Direct Electrode Coating on Porous Substrates for Electrolyzers
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Solution Overview
Problem
Traditional electrolyzer manufacturing processes require multiple decals and lamination steps, leading to inefficiencies in material usage and process complexity.
Innovation Solution
A direct coating method using slot die, spray coating, or sputtering to form anode and cathode catalyst layers with ionomer strands protruding into corrosion-resistant and porous substrates, eliminating intermediate lamination and adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional CCM process with multiple decals and lamination steps is used, then catalyst layers can be formed on substrates, but the manufacturing process becomes complex and material usage increases
Solution Approach 1:
The patent combines multiple separate manufacturing steps (catalyst layer formation, decal application, lamination) into a single direct coating operation. The catalyst ink is applied directly to the substrate in one step, eliminating the need for separate decals and multiple lamination processes, thereby simplifying the manufacturing process and reducing complexity
Solution Approach 2:
The patent extracts and eliminates the intermediate decal layer from the traditional CCM process. By applying catalyst ink directly to the substrate, the decal step is completely removed, reducing the number of materials needed and simplifying the manufacturing流程
2Ease of manufacture
If traditional CCM process with multiple decals is used, then catalyst layers can be formed, but material usage increases
Solution Approach 1:
The patent removes the decal material from the manufacturing process entirely. By applying catalyst ink directly to the substrate, no decal material is consumed, eliminating material waste associated with decal production, application, and removal
Solution Approach 2:
The substrate serves its dual function as both the structural support and the surface for catalyst deposition. The substrate's surface directly receives the catalyst ink without requiring an intermediate decal layer, making the substrate self-sufficient and eliminating the need for additional decal materials
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
Reduces material usage and simplifies the manufacturing process by integrating catalyst layers directly onto substrates, enhancing efficiency and reducing complexity.
Implementation Method 1
a corrosion resistant substrate coated with an anode catalyst ink via one of slot die, spray coating methods, or sputtering to form an anode catalyst layer
Implementation Method 2
a porous substrate coated with a cathode catalyst ink via one of slot die, spray coating methods, or sputtering to form a cathode catalyst layer
Implementation Method 3
the membrane allows protons to pass through while keeping the gases separate
Implementation Method 4
electrolyzers are devices that perform electrolysis, which is the process of using electricity to split water into oxygen and hydrogen
Data Source
AI summary
A membrane electrode assembly for one of a proton exchange membrane electrolyzer or an alkaline electrolyzer includes a corrosion resistant substrate coated with an anode catalyst ink to form an anode catalyst layer, wherein the anode catalyst layer includes ionomer strands that protrude into the corrosion resistant substrate, a porous substrate coated with a cathode catalyst ink to form a cathode catalyst layer, wherein the cathode catalyst layer includes ionomer strands that protrude into the porous substrate, and a membrane disposed between the anode catalyst layer of the corrosion resistant substrate and the cathode catalyst layer of the porous substrate.