Catalyst Ink Filtration for Fuel Cell Alloy Removal
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Solution Overview
Problem
The use of binary and ternary alloy catalysts in fuel cells leads to transition metal elution during catalyst ink production, which acts as an impurity, deteriorating catalyst performance and degrading the electrolyte membrane.
Innovation Solution
A method of manufacturing catalyst ink by forming an aggregate of eluted transition metal and polymer particles, followed by filtration to remove the aggregate, using a solution comprising a noble-metal/transition-metal alloy catalyst, an ionomer, and a solvent, with polymer particles that selectively bind to the eluted transition metal, preventing its incorporation into the catalyst layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If binary or ternary alloy catalysts (e.g., PtCo, PtNi, PtY, PtNiCr, PtCoCr) are used to reduce platinum content, then manufacturing cost is reduced and catalytic activity is improved, but transition metal elutes during catalyst ink production, causing catalyst performance deterioration and electrolyte membrane degradation
Solution Approach 1:
The patent extracts and removes the harmful eluted transition metal from the catalyst ink through filtration using a membrane filter, separating the harmful substance from the useful catalyst components while maintaining the alloy structure for cost reduction
Solution Approach 2:
The patent introduces a membrane filter as an intermediary component that mediates between the alloy catalyst and the final electrode, capturing eluted transition metal particles and preventing them from reaching the electrolyte membrane while allowing the catalyst ink to pass through
2Quantity of substance
If binary or ternary alloy catalysts are used to reduce platinum content, then manufacturing cost is reduced, but transition metal elutes during catalyst ink production, causing electrolyte membrane degradation
Solution Approach 1:
The patent extracts and removes the harmful eluted transition metal from the catalyst ink through filtration using a membrane filter, separating the harmful substance from the useful catalyst components while maintaining the alloy structure for cost reduction
Solution Approach 2:
The patent converts the harmful eluted transition metal, which would otherwise degrade the electrolyte membrane, into a captured byproduct that is removed through filtration, transforming a potential harm into a controlled separation process that protects the membrane
3Reliability
If alloy catalyst material is used to increase catalytic activity with less platinum, then catalytic performance is improved, but transition metal acts as impurity in the electrode, deteriorating catalyst performance
Solution Approach 1:
The patent extracts and removes the harmful eluted transition metal from the catalyst ink through filtration using a membrane filter, separating the harmful substance from the useful catalyst components while maintaining the alloy structure for cost reduction
Solution Approach 2:
The patent changes the physical state and concentration parameters of the catalyst ink by controlling the filtration process, adjusting the purity level of the final catalyst layer while maintaining the desired alloy composition and catalytic activity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively prevents catalyst performance deterioration and electrolyte membrane degradation by removing eluted transition metal, improving cell performance as demonstrated by increased cell voltage and reduced transition metal content in the catalyst ink.
Implementation Method 1
polymer particles that selectively bind to the eluted transition metal
Data Source
AI summary
Disclose is a method of manufacturing catalyst ink for a fuel cell, and particularly the method includes removing eluted transition metal from a noble-metal/transition-metal alloy catalyst.