Fuel Cell Electrode Binder Distribution via Drying and Heat Treatment

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Solution Overview

Problem

The existing methods for manufacturing fuel cell electrodes suffer from reduced efficiency due to regions where the binder is not present around the metal catalyst, leading to increased electron transfer resistance and instability of the slurry.

Innovation Solution

A method involving a mixing step with a carbon support, metal catalyst, and binder, followed by drying and heat treatment, then dissolving in a second solvent and coating onto release paper, ensures the binder is fixed around the metal catalyst, reducing electron transfer resistance and improving slurry dispersibility and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a slurry is prepared by mixing carbon support, metal catalyst, and binder, then the components are combined to form an electrode, but regions where the binder is not present around the metal catalyst occur, causing increased electron transfer resistance and reduced electrode efficiency

Engineering Contradiction:

Improveelectrode efficiencyVSAvoidelectron transfer resistance

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by performing a drying step before the coating step. The slurry is dried to form a dried body, which is then coated onto the membrane. This preliminary drying action ensures that the binder and metal catalyst are fixed in position before final electrode formation, preventing regions where binder is absent around the metal catalyst, thereby reducing electron transfer resistance and improving electrode efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies parameter changes by controlling the viscosity of the slurry through specific binder content and drying conditions. By adjusting these parameters, the slurry achieves optimal flow characteristics that ensure complete coverage of metal catalyst particles with binder, eliminating binder-free regions and reducing electron transfer resistance

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If the binder flows in the slurry to mix components, then the slurry is formed, but the viscosity of the slurry changes, degrading the dispersibility and stability of the slurry

Engineering Contradiction:

Improveslurry stabilityVSAvoidviscosity change

Core Design Contradiction:

Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

The patent applies preliminary action by drying the slurry before coating. This preliminary drying step fixes the binder and prevents excessive flow and viscosity changes during subsequent handling, thereby maintaining slurry stability and dispersibility while avoiding degradation from uncontrolled binder flow

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies parameter changes by optimizing the binder content and drying conditions to control slurry viscosity. By maintaining viscosity within a specific range through these parameter adjustments, the slurry achieves both good dispersibility and stability, preventing degradation while ensuring proper component distribution

Inventive Principle:

Principle #35Parameter changes

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

This process enhances the electrode's efficiency by ensuring the binder is uniformly distributed around the metal catalyst, reducing electron transfer resistance and improving the slurry's stability and dispersibility, resulting in improved performance as shown by increased cell voltage and stability over time.

Implementation Method 1

allowing the binder and the metal catalyst to flow together in the slurry

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

a drying step of producing a first mixed solution dried body by drying the first mixed solution

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

a heat treatment step of adding heat to the first mixed solution dried body

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 4

a second mixed solution production step of producing a second mixed solution by dissolving the heat-treated first mixed solution dried body in a second dispersion solvent

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 5

a release paper coating step of producing an electrode by coating the second mixed solution onto a release paper, and then drying the second mixed solution

Methodology Applied

Scientific EffectCoating: Coatings

Implementation Method 6

drying the second mixed solution

Methodology Applied

Scientific EffectDrying: Evaporation

Data Source

PatentUS10439230B2Method for manufacturing electrode for fuel cell and electrode manufactured thereby

Publication Date: 2019.10.08 HYUNDAI MOTOR CO LTD

AI summary

A method for manufacturing an electrode for a fuel cell includes a mixing step of producing a first mixed solution by mixing a carbon support, a metal catalyst, a binder and a first dispersion solvent, a drying step of producing a first mixed solution dried body by drying the first mixed solution, a heat treatment step of heating the first mixed solution dried body, a second mixed solution production step of producing a second mixed solution by dissolving the heat-treated first mixed solution dried body in a second dispersion solvent, and a release paper coating step of producing an electrode by coating the second mixed solution onto a release paper, and then drying the second mixed solution.