Electrocatalyst Layer Preparation With Removable Silicon Oxide
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Solution Overview
Problem
Conventional methods for preparing electrocatalyst layers in fuel cells do not efficiently incorporate silicon oxide, affecting electrochemical performance and requiring high amounts of ion-conducting polymer, which reduces porosity and transport rates.
Innovation Solution
A method involving the deposition of a silicon oxide precursor on a support material, followed by heat treatment to convert it to silicon oxide, then deposition of a platinum group metal electrocatalyst, and subsequent removal of silicon oxide, resulting in a catalyst material with reduced ion-conducting polymer usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to prepare electrocatalyst layers, then the layers can be formed with standard composition, but high amounts of ion-conducting polymer are required which reduces porosity and transport rates
Solution Approach 1:
The patent extracts and removes silicon oxide from the electrocatalyst layer after it has served its function as a deposition aid. This removal allows the layer to achieve high electrochemical performance with reduced ion-conducting polymer content, as the silicon oxide is no longer present to occupy space and reduce porosity.
Solution Approach 2:
Silicon oxide is deposited on the support material before the electrocatalyst deposition step. This preliminary action facilitates the subsequent electrocatalyst deposition process, allowing for better distribution and adhesion of the electrocatalyst particles, which ultimately reduces the need for ion-conducting polymer.
2Reliability
If high amounts of ion-conducting polymer are used to ensure proper function, then ion conduction is maintained, but porosity and transport rates decrease
Solution Approach 1:
By removing silicon oxide after it has facilitated electrocatalyst deposition, the patent creates space and improves porosity without compromising ion conduction. The electrocatalyst layer maintains its functionality with lower ion-conducting polymer content because the silicon oxide removal optimizes the layer structure.
3Reliability
If silicon oxide is incorporated into the electrocatalyst layer, then electrochemical performance is enhanced, but the complexity of the preparation method increases
Solution Approach 1:
The patent merges the silicon oxide deposition step with the existing electrocatalyst preparation process. The silicon oxide is deposited using the same ink formulation and application methods already established for electrocatalyst deposition, thereby integrating the performance-enhancing step into the conventional workflow without requiring entirely new equipment or processes.
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 method enhances electrochemical performance by maintaining activity with less ion-conducting polymer, increasing porosity and transport rates in the electrocatalyst layer.
Implementation Method 1
carrying out a heat treatment step to convert the silicon oxide precursor to silicon oxide
Implementation Method 2
depositing said electrocatalyst or a precursor of said electrocatalyst on the support material
Data Source
Figure 1~2
Figure 3
AI summary
The present invention provides a method of preparing a catalyst material, said catalyst material comprising a support material and an electrocatalyst dispersed on the support material; said method comprising the steps: i) providing a support material; then ii)10 depositing a silicon oxide precursor on the support material; then iii) carrying out a heat treatment step to convert the silicon oxide precursor to silicon oxide; then iv) depositing said electrocatalyst or a precursor of said electrocatalyst on the support material; then v) removal of at least some of the silicon oxide.