Fuel Cell Catalyst with Boron-Doped Diamond Intermediate Layer
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Solution Overview
Problem
Fuel cells face durability issues due to carbon support degradation and hydrophilic metal oxide/phosphate supports that cause flooding, limiting their application in low temperature fuel cells.
Innovation Solution
A modified metal oxide/phosphate based supported catalyst with a conductive, corrosion-resistant intermediate layer, such as boron-doped-diamond, is used to enhance durability and reduce hydrophilicity, allowing for effective electron transfer and oxygen reduction reaction activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal oxide/phosphate support is used to replace carbon support, then corrosion resistance is improved, but hydrophilicity increases causing flooding
Solution Approach 1:
A hydrophobic coating layer is applied to the metal oxide/phosphate support surface to act as an intermediary between the hydrophilic support and the fuel cell environment. This coating layer repels water and prevents flooding while allowing the underlying metal oxide/phosphate support to maintain its corrosion resistance properties.
2Area of stationary object
If high surface area metal oxide/phosphate is used, then catalyst dispersion is improved, but electrical conductivity decreases
Solution Approach 1:
The support structure is designed as a composite material system combining metal oxide/phosphate (providing high surface area) with conductive additives or coatings (providing electrical conductivity). This composite approach allows the system to simultaneously achieve high catalyst dispersion and adequate electrical conductivity for fuel cell operation.
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 solution provides a catalyst with improved durability and reduced flooding, enabling stable performance in low temperature fuel cells by using a conductive intermediate layer to support catalyst particles on a metal oxide/phosphate structure.
Implementation Method 1
An intermediate conductive, corrosion-resistant layer, such as boron-doped-diamond, is arranged onto and in engagement with the support structure to surround the catalyst particles
Implementation Method 2
Fuel cells utilize a catalyst that creates a chemical reaction between a fuel, such as hydrogen, and an oxidant, such as oxygen
Implementation Method 3
Catalyst particles are arranged onto and in engagement with the support structure
Data Source
AI summary
A fuel cell supported catalyst includes an underlying support structure having at least one of a metal oxide and a metal phosphate. Catalyst particles are arranged onto and in engagement with the support structure. An intermediate conductive, corrosion-resistant layer, such as boron-doped-diamond, is arranged onto and in engagement with the support structure to surround the catalyst particles. The supported catalyst is produced by depositing the intermediate layer onto the support structure after the catalyst particles have been deposited on the underlying support structure, in one example. In another example, voids are provided in the intermediate layer, which has been deposited onto the underlying support structure, to subsequently receive the catalyst particles.