Cerium-Modified Microporous Layer for Fuel Cell Membrane Protection

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Solution Overview

Problem

Conventional membrane electrode gas diffusion layer assemblies face a production rate reduction due to the lengthy calcination time required for the microporous layer, which can lead to increased risk of electrolyte membrane breakdown from hydrogen peroxide radicals generated during fuel cell operation.

Innovation Solution

Incorporating a cerium compound into the microporous layer of the diffusion layers, which allows for a catalytic reaction during calcination to burn off dispersing agents and moisture, reducing calcination time and providing a stable supply of cerium ions to neutralize hydrogen peroxide radicals, thus preventing electrolyte membrane breakdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the microporous layer is manufactured by applying ink and calcining to dry the ink, then the microporous layer structure is formed, but the calcination time becomes long which reduces production rate

Engineering Contradiction:

Improvemicroporous layer formationVSAvoidproduction rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the chemical composition parameters of the ink by incorporating a cerium compound (cerium nitrate, cerium acetate, or cerium formate) into the conventional microporous layer ink formulation. This chemical parameter change enables the cerium compound to act as a catalyst during calcination, accelerating the decomposition and evaporation of the binder and solvent, thereby significantly reducing the calcination time required while still forming the necessary microporous structure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The cerium compound serves as a chemical intermediary or catalyst in the calcination process. It facilitates the decomposition of the binder and solvent at lower temperatures and faster rates than would occur through simple thermal heating alone. The cerium compound mediates the calcination reaction, enabling faster processing while maintaining the integrity of the microporous layer structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If calcination time is reduced to increase production rate, then productivity improves, but the electrolyte membrane may break down due to hydrogen peroxide radicals

Engineering Contradiction:

Improveproduction rateVSAvoidelectrolyte membrane stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent incorporates the cerium compound into the microporous layer during the manufacturing process, before the fuel cell begins operation. This preliminary action ensures that cerium ions are already present in the microporous layer and can immediately neutralize hydrogen peroxide radicals as soon as they are generated during fuel cell operation, providing preemptive protection to the electrolyte membrane against radical-induced degradation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful effect of hydrogen peroxide radicals, which normally cause electrolyte membrane breakdown, into a beneficial process. The cerium compound captures these radicals through redox reactions, converting the harmful oxidative radicals into harmless water and oxygen, thereby transforming a degradation mechanism into a protective function that extends membrane life while allowing faster production.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

The cerium compound in the microporous layer shortens calcination time and ensures continuous neutralization of hydrogen peroxide radicals, maintaining electrolyte membrane integrity and enhancing fuel cell performance by preventing membrane breakdown.

Implementation Method 1

Incorporating a cerium compound into the microporous layer of the diffusion layers, which allows for a catalytic reaction during calcination to burn off dispersing agents and moisture

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

providing a stable supply of cerium ions to neutralize hydrogen peroxide radicals, thus preventing electrolyte membrane breakdown

Methodology Applied

Scientific EffectNeutralization reaction: Redox Reactions

Data Source

PatentUS10916780B2Membrane electrode gas diffusion layer assembly and manufacturing method thereof

Publication Date: 2021.02.09 TOYOTA JIDOSHA KK

AI summary

A membrane electrode gas diffusion layer assembly for a fuel cell includes a membrane electrode assembly including an electrolyte membrane, an anode catalyst layer, and a cathode catalyst layer, an anode diffusion layer joined to the anode catalyst layer of the membrane electrode assembly, and a cathode diffusion layer joined to the cathode catalyst layer of the membrane electrode assembly, in which at least one of the anode diffusion layer and the cathode diffusion layer includes a microporous layer that makes contact with the membrane electrode assembly, the microporous layer contains a cerium compound, and at least one of the electrolyte membrane, the anode catalyst layer, and the cathode catalyst layer comprises cerium ions.