the present invention relates to preparing a catalyst layer for use in an internal reformer interconnect plate within a solid oxide fuel cell (“SOFC”). The catalyst can be applied to a substrate (such as an interconnect plate) using digital methods as described herein, wherein catalyst ink can be applied in a predetermined pattern, and the thickness of the layer can be more easily controlled than with conventional catalyst application methods. In some aspects, the method of the present invention relates to applying a reformer catalyst to an interconnect plate to be used within an SOFC stack. Such a catalyst can convert methane or natural gas into hydrogen (and CO2), enabling the SOFC plate within the stack to generate electricity. In other aspects, the method can be used, as needed, to prepare an anode catalyst layer and / or a cathode catalyst layer. The method includes the use of a laser-induced forward transfer (LIFT) process. The method of the present invention can be performed using, for example, the equipment described in WO2019 / 145300.

[0022] The method includes the step of providing a donor substrate having opposite first and second surfaces. The donor substrate is preferably permeable to laser radiation; that is, the absorption of laser radiation by the donor substrate is substantially negligible. The donor substrate is an ink carrier, such as a recirculating strip. A catalyst ink layer is provided as a layer on the donor substrate. The catalyst ink can be applied to the donor substrate using an ink delivery unit. Preferably, the catalyst ink is applied in layers to substantially uniformly coat the donor substrate on the second surface. The catalyst ink layer on the second surface may have a thickness of 100 μm or less, preferably 75 μm or less, preferably 50 μm or less, more preferably 30 μm or less, and most preferably 25 μm or less. The catalyst ink layer disposed on the second surface of the donor substrate may have a thickness of 10 μm or more, 15 μm or more, or 20 μm or more. The thickness of the catalyst ink layer disposed on the second surface of the donor substrate can be in any combination of the aforementioned ranges, for example, in the range of about 10 μm to 100 μm, preferably about 15 μm to 75 μm, preferably about 20 μm to 50 μm.

[0023] The method also includes the step of providing a recipient substrate, wherein a second surface of the donor substrate faces the recipient substrate. The second surface of the donor substrate and the recipient substrate are typically separated by a gap. The gap can be a distance of about 2 mm or less, 500 μm or less, 300 μm or less, or 200 μm or less. In some aspects, the gap can be a distance of about 200 μm to 400 μm. When the recipient substrate includes an uneven surface, the gap refers to the distance between a surface of the donor substrate and the nearest surface or portion thereof of the recipient substrate. In some aspects, the recipient substrate comprises a sheet of metal, such as aluminum or stainless steel. The recipient substrate may include, for example, an interconnect plate, such as for SOFC.

[0024] The method further includes the step of irradiating the catalyst ink (located on the donor substrate) with laser radiation to transfer the catalyst ink from the donor substrate to the acceptor substrate. Preferably, the catalyst ink is irradiated with laser radiation pulses. The laser radiation can be directed through a first surface of the donor substrate to be projected onto the catalyst ink, preferably at or near the interface between the catalyst ink and a second surface of the donor substrate. The catalyst ink absorbs the laser radiation. In some aspects, the catalyst ink may include absorption promoters, such as receptor particles or effect pigments, to promote efficient absorption of the laser radiation. Receptor particles may be metals, metal oxides, carbon, or other suitable particles of appropriate size, preferably up to 1 μm in diameter, more preferably up to 5 μm in diameter. Receptor particles can be selected so as not to impede the function of the catalyst particles, and more preferably to promote catalytic function, i.e., as a carrier material for the catalyst particles. WO2019 / 145300 describes the use of effect pigments and is incorporated herein by reference.

[0025] The laser can be controlled at an appropriate power for the catalyst ink, for example, from about 100W to about 500W. Laser radiation heats the catalyst ink in a target localized area to evaporate a portion of the ink within that area. This process induces droplets of the catalyst ink to be ejected from the donor substrate to the acceptor substrate. That is, droplets of the catalyst ink are transferred precisely from a second surface of the donor substrate to the acceptor substrate. In some respects, if the gap between the donor and acceptor substrates is sufficiently narrow, the catalyst ink can contact both substrates simultaneously, where the adhesive / wetting forces of the droplets on the acceptor substrate and the relative motion between the donor and acceptor substrates cause the breakage of the catalyst ink bond.

[0026] The acceptor substrate can be conveyed beneath the laser to deposit a catalyst layer onto a desired area of ​​the acceptor substrate. As the acceptor substrate passes beneath it, the catalyst layer is deposited on the acceptor substrate based on the location where the laser is programmed to be excited. Laser power and acceptor substrate speed can each be used to control the transfer of catalyst ink to the acceptor substrate. Increasing laser power increases catalyst deposition per layer, while decreasing laser power decreases catalyst deposition per layer. Decreasing conveyor / acceptor substrate speed increases catalyst deposition per layer, while increasing conveyor / acceptor substrate speed decreases catalyst deposition per layer. This ability to arbitrarily change the area, design, and thickness of the catalyst layer without requiring new tools offers significant benefits.

[0027] Furthermore, the ability of the catalyst ink to absorb laser radiation can also affect its transfer. Therefore, controlling the concentration of the absorption promoter can effectively limit the amount of catalyst ink deposited; a higher concentration of absorption promoter in the catalyst ink can increase catalyst deposition, while a lower concentration can reduce it. For example, with the laser power and acceptor-substrate velocity kept constant, variable concentrations of absorption promoter in the catalyst ink will result in different amounts of catalyst deposition on the acceptor-substrate.

[0028] The method may also include a step of drying the catalyst ink on the acceptor substrate to substantially remove all solvents. This drying step may include heating the acceptor substrate to a temperature suitable for drying the catalyst ink. A suitable temperature can be determined by a number of factors, including the composition of the catalyst ink, the volume of the deposited catalyst ink, and the efficiency of heating the acceptor substrate. In some aspects, the drying step may include heating the acceptor substrate to a temperature of at least 40°C, at least 50°C, at least 60°C, at least 70°C, at least 80°C, at least 90°C, or at least 100°C.

[0029] This method (optionally including a drying step) can be repeated as needed to prepare a catalyst layer with a desired thickness and / or desired catalyst loading. The catalyst layer may have a substantially uniform thickness. The catalyst layer may have a (dried) thickness of at least 1 μm, at least 2 μm, or at least 3 μm. The catalyst layer may have a (dried) thickness of 70 μm or less, 60 μm or less, 50 μm or less, 30 μm or less, 20 μm or less, or 15 μm or less. The catalyst layer may have a (dried) thickness within any combination of the aforementioned lower and upper limits. In some embodiments, the catalyst layer may have a substantially non-uniform thickness, or may be pre-patterned. In such cases, the catalyst layer may include at least one first region having a first thickness and at least one second region having a second thickness, wherein the first thickness differs from the second thickness. In some embodiments, the catalyst layer may include at least one region having a first thickness and at least one region with no thickness (i.e., an area where the catalyst ink has not been transferred). In some respects, the minimum layer thickness is limited by the particle size distribution of the catalyst ink; that is, the thickness of the catalyst layer will not be less than the maximum particle size in the catalyst ink. The first thickness can be at least 1 μm, at least 2 μm, or at least 3 μm. The first thickness can be 50 μm or less, 30 μm or less, 20 μm or less, or 15 μm or less. The second thickness can be ≥0 μm, at least 1 μm, at least 2 μm, or at least 3 μm. The second thickness can be less than 50 μm or less, 30 μm or less, 20 μm or less, 15 μm or less, or 5 μm or less. The first and second thicknesses can each fall within any combination of the aforementioned lower and upper limits.

[0030] A suitable acceptor substrate can be selected for the desired environment. In some aspects, the acceptor substrate includes plates, such as metal plates, such as interconnect plates for SOFCs. In other aspects, the plate can be coated as a reformer catalyst in an SOFC.

[0031] In some aspects, the catalyst layer may be deposited in a predetermined pattern on a acceptor substrate having a flat surface. In other aspects, the catalyst layer may be deposited in a predetermined pattern on a acceptor substrate having a non-flat surface. The non-flat acceptor substrate surface may include a textured surface, such as a surface having raised segments and / or recessed segments. For clarity, the terms raised and recessed are used to describe the position of surface segments relative to each other. Examples of non-flat acceptor substrate surfaces may include ridged or shallowly concave surfaces. Suitable non-flat acceptor substrates may include raised segments and recessed segments forming repeating patterns. Suitable non-flat acceptor substrates may also include raised segments and recessed segments that do not form repeating patterns.

[0032] In some aspects, the catalyst layer can be deposited in a predetermined pattern corresponding to the texture of the receptor substrate surface. For example, the catalyst layer can be deposited such that it is deposited on recessed segments of the receptor substrate surface, but not on raised segments. In some aspects, the catalyst layer can be deposited such that it is deposited on raised segments of the receptor substrate surface, but not on recessed segments. In another example, the catalyst layer can be deposited such that it is deposited in one amount on raised segments of the receptor substrate surface and in different amounts on recessed segments. In yet another example, the catalyst layer can be deposited such that, in a separate process, one type of catalyst is deposited on raised segments of the receptor substrate surface, and different catalysts are deposited on recessed segments.

[0033] This method (optionally including a drying step) can be repeated as needed to prepare a catalyst layer with the desired catalyst loading. The plate can optionally be calcined therebetween to decompose any ligands, salts, or organic matter present in the catalyst coating. Suitable calcination temperatures can be from about 350°C to about 750°C, or from about 450°C to about 650°C.

[0034] The catalyst layer can have a substantially uniform catalyst loading. The catalyst layer can have a loading of 0.0001 g / cm³. 2 Up to 0.1 g / cm 2 Or 0.001g / cm 2 Up to 0.01 g / cm 2 The catalyst loading is within a certain range. In some embodiments, the catalyst layer may have a substantially non-uniform catalyst loading (e.g., as a gradient in the catalyst layer) or be deposited in a predetermined pattern (e.g., a continuous trajectory with a serpentine path). In such cases, the catalyst layer may include at least one first region having a first catalyst loading and at least one second region having a second catalyst loading, wherein the first catalyst loading differs from the second catalyst loading. In some embodiments, the catalyst layer may include at least one region having a first catalyst loading and at least one region with a zero catalyst loading (i.e., a region where the catalyst ink has not been transferred). The first catalyst loading may be at 0.001 g / cm³. 2 Up to 0.1 g / cm 2 Within the range. The second thickness can be ≥0 g / cm. 2 to <0.1g / cm 2 Within the range.

[0035] Suitable catalyst inks for use in the methods of the present invention include any catalyst ink having the desired catalyst properties. In one aspect, suitable catalyst inks comprise reformer catalysts for SOFCs. In another aspect, suitable catalyst inks are those used to manufacture catalyst layers for electrochemical devices, such as anodes, cathodes, and electrolytes in fuel cells and electrolyzers.

[0036] The catalyst used will depend on the reaction it is intended to catalyze, and its selection is within the capabilities of those skilled in the art. The catalyst may be a reformer catalyst, such as a reformer catalyst used in SOFCs. The catalyst may comprise catalytic particles (e.g., metal-containing particles, such as a first metal, an alloy of a first metal, or oxides thereof), which are preferably dispersed or otherwise supported on a particulate support material. The particulate support material may comprise metal oxides, such as alumina, silica, silica-alumina, cerium dioxide, or combinations thereof.

[0037] The catalyst particles are appropriately selected from:

[0038] (i) Platinum group metals (platinum, palladium, rhodium, ruthenium, iridium and osmium);

[0039] (ii) Gold or silver;

[0040] (iii) Base metals;

[0041] (iv) Rare earth metals and / or rare earth metal oxides; or

[0042] (v) An alloy or mixture containing one or more of these metals or their oxides.

[0043] Base metals are transition metals that are not noble metals. Noble metals are platinum group metals (platinum, palladium, rhodium, ruthenium, iridium, or osmium) or gold. Preferred base metals are copper, cobalt, nickel, zinc, iron, titanium, molybdenum, vanadium, manganese, niobium, tantalum, chromium, and tin. Rare earth metals are scandium, yttrium, and lanthanides, such as, but not limited to, lanthanum and cerium.

[0044] Reformer catalysts are known in the art, for example, WO 2004 / 047985 and GB2424196, each of which is incorporated herein by reference. In some aspects, suitable reformer catalysts may comprise platinum group metals or alloys of platinum group metals, preferably having one or more rare earth metals. The metals are preferably dispersed or otherwise supported on a particulate support material comprising metal oxides, such as alumina. Catalyst inks containing reformer catalysts may include other components that may be necessary for the use of the catalyst inks in LIFT systems, such as cellulose polymers and carbon particle slurries in water. Cellulose polymers may be included as membrane enhancers and / or as rheology modifiers. Carbon may be included as laser absorption promoters or contrast agents. Such additives are further described in US 2020 / 0369064, which is incorporated herein by reference.

[0045] When the catalyst comprises catalytic particles supported on a support, the catalytic particles (i.e., metal-containing particles) may have a density of no more than 50 nm, no more than 30 nm, no more than 20 nm, preferably no more than 10 nm, and more preferably no more than 5 nm. 50 Particle size. For example, particles may have a density of at least 1 nm. 50 Particle size. D 50 Particle size was measured by examination using a transmission electron microscope (TEM). 50 The granularity can be within any combination of the aforementioned upper and lower limits.

[0046] The catalyst (i.e., the catalyst particles, and, if present, the support) in the catalyst ink may have a D-size of at least 0.1 μm, at least 0.3 μm, at least 0.5 μm, at least 0.75 μm, at least 1 μm, at least 3 μm, or at least 5 μm. 50 Particle size (or aggregate particle size, as appropriate). The catalyst in the catalyst ink may have a D particle size not exceeding 30 μm, 20 μm, 15 μm, 12 μm, or 8 μm. 50 Particle size (or aggregate size, as applicable). The catalyst may have a D in the range of 0.1 μm to 20 μm, 2 μm to 15 μm, 5 μm to 12 μm, and 3 μm to 8 μm, and inclusivity thereof. 50 Particle size (or aggregate size, depending on the situation). For example, supported catalysts may have a Dsize of approximately 1 μm. 50 Particle size. D 50 Granularity using MalvernMastersizer ™ Measurements are taken using dynamic light scattering.

[0047] The catalyst ink may contain at least 5 wt%, at least 10 wt%, at least 15 wt%, at least 20 wt%, at least 25 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% of catalyst based on the total weight of the catalyst ink. The catalyst ink may contain at least 5 wt%, at least 10 wt%, at least 15 wt%, at least 16 wt%, at least 17 wt%, at least 20 wt%, or at least 25 wt% of total solids content (including metal oxide supports, noble metals, any base metals, transition metals, or rare earth metals and / or any other optional solid additives) based on the total weight of the catalyst ink. The catalyst ink may have a total solids content of less than 50 wt%, less than 40 wt%, or less than 30 wt% based on the total weight of the catalyst ink. The total solids content may be within any combination of the aforementioned lower and upper limits, for example, from 5 wt% to 50 wt%. The method of the present invention can use a wider range of inks, including inks with higher solids content, which, if employing known techniques such as slot die coating, would result in layer defects.

[0048] The solvent may have a boiling point of at least 80°C, at least 95°C, at least 100°C, and at least 110°C. The solvent may include water, an organic solvent, or a mixture of water and an organic solvent. The organic solvent is preferably miscible with water. The organic solvent is preferably a protic polar solvent, such as an alcohol solvent. The organic solvent may be methanol, ethanol, 1-propanol or isopropanol, n-butanol, ethylene glycol, propylene glycol, dipropylene glycol, poly(ethylene glycol), poly(propylene glycol), ethylene carbonate, propylene carbonate, dimethyl carbonate, diethyl carbonate, or any combination thereof. Preferably, the organic solvent is ethanol, n-propanol, isopropanol, ethylene glycol, propylene glycol, ethylene carbonate, propylene carbonate, or any combination thereof. Preferably, the solvent contains water, at least 50% by weight, preferably ≥60% by weight, more preferably ≥70% by weight, more preferably ≥80% by weight, ≥90% by weight, and more preferably 95% by weight, based on the total weight of the solvent. More preferably, the solvent is substantially composed of water or only water. Using a solvent free of volatile organic components reduces the flammability of the ink, resulting in a safer method with less chemical waste. When depositing catalyst inks onto highly hydrophobic substrates, organic solvents are typically added to the ink to help prevent desiccation. The method of the present invention is unexpectedly applicable to printing catalyst inks with solvents that are substantially composed of water (or entirely composed of water) onto a variety of different acceptor substrates, including hydrophobic substrates, while maintaining good catalyst layer properties and structure.

[0049] Compared to catalyst inks suitable for coating techniques known in the art (such as slot die coating, spraying, screen printing, inkjet printing, and gravure printing), the catalyst inks of the present invention can have a much wider range of acceptable rheological properties. For example, the viscosity of the catalyst inks of the present invention at 25°C and 100s... -1 When measured at shear rates, the values ​​can range from at least about 10 cP to about 1,000 cP or less. Furthermore, the method of the present invention does not require ink to pass through the printhead or nozzle. Therefore, the method of the present invention is not affected by printhead or nozzle clogging problems, which can cause machine downtime.

[0050] Examples of typical device setups applicable to the method of the present invention are detailed in Table 1.

[0051] Table 1

[0052]

[0053] Example

[0054] Example 1

[0055] Catalyst inks were prepared and applied to a flat metal surface using a LIFT system as described herein. The catalyst ink properties and LIFT parameters can be adjusted to achieve the desired catalyst layer quality, resolution, and overall quality. The catalyst inks were prepared using the following methods:

[0056] -80.4% reformer catalyst (35% solids, in water)

[0057] -6.7% ethylene glycol

[0058] -12.7% water

[0059] -0.2% carbon

[0060] -0.1% high molecular weight cellulose

[0061] Apply ink to the receptor substrate in a predetermined pattern using the following LIFT parameters:

[0062] -Laser power = 140W

[0063] - Printing distance = 0.2mm

[0064] - Donor layer thickness = 20 μm

[0065] -Base velocity = 8m / min

[0066] - Substrate = 0.1mm flat aluminum sheet

[0067] The catalyst ink is then dried on the substrate. Figure 1 A substrate with an applied catalyst layer is shown.

[0068] Example 2

[0069] The catalyst ink from the formulation of Example 1 was applied to a substrate with a textured surface, particularly a shallowly concave aluminum sheet, using the LIFT system as described herein. The ink was applied to the acceptor substrate using the following LIFT parameters:

[0070] -Laser power = 140W

[0071] - Printing distance = 1mm

[0072] - Donor layer thickness = 20 μm

[0073] -Base velocity = 8m / min

[0074] -Substrate = 0.1mm shallow concave aluminum sheet

[0075] Four layers of catalyst ink were applied to the acceptor substrate. In the first test, the four layers were applied without interlayer drying. Figure 2 The product is shown. In the second test, four layers were applied by interlayer drying using a handheld heat gun between each layer. Figure 3 The product is shown.

[0076] Example 3

[0077] The catalyst ink from the formulation of Example 1 was applied to a substrate comprising high-quality printing paper using the LIFT system as described herein. The ink was applied to the acceptor substrate in a predetermined pattern using the following LIFT parameters:

[0078] -Laser power = 127W

[0079] - Printing distance = 0.2mm

[0080] - Donor layer thickness = 20 μm

[0081] -Base velocity = 8m / min

[0082] -Base = Invercote (high-quality printing paper)

[0083] Figure 4 A substrate with an applied catalyst layer is shown.

[0084] Example 4

[0085] The catalyst ink from the formulation of Example 1 was applied to a substrate comprising an FeCr alloy sheet using the LIFT system as described herein. The ink was applied to the acceptor substrate using the following LIFT parameters:

[0086] -Laser power = 140W

[0087] - Printing distance = 0.2mm

[0088] - Donor layer thickness = 20 μm

[0089] -Base velocity = 8m / min

[0090] - Substrate = 0.1mm FeCr alloy sheet

[0091] Using these parameters, a substrate with a uniformly applied catalyst layer was prepared, such as... Figure 5 As shown. On another acceptor substrate, four uniform catalyst layers were applied by interlayer drying using a handheld heat gun, as... Figure 6 As shown.

[0092] Example 5

[0093] Catalyst inks were prepared using the following formulations:

[0094] -80% alumina carrier coating (28% solids, in water)

[0095] -19.7% water

[0096] -0.2% carbon

[0097] -0.1% cellulose ether

[0098] The catalyst ink was applied to a substrate comprising an FeCr alloy sheet using the LIFT system as described herein. The ink was applied to the acceptor substrate using the following LIFT parameters:

[0099] -Laser power = 180W

[0100] - Printing distance = 0.2mm

[0101] - Donor layer thickness = 18 μm

[0102] -Base velocity = 8m / min

[0103] - Substrate = 0.1mm FeCr alloy sheet

[0104] Four layers of catalyst ink were applied to the acceptor substrate; the pattern of each layer corresponded to, for example... Figure 7 The four images shown (one image = one layer) are applied sequentially from left to right and from first to last. Subsequent layers are overlaid on top of previous layers. The finished product is... Figure 8 The image shows precise ink placement through its pixel density.

Claims

1. A method for applying a catalyst layer to a surface, the method comprising the steps of: A donor substrate having opposite first and second surfaces is provided, and a catalyst ink is provided as a layer disposed on the second surface, wherein the catalyst ink comprises a catalyst and a solvent; A receptor substrate is provided, wherein the second surface of the donor substrate faces the receptor substrate; as well as The catalyst ink is irradiated with laser light at a wavelength absorbed by the catalyst ink in order to transfer the catalyst ink from the donor substrate to the acceptor substrate.

2. The method of claim 1, wherein the method further comprises the step of drying the catalyst ink on the acceptor substrate to substantially remove all of the solvent.

3. The method according to any one of the preceding claims, wherein the catalyst comprises a reformer catalyst.

4. The method according to any one of the preceding claims, wherein the receptor substrate comprises a non-planar surface.

5. The method according to any one of the preceding claims, wherein the receptor substrate comprises a textured surface.

6. The method according to any one of the preceding claims, wherein the receptor substrate comprises a surface having raised sections and recessed sections.

7. The method according to any one of the preceding claims, wherein the receptor substrate comprises a surface having pits.

8. The method according to any one of the preceding claims, wherein the receptor base comprises a surface having ridges.

9. The method according to any one of the preceding claims, wherein the acceptor substrate comprises a plate for a solid oxide fuel cell.

10. The method of claim 5, wherein the catalyst ink is applied to the textured surface with a uniform coating thickness.

11. The method of claim 5, wherein the catalyst ink is applied to the textured surface with a predetermined non-uniform coating thickness.

12. The method according to any one of the preceding claims, wherein the catalyst ink is applied to the receptor substrate in a predetermined pattern.

13. The method according to any one of the preceding claims, wherein the catalyst ink is applied to the receptor substrate in a predetermined pattern corresponding to the texture of the receptor substrate surface.

14. The method according to any one of claims 1 to 9 or 11 to 13, wherein the catalyst layer comprises at least one region having a first thickness and at least one region having a second thickness, wherein the first thickness is different from the second thickness.

15. The method according to any one of the preceding claims, wherein the receptor substrate has a textured surface including a concave surface and a convex surface, and wherein the catalyst ink is applied to the receptor substrate in a predetermined pattern corresponding to the texture of the surface of the receptor substrate, such that the concave surface is coated and the convex surface is not coated.

16. The method according to any one of the preceding claims, wherein the receptor substrate has a textured surface including recessed surfaces and raised surfaces, and wherein the catalyst ink is applied to the receptor substrate in a predetermined pattern corresponding to the texture of the surface of the receptor substrate, such that the raised surfaces are coated and the recessed surfaces are not coated.

17. The method according to any one of claims 1 to 3, 9 or 12, wherein the receptor substrate comprises a flat surface.

18. The method according to any one of the preceding claims, wherein the solvent has a boiling point of at least 80°C, at least 95°C, at least 100°C, or at least 110°C.

19. The method according to any one of the preceding claims, wherein the solvent comprises water, ethanol, n-propanol, isopropanol, n-butanol, methanol, ethylene glycol, propylene glycol, dipropylene glycol, poly(ethylene glycol), poly(propylene glycol), ethylene carbonate, propylene carbonate, diethyl carbonate, dimethyl carbonate, or combinations thereof.

20. The method of claim 17, wherein the solvent is substantially composed of water.

21. The method according to any one of the preceding claims, wherein the catalyst ink comprises at least 5% by weight, at least 10% by weight, at least 15% by weight, at least 20% by weight, at least 25% by weight, at least 30% by weight, at least 40% by weight, or at least 50% by weight of the catalyst ink based on the total weight of the catalyst ink.

22. The method according to any of the preceding claims, wherein the catalyst layer has a substantially uniform catalyst loading.

23. The method according to any one of claims 1 to 21, wherein the catalyst layer has a substantially non-uniform catalyst loading.

24. A catalyst layer obtained using the method according to any of the preceding claims.

25. A catalyst-coated plate, the catalyst-coated plate comprising the catalyst layer according to claim 24.

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