Dual-Layer Anode Structure for Fuel Cell Membrane Protection

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Solution Overview

Problem

Current fuel cell membrane electrode assemblies (MEAs) face challenges in extending lifespan without performance tradeoffs, with cerium oxide instability and cerium ions occupying proton sites, affecting the anode and cathode sides.

Innovation Solution

A dual-layer anode structure is introduced, where a first layer based on platinum on carbon (Pt/C) catalyst with ionomer is combined with a second layer containing a cerium oxide and CeO2—NbO2 composite, surface modified and annealed, to function as a hydrogen oxidization layer and secondary microporous layer, reducing cerium ion impact and improving lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If cerium oxide is used in the microporous layer and gas diffusion layer to improve MEA lifespan, then the lifespan is extended, but cerium ions occupy proton sites on both cathode and anode, negatively affecting performance

Engineering Contradiction:

ImproveMEA lifespanVSAvoidperformance

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The anode is divided into two distinct layers: a first layer containing Pt/C catalyst with ionomer for hydrogen oxidation, and a second layer containing cerium oxide and CeO2-NbO2 composite for radical scavenging. This segmentation isolates cerium oxide from direct contact with the membrane, preventing cerium ion migration to proton sites while maintaining both catalytic activity and membrane protection functions

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first layer acts as an intermediary barrier between the hydrogen fuel and the cerium oxide in the second layer. This intermediate layer prevents direct interaction between cerium oxide and the membrane, blocking the harmful effect of cerium ion migration while allowing the cerium oxide to continue providing antioxidant protection to the membrane

Inventive Principle:

Principle #24Intermediary (Mediator)

2Duration of action of stationary object

If antioxidant is incorporated in the commercial membrane to improve lifespan, then the lifespan is extended, but cerium ions still occupy proton sites and affect performance

Engineering Contradiction:

ImproveMEA lifespanVSAvoidcerium ion occupation of proton sites

Core Design Contradiction:

Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The harmful effect of cerium ion migration is extracted and isolated by placing cerium oxide in a separate second layer away from the membrane. The beneficial antioxidant function is retained in this isolated location, while the harmful ion migration is prevented by the spatial separation and the protective first layer

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Different regions of the anode are assigned different functions: the first layer near the membrane interface is optimized for hydrogen oxidation catalysis, while the second layer containing cerium oxide is optimized for radical scavenging and membrane protection. This local differentiation allows each layer to perform its specific function without interfering with the other

Inventive Principle:

Principle #3Local quality

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 dual-layer anode structure slows down cerium release, mitigates cerium ion occupation of proton sites, and enhances the lifespan of the MEA while maintaining performance, effectively addressing the limitations of existing MEAs.

Implementation Method 1

a fuel (e.g., hydrogen) is dissociated by an anode catalyst to protons and electrons

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

A fuel cell combines fuel and air in an electrochemical reaction that produces both electricity and heat

Methodology Applied

Scientific EffectElectrochemical reaction:

Implementation Method 3

The protons can diffuse through the membrane and be met on the cathode end by an oxidant

Methodology Applied

Scientific EffectProton diffusion: Diffusion

Implementation Method 4

The second layer can include a cerium oxide and CeO2—NbO2 composite, surface modified and annealed, to function as a hydrogen oxidization layer and secondary microporous layer, reducing cerium ion impact and improving lifespan

Methodology Applied

Scientific EffectRadical scavenging:

Implementation Method 5

The present technology can assist in releasing cerium at a slower rate. This can improve the lifespan of the MEA

Methodology Applied

Scientific EffectControlled release:

Data Source

PatentUS20230099815A1Fuel cells with improved membrane life

Publication Date: 2023.03.30 HYZON MOTORS USA INC

AI summary

A membrane electrode assembly can include an anode layer. The anode layer can include a first layer, and a second layer. The second layer can include a cerium oxide. A method of assembling a membrane electrode assembly can include provision of a membrane, a first layer, and a second layer. The second layer can include a cerium oxide. The first layer can be disposed on the second layer to form an anode layer. The anode layer can be disposed on an anode side of the membrane.