Production of a high-performance fuel cell electrode with core-shell catalyst

Abstract

Method for forming a fuel cell catalyst, the method encompassing a) Formation of an ionomer-containing layer including carbon particles and an ionomer; b) Formation of tungsten-nickel alloy particles on the carbon particles, wherein the tungsten-nickel alloy particles are electrochemically formed from a solution containing a nickel-containing salt and a tungsten-containing salt; c) Replacing at least some of the nickel in the tungsten-nickel alloy particles with palladium to form palladium-coated particles, such that the palladium-coated particles have a palladium shell covering the tungsten-nickel alloy particles; and d) Coating the palladium-coated particles with platinum to form an electrode layer, including core-shell catalysts distributed therein.

Description

TECHNICAL FIELD

[0001] In at least one embodiment, the present invention relates to layers of fuel cell catalysts. BACKGROUND

[0002] Fuel cells are used as a source of electrical energy in many applications. In particular, there are plans to use fuel cells in automobiles as a replacement for internal combustion engines. A commonly used fuel cell design uses a solid polymer electrolyte ("SPE") membrane or a proton exchange membrane ("PEM") for ion transport between the anode and cathode.

[0003] In proton exchange membrane fuel cells, hydrogen is supplied to the anode as fuel and oxygen is supplied to the cathode as an oxidant. The oxygen can be used either in pure form (O2) or as air (a mixture of O2 and N2). PEM fuel cells typically feature a membrane electrode assembly ("MEA") in which a solid polymer membrane has an anode catalyst on one side and a cathode catalyst on the opposite side. The anode and cathode layers of a typical PEM fuel cell are formed from porous conductive materials, such as woven graphite, graphitized sheets, or carbon paper, to allow the fuel to disperse over the surface of the membrane facing the fuel supply electrode.Each electrode has finely divided catalyst particles (e.g., platinum particles) supported by carbon particles, which promote the oxidation of hydrogen at the cathode and the reduction of oxygen at the anode. Protons flow from the anode through the ionically conductive polymer membrane to the cathode, where they combine with oxygen to form water, which is exhausted from the cell. The MEA is sandwiched between a pair of porous gas diffusion layers ("GDL"), which in turn are sandwiched between a pair of non-porous, electrically conductive elements or plates called flow field plates. The plates act as current collectors for the anode and cathode, and contain suitable channels and orifices formed therein for distributing the fuel cell's gaseous reactants over the surface of the respective anode and cathode catalysts.To produce electricity efficiently, the polymer electrolyte membrane of a PEM fuel cell must be thin, chemically stable, proton-permeable, electrically non-conductive, and gas-impermeable. In typical applications, fuel cells are arranged in arrays of many individual fuel cell stacks to provide high electrical power.From US 2010 / 0197490 A1, a process for producing core-shell catalyst particles for fuel cell electrodes is known, in which a powder of nickel-gold mixture particles supported on carbon particles is obtained from an aqueous suspension of nickel chloride, gold chloride and carbon powder by reduction with sodium borohydride, which is then heated under a hydrogen atmosphere so that nickel particles coated with gold (NiAu / C) are formed by the separation of the gold portion on the particle surface, whereupon a copper layer is temporarily deposited on the gold surface, which is then displaced by platinum by immersion in K2PtCl4 solution (NiAuPt / C).

[0004] The preparation of conventional, highly active fuel cell catalysts involves the deposition of Pt and other metals on a carbon black support, heat treatment, acid treatment, and multiple cycles of washing, filtration, and drying. In many cases, they also use organic solvents, acids, or harsh chemicals, requiring waste management. These processes increase the cost of catalyst production. Recently, catalysts have been prepared using a method that involves electroplating WNi nanoparticles directly onto the MPL layer of the GDL in an aqueous solution. No heat treatment or organic solvent is required. However, although ORR activity and stability were promising, fuel cell performance was poor due to poor catalyst dispersion across the electrode thickness.

[0005] Accordingly, there is a need for improved processes for highly active fuel cell catalysts. SUMMARY

[0006] The present invention solves one or more of the problems of the prior art by providing a method for producing a fuel cell catalyst. The method comprises a step of forming an ionomer-containing layer including carbon particles and an ionomer. Tungsten-nickel alloy particles are electrochemically formed on the carbon particles from a solution containing a nickel-containing salt and a tungsten-containing salt. At least a portion of the nickel in the tungsten-nickel alloy particles is replaced with palladium to form palladium-coated particles. The palladium-coated particles include a palladium shell covering the tungsten-nickel alloy particles. The palladium-coated particles are coated with platinum to form an electrode layer including core-shell catalysts dispersed therein.

[0007] In one embodiment, a method for producing a fuel cell catalyst is provided. The method comprises a step of forming an ionomer-containing layer including carbon particles and an ionomer. Tungsten-nickel alloy particles are electrochemically formed on the carbon particles from a solution including a nickel-containing salt and a tungsten-containing salt. At least a portion of the nickel in the tungsten-nickel alloy particles is replaced with palladium using a galvanic displacement reaction. In this reaction, the tungsten-nickel alloy particles are contacted with a palladium-containing solution to form palladium-coated particles.The palladium-coated particles are coated with platinum to form an electrode layer including core-shell catalysts dispersed therein, wherein the palladium-coated particles are coated with platinum by depositing copper onto the palladium-coated particles and then replacing at least a portion of the copper with platinum. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic representation of a fuel cell system including an embodiment of a carbon bipolar plate; and Fig. 2A and Fig. 2B are schematic flow diagrams showing the formation of core-shell catalyst particles and their introduction into a fuel cell; and Fig. Figure 3 is a schematic representation of a roll-to-roll manufacturing system for forming the core-shell catalyst particles. DETAILED DESCRIPTION

[0008] Described in detail are presently preferred compositions, embodiments, and methods of the present invention, illustrating the best modes presently known to the inventors for carrying out the invention. The figures are not necessarily to scale. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Accordingly, the specific details discussed herein are not to be construed as limitations, but merely as a basis for teaching the various aspects of the invention or as a basis for teaching those skilled in the art its various applications.

[0009] Except as used in the examples or where expressly stated, all numerical references to amounts of material or conditions of reaction or use in this specification are to be understood as being modified by the suffix "about" so as to reflect the widest possible scope of the invention. Practical application within the specified numerical limits is generally preferred. Furthermore, unless expressly stated otherwise, percent, "parts," and ratios are by weight. When a group or class of materials is described as suitable or preferred for a particular purpose in connection with the invention, it is meant that mixtures of two or more members of the group or class are to be understood as equally suitable or preferred.The description of components in chemical terms refers to the components as added to any combination specified in the description and does not necessarily preclude chemical interactions between the components of a mixture once mixed. The first definition of an acronym or other abbreviation refers to all subsequent uses of the same abbreviation and applies, mutatis mutandis, to normal grammatical variations of the initially defined abbreviation. Finally, unless explicitly stated otherwise, a property is measured using the same technique as previously or subsequently stated for the same property.

[0010] It should also be understood that this invention is not limited to the specific embodiments and methods described below, as specific components and conditions may, of course, vary. Otherwise, the terminology used herein is for the purpose of describing various embodiments of the present invention and is not intended to be limiting in any way.

[0011] It is further noted that, as used in the specification and the appended claims, the singular forms "a" and "an" and "the" include the plural, unless the context clearly indicates otherwise. For example, reference to a singular component is intended to encompass a plurality of components.

[0012] Publications referred to in the application are deemed to be incorporated in this application in their entirety by citing a reference in order to more accurately describe the prior art to which this invention relates.

[0013] Fig. Figure 1 is a schematic cross-section of a fuel cell incorporating one embodiment of a grafted porous membrane. Proton exchange membrane fuel cell 10 includes a polymeric ion-conducting membrane 12 disposed between cathode catalyst layer 14 and anode catalyst layer 16. The combination of ion-conducting membrane 12, cathode catalyst layer 14, and anode catalyst layer 16 forms a metal electrode assembly. Fuel cell 10 also includes flow field plates 18, 20, gas channels 22 and 24, and gas diffusion layers 26 and 28. Typically, gas diffusion layers 26 and 28, respectively, contain microporous layers 30, 30' disposed over the surface of a diffusion material in the gas diffusion layers. The microporous layers 30 and 30' contact the cathode catalyst layer 14 and the anode catalyst layer 16. In a more precise definition, the flow field plates 18, 20 are bipolar plates.Typically, flow-field plates are electrically conductive and are therefore formed from a metal, such as stainless steel. In other specific embodiments, the flow-field plates are formed from an electrically conductive polymer. Advantageously, the flow-field plates 18, 20 are coated with a carbon coating, and in particular with a graphene-containing or carbon nanotube-containing coating, as explained in more detail below. Hydrogen ions generated by the anode catalyst layer 16 migrate through the polymeric ion-conducting membrane 12, where they react on the cathode catalyst layer 14 and become water. This electrochemical process generates an electric current through a load connected to the flow-field plates 18 and 20.

[0014] Fig. Figure 2 is a schematic representation of a process for forming fuel cell catalysts. In step a), an ionomer-containing layer 32 is first deposited onto the substrate 34. Substrates suitable for fuel cell applications include gas diffusion layers (GDLs), microporous layers, and ion exchange membranes. Fig. Figure 2 shows an example with an ionomer-containing layer 32 layered on a microporous layer 38, which is layered on the gas diffusion material 40. Gas diffusion material may include carbon fibers and / or carbon powder held together with a binder. The gas diffusion material has sufficient porosity to allow the reaction gases (e.g., hydrogen and air) to pass through. The microporous layer 38 may also include carbon fibers and / or carbon powder bonded with a binder (e.g., TEFLON ®) are held together. Typically, layer 32 is formed by coating an ink composition onto substrate 34, followed by drying. Layer 32 therefore comprises an ionomeric matrix 44 with carbon particles 46 dispersed therein. A slot die may be used for this coating step. Such ink compositions include ionomer and carbon particles. Suitable carbon particles include, but are not limited to, carbon black. Examples of ionomers include, but are not limited to, perfluorosulfonic acid polymers such as NAFION®. In one variation, the carbon particles are prefabricated with tungsten metal, and more particularly, tungsten metal particles 48, supported thereon. Typically, the thickness of layer 32 is 3-20 micrometers. In another refinement, the thickness of layer 32 is 8-15 micrometers, or about 10 micrometers.

[0015] In step b), tungsten-nickel alloy particles 50 are formed on the carbon particles. If the carbon particles were preformed with tungsten particles thereon, the tungsten particles act as nuclei that promote the formation of tungsten-nickel alloy particles and thereby improve the dispersion of the tungsten-nickel alloy particles throughout the thickness of the layer. In a refinement, the tungsten-nickel alloy particles are formed by an electrochemical process. Tungsten-nickel alloy particles are typically formed electrochemically from a solution containing a nickel-containing salt and a tungsten-containing salt. Examples of nickel-containing salts include NiSO4 and (Ni)3(PO4)2. Examples of tungsten-containing salts include metal tungstates, such as Na2WO4. The tungsten-nickel alloy is formed electrochemically using a constant current or, alternatively, using multiple current pulses.

[0016] In step c), at least a portion of the nickel in the tungsten-nickel alloy particles 50 is replaced with palladium to form palladium-coated particles 54, such that the palladium-coated particles have a palladium shell 56 covering the tungsten-nickel alloy particles 50 supported on the carbon particles 44. In a refinement, the tungsten-nickel alloy is at least partially replaced with palladium using a galvanic displacement reaction. In this reaction, the tungsten-nickel alloy particles are brought into contact with a palladium-containing solution to form palladium-coated particles. Such palladium-containing solutions are formed by dissolving a palladium-containing compound (e.g., a salt) in a suitable solvent (e.g., water, alcohol, etc.).

[0017] In step d), the palladium-coated particles 54 are coated with platinum to form an electrode layer, including core-shell catalysts 64 distributed therein. In one variant, the palladium-coated particles are coated with platinum by depositing copper on the palladium-coated particles and then replacing at least a portion of the copper with platinum. In a refinement, the copper is formed electrochemically. In a particularly useful variant, the palladium-coated particles are coated with platinum from a solution containing a platinum-containing salt and a salt-containing copper. In this variant, a potential is applied to the palladium-coated particles for a first period of time (e.g., 0.5-2 seconds) to form the copper on the palladium-coated particles, after which at least a portion of the copper is replaced with platinum.An open cycle is then applied for a second period (e.g., 30 seconds to 3 minutes or more) until the platinum has replaced the copper. Step d) can be repeated several times (e.g., 3 to 5 times) until several monolayers of Pt on Pd / WNi particles are formed. The platinum-coated particles formed in step d) are referred to as core-shell catalyst particles. The platinum-coated particles can optionally be subjected to anodic potential holding or potential cycling to dissolve excess transition metals. In step e), the particles are incorporated into a fuel cell as part of one or both catalyst layers.

[0018] Fig. 2 and Fig. 3 is a schematic representation of a roll-to-roll production system for the formation of the core-shell catalyst particles described above. In particular, steps a), b), c), and d) are carried out sequentially in a continuous manner in the roll-to-roll system of Fig.carried out. System 70 includes a supply reel 72 that provides a web 74 of substrate 34. Step a) occurs at station 76, where an ionomer-containing layer 32 is first coated onto substrate 34 from an ink composition as set forth above. Typically, the ink composition can be applied using a slot die. The web 74 is then provided to dryer 78, wherein the applied ink composition is dried. Web 74 then passes sequentially through stations 80, 82, 84, and 86. At station 80, the tungsten-nickel alloy is applied using step b) described above. The web is rinsed in a deionized water bath 82. At station 84, step c) is performed as explained above. At station 86, step d) is performed. The tape then passes through a deionized water bath 87 where it is rinsed, and then the dryer 88. Finally, the tape 74 is transferred to the take-up reel 90.It is noted that tape 74 moves continuously from supply reel 72 through stations 76 to 88 to take-up reel 90.

[0019] The following examples illustrate various embodiments of the present invention. Those skilled in the art will recognize many other variations within the scope of the present invention and the claims.

[0020] An ionomer-containing layer is first deposited onto a gas diffusion layer (GDL) by applying an ink-ionomer and a pre-formulated water / carbon mixture to the GDL using a slot die, followed by drying. The target electrode thickness is 10 microns. The coated GDL is then placed in an electrochemical cell filled with a deaerated solution of 50 mM NiSO4, 400 mM Na2WO4, and 600 mM trisodium citrate. A cathodic constant current density of 15 mA / cm 2is applied until the desired deposition is determined by the Coulomb / cm 2 This process typically takes approximately 5 minutes and deposits WNi alloy nanoparticles evenly distributed throughout the coating thickness. Alternatively, the current holder can be replaced with multi-pulse deposition to improve the uniformity of WNi deposition in the electrode. A series of alternating 10 seconds at 15 mA / cm2 and 20 seconds at 1 mA / cm 2can be applied, for example. The electrolyte solution is then pumped out and the electrode is rinsed several times with deaerated demineralized water. A deaerated Pd precursor solution (1 mM PdCl2 + 50 mM H2SO4) is then pumped into the cell. As the solution comes into contact with the WNi particles, Ni is oxidized and dissolved in the solution, and Pd is reductively deposited onto the WNi particles. This reaction, also called galvanic displacement (GD), is driven by the difference in the redox potential of the two metals. One could monitor the progress of this reaction by observing the cell's open circuit potential. As more Pd replaces Ni on the surface of the WNi particles, the voltage increases. This process creates a Pd shell covering the WNi particles, upon which carbon is supported. The electrolyte solution is then pumped out and the electrode is rinsed several times with deaerated demineralized water.A deaerated Cu and Pt precursor solution (0.1 mM K2PtCl4 + 50 mM CuSO4 + 50 mM H2SO4) is then pumped into the cell. A 0.02 V vs. Cu / Cu voltage is measured. 2 + Electrode potential is applied for 1 second to form a sub-monolayer of Cu on the Pd / WNi particles. The 1-second potential holder is followed by an open circuit for 1 minute to allow Pt to replace Cu. This process is repeated 3-5 times to deposit a monolayer of PT on the Pd / WNi particles. Optionally, the electrode can be subjected to an anodic potential holder or potential cycling up to 1 V to dissolve excess transition metals. The finished gas diffusion electrode (GDE) is then rinsed with deionized water and is ready to be laminated to a polymer electrolyte membrane to form a membrane electrode assembly.

[0021] An ionomer-containing layer is first deposited onto a gas diffusion layer (GDL) by applying an ink-ionomer and a carbon mixture to the GDL using a slot die and then drying it. The target electrode thickness is 10 microns. The coated GDL is then placed in an electrochemical cell filled with a deaerated solution of 50 mM NiSO4, 400 mM Na2WO4, and 600 mM trisodium citrate. A cathodic constant current density of 15 mA / cm 2 is applied until the desired deposition is achieved, determined by the C / cm 2 This process typically takes approximately 5 minutes and deposits WNi alloy nanoparticles evenly distributed throughout the coating thickness. Alternatively, the current holder can be replaced by multi-pulse deposition to improve the uniformity of WNi deposition in the electrode. For example, a series of alternating 10 seconds at 15 mA / cm2 and 20 seconds at 1 mA / cm 2-pulses are applied. The electrolyte solution is then pumped out and the electrode is rinsed several times with deaerated demineralized water. A deaerated Pd precursor solution (1 mM PdCl2 + 50 mM H2SO4) is then pumped into the cell. As the solution comes into contact with the WNi particles, Ni is oxidized and dissolved in the solution, and Pd is reductively deposited onto the WNi particles. This reaction, also called galvanic displacement (GD), is driven by the difference in the redox potential of the two metals. The progress of this reaction can be monitored by observing the cell's open circuit potential. As more Pd replaces Ni on the surface of the WNi particles, the voltage increases. This process creates a Pd shell covering the WNi particles, upon which carbon is supported. The electrolyte solution is then pumped out and the electrode is rinsed several times with deaerated demineralized water.A deaerated Cu and Pt precursor solution (0.1 mM K2PtCl4 + 50 mM CuSO4 + 50 mM H2SO4) is then pumped into the cell. A 0.02 V vs. Cu / Cu2+ electrode potential is applied for 1 sec to form a sub-monolayer of Cu on the Pd / WNi particles. The 1-sec potential holder is followed by an open circuit for 1 minute to allow Pt to replace Cu. This process is repeated 3-5 times to deposit a monolayer of PT on the Pd / WNi particles. Optionally, the electrode can be subjected to an anodic potential holder or potential cycling up to 1 V to dissolve excess transition metals. The finished gas diffusion electrode (GDE) is then rinsed with demineralized water and is ready to be laminated to a polymer electrolyte membrane to form a membrane electrode assembly.

[0022] The above-described embodiments are for illustrative purposes only; they are not intended to describe all possible applications of the invention. Rather, the words used in the specification are words of description, not limitation. It is understood that various changes may be made without departing from the spirit and scope of the invention. In addition, the features of the various embodiments may be combined to form further embodiments of the invention.

Claims

[1] A method for forming a fuel cell catalyst, the method comprising (a) forming an ionomer-containing layer including carbon particles and an ionomer; b) forming tungsten-nickel alloy particles on the carbon particles, wherein the tungsten-nickel alloy particles are formed electrochemically from a solution comprising a nickel-containing salt and a tungsten-containing salt; (c) replacing at least a portion of the nickel in the tungsten-nickel alloy particles with palladium to form palladium-coated particles, such that the palladium-coated particles have a palladium shell covering the tungsten-nickel alloy particles; and d) Coating the palladium-coated particles with platinum to form an electrode layer including core-shell catalysts dispersed therein. [2] The method according to claim 1, wherein the ionomer-containing layer is formed on a gas diffusion layer. [3] The method of claim 1, wherein the ionomer-containing layer further comprises tungsten metal supported on the carbon particles. [4] The method of claim 1, wherein the nickel-containing salt is NiSO4 or (Ni)3(PO4)2 and the tungsten-containing salt is a metal tungstate. [5] The method of claim 1, wherein the tungsten-nickel alloy particles are formed with a constant current or with multiple current pulses. [6] The method of claim 1, wherein at least a portion of the nickel in the tungsten-nickel alloy particles in step c) is replaced by palladium by means of a galvanic displacement reaction in which the tungsten-nickel alloy particles are brought into contact with a palladium-containing solution. [7] The method of claim 1, wherein the palladium-coated particles are coated with platinum by depositing copper onto the palladium-coated particles and replacing at least a portion of the copper with platinum, wherein the palladium-coated particles are coated with platinum from a solution containing a platinum-containing salt and a copper-containing salt. [8] A method according to claim 7, wherein a potential is applied to the palladium-coated particles for a first period of time to form the copper on the palladium-coated particles, whereupon at least a portion of the copper is replaced by platinum and an open circuit is applied for a second period of time until the platinum has replaced the copper. [9] A process according to claim 8, wherein the palladium-coated particles are subjected to anodic potential holding or potential cycling to dissolve excess transition metals.

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