U.S. patent application number 16/497875 was filed with the patent office on 2020-04-02 for water electrolyzers.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Krzysztof A. Lewinski, Sean M. Luopa, Attila Molnar, Jiyoung Park.
Application Number | 20200102660 16/497875 |
Document ID | / |
Family ID | 1000004525957 |
Filed Date | 2020-04-02 |
United States Patent
Application |
20200102660 |
Kind Code |
A1 |
Lewinski; Krzysztof A. ; et
al. |
April 2, 2020 |
WATER ELECTROLYZERS
Abstract
A water electrolyzer comprising a membrane comprising at least
one of metallic Pt or Pt oxide, a cathode, and an anode. The
cathode comprises a first catalyst consisting essentially of both
metallic Pt and Pt oxide. The anode comprising a second catalyst
comprising at least 95 percent by weight of collectively metallic
Ir and Ir oxide present, calculated as elemental Ir, based on the
total weight of the second catalyst.
Inventors: |
Lewinski; Krzysztof A.;
(Mahtomedi, MN) ; Luopa; Sean M.; (Minneapolis,
MN) ; Park; Jiyoung; (Woodbury, MN) ; Molnar;
Attila; (Vadnais Heights, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St Paul |
MN |
US |
|
|
Family ID: |
1000004525957 |
Appl. No.: |
16/497875 |
Filed: |
March 28, 2018 |
PCT Filed: |
March 28, 2018 |
PCT NO: |
PCT/IB2018/052145 |
371 Date: |
September 26, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62480794 |
Apr 3, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C25B 1/10 20130101; C25B
11/04 20130101; C25B 13/04 20130101; C25B 9/10 20130101 |
International
Class: |
C25B 9/10 20060101
C25B009/10; C25B 1/10 20060101 C25B001/10; C25B 11/04 20060101
C25B011/04; C25B 13/04 20060101 C25B013/04 |
Claims
1. A water electrolyzer comprising: a membrane having first and
second opposed major surfaces and comprising at least one of
metallic Pt or Pt oxide; a cathode on the first major surface of
the membrane, the cathode comprising a first catalyst consisting
essentially of both metallic Pt and Pt oxide; and an anode on the
second major surface of the membrane, the anode comprising a second
catalyst, wherein the second catalyst is a nanostructured thin film
catalyst comprising at least 95 percent by weight of collectively
metallic Ir and Ir oxide, calculated as elemental Ir, based on the
total weight of the second catalyst, wherein at least one of
metallic Ir or Ir oxide is present.
2. The water electrolyzer of claim 1, wherein the second catalyst
consists essentially of at least one of metallic Ir or Ir
oxide.
3. The water electrolyzer of claim 1, wherein the second catalyst
further comprises at least one of metallic Pt or Pt oxide.
4. The water electrolyzer of claim 3, wherein the second catalyst
consists essentially of at least one of metallic Pt or Pt oxide and
at least one of metallic Ir or Ir oxide.
5. The water electrolyzer of claim 3, wherein the at least one of
metallic Ir or Ir oxide and at least one of metallic Pt or Pt oxide
have a collective weight ratio, calculated as elemental Ir and Pt,
respectively, of at least 20:1 Ir to Pt.
6. The water electrolyzer of claim 1, wherein the at least one of
metallic Ir or Ir oxide of the second catalyst collectively has an
areal density of at least 0.01 mg/cm.sup.2.
7. The water electrolyzer of claim 1, wherein the membrane further
comprises polymer electrolyte.
8. The water electrolyzer of claim 7, wherein the polymer
electrolyte is at least one of perfluorosulfonic acid or
perfluorosulfonimide acid.
9. The water electrolyzer of claim 1, wherein the at least one of
metallic Pt or Pt oxide is collectively present in the membrane at
a concentration in a range from 0.05 mg/cm.sup.3 to 100
mg/cm.sup.3.
10. The water electrolyzer of claim 1, wherein the at least one of
metallic Pt or Pt oxide is distributed throughout the membrane.
11. The water electrolyzer of claim 1, wherein the membrane has a
thickness extending between the first and second major surfaces,
and first, second, and third regions equally spaced across the
thickness, wherein the first region is the closest region to the
first major surface, wherein the second region is the closest
region to the second major surface, wherein the third region is
located between the first and second regions, wherein the first and
third regions are each essentially free of both metallic Pt and Pt
oxide, and wherein the second region comprises the at least one of
metallic Pt or Pt oxide in the membrane.
12. The water electrolyzer of claim 1, wherein the membrane has a
thickness extending between the first and second major surfaces,
wherein the thickness has a midpoint between the first and second
major surfaces, a first region between the first major surface and
the midpoint, and a second region between the second major surface
and the midpoint, and wherein the first region comprises the at
least one of metallic Pt or Pt oxide in the membrane and the second
region is essentially free of both metallic Pt and Pt oxide.
13. The water electrolyzer of claim 1, wherein the membrane has a
thickness extending between the first and second major surfaces,
wherein the thickness has a midpoint between the first and second
major surfaces, a first region between the first major surface and
the midpoint, and a second region between the second major surface
and the midpoint, and wherein the first region is essentially free
of both metallic Pt and Pt oxide and the second region comprises
the at least one of metallic Pt or Pt oxide in the membrane.
14. The water electrolyzer of claim 1, wherein the membrane has a
thickness extending between the first and second major surfaces,
wherein the thickness has a midpoint between the first and second
major surfaces, wherein the at least one of metallic Pt or Pt oxide
in the membrane is present in and only within 0.05 micrometer to
0.5 micrometer from the midpoint toward both the first and second
major surfaces of the membrane.
15. The water electrolyzer of claim 1, wherein the at least a
portion of the at least one of metallic Pt or Pt oxide in the
membrane is present on a support.
16. A method of generating hydrogen and oxygen from water, the
method comprising: providing a water electrolyzer of claim 1;
providing water in contact with the anode; and providing an
electrical potential difference across the membrane with sufficient
current to convert at least a portion of the water to hydrogen and
oxygen on the cathode and anode, respectively.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/480,794, filed Apr. 3, 2017, the
disclosure of which is incorporated by reference herein in its
entirety.
BACKGROUND
[0002] Water electrolyzers are common electrochemical devices for
producing ultra-pure (e.g., typically, at least 99.9% pure)
hydrogen from pure water. In the case of proton exchange membrane
(PEM) based water electrolyzers, hydrogen can be obtained at high
pressure. These electrolyzers often contain membrane electrode
assemblies (MEAs) similar to proton exchange membrane electrode
assemblies for fuel cells. PEM based water electrolyzers, however,
produce hydrogen at the cathode via a hydrogen evolution reaction
(HER) and oxygen at the anode via an oxygen evolution reaction
(OER). The designation of the electrodes as anode or cathode in an
electrochemical device follows the IUPAC convention that the anode
is the electrode at which the predominant reaction is oxidation
(e.g., the H.sub.2 oxidation electrode for a fuel cell, or the
water oxidation/O.sub.2 evolution reaction electrode for a water or
CO.sub.2 electrolyzer).
[0003] Higher operating pressures on the water electrolyzer cathode
(e.g., even approaching 50 bar) create a situation known in the
field as hydrogen crossover, where the hydrogen gas (H.sub.2)
crosses from the cathode where it is produced through the PEM, back
to the anode. This situation creates both an efficiency loss and in
some situations an undesired amount of H.sub.2 mixing with the
anode gas (O.sub.2) (e.g., exceeds 4 vol. %, which is about the
lower explosive limit (LEL)).
[0004] There is a desire to mitigate this crossover of hydrogen to
the anode.
SUMMARY
[0005] In one aspect, the present disclosure provides a water
electrolyzer comprising:
[0006] a membrane having first and second opposed major surfaces
and comprising at least one of metallic Pt or Pt oxide;
[0007] a cathode on the first major surface of the membrane, the
cathode comprising a first catalyst consisting essentially of at
least one of metallic Pt or Pt oxide (i.e., consists essentially of
metallic Pt, consists essentially of Pt oxide, or consists
essentially of both metallic Pt and Pt oxide); and
[0008] an anode on the second major surface of the membrane, the
anode comprising a second catalyst, the second catalyst comprising
at least 95 (in some embodiments, at least 96, 97, 98, or even at
least 99) percent by weight of collectively metallic Ir and Ir
oxide, calculated as elemental Ir, based on the total weight of the
second catalyst (understood not to include any support, if any is
present), wherein at least one of metallic Ir or Ir oxide is
present.
[0009] In another aspect, the present disclosure provides a method
of generating hydrogen and oxygen from water, the method
comprising:
[0010] providing a water electrolyzer described herein;
[0011] providing water in contact with the anode; and
[0012] providing an electrical current with sufficient potential
difference across the membrane to convert at least a portion of the
water to hydrogen and oxygen on the cathode and anode,
respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic of an exemplary water electrolyzer
described herein.
[0014] FIGS. 2A-2D are side views of various exemplary membrane
configurations described herein.
DETAILED DESCRIPTION
[0015] Single cell water electrolyzers are known, but water
electrolyzers typically comprise a plurality (e.g., at least two)
of cells that in turn comprise a membrane, cathode, and anode.
Referring to FIG. 1, exemplary water electrolyzer cell 100
comprising membrane 101, cathode 120, and anode 130. Membrane 100
comprises platinum 105, in the form of at least one of metallic Pt
or Pt oxide. Platinum 105 may be supported platinum. Cathode 120
has first catalyst consisting essentially of at least one of
metallic Pt or Pt oxide (i.e., consists essentially of metallic Pt,
consists essentially of Pt oxide, or consists essentially of both
metallic Pt and Pt oxide). Anode 130 has second catalyst comprising
at least 95 percent by weight of collectively metallic Ir and Ir
oxide, calculated as elemental Ir, based on the total weight of the
second catalyst, wherein at least one of metallic Ir or Ir oxide is
present. As shown, cell 100 also includes optional first fluid
transport layer (FTL) 135 adjacent anode 130, and optional second
fluid transport layer 125 situated adjacent cathode 120. FTLs 125
and 135 can be referred to as diffuser/current collectors (DCCs) or
gas diffusion layers (GDLs). In operation, water is introduced into
the anode portion of cell 100, passing through first fluid
transport layer 135 and over anode 130. Power source 140 applies an
electrical current source on cell 100.
[0016] In some embodiments, membrane 101 is a proton exchange
membrane (PEM) that preferentially permits hydrogen ions (solvated
protons) to pass through the membrane to the cathode portion of the
cell, thus conducting an electrical current through the membrane.
The electrons cannot normally pass through the membrane and,
instead, flow through an external electrical circuit in the form of
electrical current.
[0017] The hydrogen ions (H) combine with the electrons at cathode
120 to form hydrogen gas, and the hydrogen gas is collected through
second fluid transport layer 125 situated adjacent cathode 120.
Oxygen gas is collected at the anode of cell 100 via first fluid
transport layer 135 situated adjacent anode 130.
[0018] Gas diffusion layer (GDL) 135 facilitates water and oxygen
gas transport to and from the anode, respectively, and hydrogen
ions (H.sup.+) and water (carried electro-osmotically through the
PEM membrane with the solvated protons) transport from the anode
through the membrane to the cathode, conducting electrical current.
Also, some of the produced hydrogen gas transports through the
membrane from the cathode to the anode by diffusion, resulting in
undesired "hydrogen crossover." GDLs 125, 135 are both porous and
electrically conductive, and on the cathode side are typically
composed of carbon fibers. However, in order to avoid degradation
of carbon at the high potentials of the anode, it is preferred to
use a more corrosion resistant material, such as porous titanium,
as the GDL on the anode. The GDL may also be called a fluid
transport layer (FTL) or a diffuser/current collector (DCC). In
some embodiments, the anode and cathode layers are applied to GDLs
and the resulting catalyst-coated GDLs (also called CCBs, catalyst
coating backings) are sandwiched with a polymer electrolyte such as
a PEM to form a five-layer MEA. The five layers of such a
five-layer MEA are, in order: anode GDL, anode layer, ion
conducting membrane, cathode layer, and cathode GDL. The anode
layer and cathode layer typically comprise an anode catalyst and a
cathode catalyst, respectively. In other embodiments, the anode and
cathode layers are applied to either side of the ion conducting
membrane, and the resulting catalyst-coated membrane (CCM) is
sandwiched between two GDLs (or FTLs) to form a five-layer MEA.
[0019] An ion conducting membrane used in a CCM or MEA described
herein may comprise any suitable polymer electrolyte. Exemplary
polymer electrolytes typically bear anionic functional groups bound
to a common backbone, which are typically sulfonic acid groups but
may also include carboxylic acid groups, imide groups, imide acid
groups, amide groups, or other acidic functional groups. Anion
conducting membranes comprising cationic functional groups bound to
a common backbone are also possible, but are less commonly used.
Exemplary polymer electrolytes are typically highly fluorinated and
most typically perfluorinated (e.g., at least one of
perfluorosulfonic acid and perfluorosulfonimide acid). Exemplary
electrolytes include copolymers of tetrafluoroethylene and at least
one fluorinated, acid-functional co-monomer. Typical polymer
electrolytes include those available from DuPont Chemicals,
Wilmington, Del., under the trade designation "NAFION;" Solvay,
Brussels, Belgium, under the trade designation "AQUIVION;" and from
Asahi Glass Co. Ltd., Tokyo, Japan, under the trade designation
"FLEMION." The polymer electrolyte may be a copolymer of
tetrafluoroethylene (TFE) and
FSO.sub.2--CF.sub.2CF.sub.2CF.sub.2CF.sub.2--O--CF.dbd.CF.sub.2,
described in U.S. Pat. No. 6,624,328 (Guerra) and U.S. Pat. No.
7,348,088 (Hamrock et al.), and U.S. Pub. No. 2004/0116742
(Guerra), the disclosures of which are incorporated herein by
reference. The polymer typically has an equivalent weight (EW) up
to 1200 (in some embodiments, up to 1100, 1000, 900, 825, 800, 725,
or even up to 625).
[0020] The polymer can be formed into a membrane by any suitable
method. The polymer is typically cast from a suspension. Any
suitable casting method may be used, including bar coating, spray
coating, slit coating, and brush coating. Alternately, the membrane
may be formed from neat polymer in a melt process such as
extrusion. After forming, the membrane may be annealed, typically
at a temperature of at least 120.degree. C. (in some embodiments,
at least 130.degree. C., 150.degree. C., or higher). The membrane
typically has a thickness up to 250 micrometers (in some
embodiments, up to 225 micrometers, 200 micrometers, 175
micrometers, 150 micrometers, 100 micrometers, or even up to 50
micrometers).
[0021] The polymer membrane can also include a support matrix
consisting of a porous network of interlinked fibers that will
provide the ion exchange polymer (ionomer) with additional
mechanical strength to withstand the sometimes large pressure
differentials across the membrane due to the high pressure of the
cathode side during hydrogen evolution. The support matrix can be
made of an expanded polytetrafluoroethylene (e.g., that available
under the trade designation "TEFLON" from DuPont Chemicals,
Wilmington, Del.), or a partially fluorinated fibrous matrix that
will be stable in the acidic environment of the ionomer.
[0022] In some embodiments, the membrane has a first proton
conducting polymer reinforced with a nanofiber mat; wherein the
nanofiber mat is made from a nanofiber comprising a fiber material
selected from polymers and polymer blends; wherein the fiber
material has a fiber material proton conductivity; wherein the
first proton conducting polymer has a first proton conducting
polymer conductivity; and wherein the fiber material proton
conductivity is less than the first proton conducting polymer
conductivity.
[0023] In some embodiments, the fiber material in the membrane may
include highly fluorinated polymer, perfluorinated polymer,
hydrocarbon polymer, or blends and combinations thereof. In some
embodiments, the fiber material in the membrane may include a
polymer suitable for electrospinning selected from the group
consisting of polyvinylidene fluoride (PVDF), polysulfone (PSU),
poly(ethersulfone) (PES), polyethylenimine (PEI), polybenzimidazole
(PBI), polyphenylene oxide (PPO), polyether ether ketone (PEEK),
polyphenyl ether (PPE), polyphenylene ether sulfone (PPES), poly
ether ketone (PEK), blends, and combinations thereof. In some
embodiments, the fiber in the membrane may be an electrospun
nanofiber.
[0024] Typically, it is desirable that the membrane be free of any
Ce or Mn (i.e., no greater than 0.001 mg/cm.sup.3 of either Ce or
MN, calculated as elemental Ce and Mn, respectively).
[0025] Additional details for exemplary membranes can be found, for
example, in U.S. Pat. Pub. Nos. 2008/0113242, 2002/0100725, and
2011/036935, the disclosures of which are incorporated herein by
reference.
[0026] Optionally, the membrane is washed in acid (e.g., 1.0 molar
nitric acid to remove any metal cation impurities, or nitric acid
plus hydrogen peroxide to remove metal cation impurities and
organic impurities, followed by rinsing in deionized water) prior
to deposition or lamination of catalyst (including catalyst-bearing
nanostructured whiskers) to remove cation impurities. Heating the
washing bath (e.g., to 30.degree. C., 40.degree. C., 50.degree. C.,
60.degree. C., 70.degree. C., or even 80.degree. C.) may make the
cleaning faster. Benefits of acid washing the membrane may depend
on the particular membrane.
[0027] In making an MEA, GDLs may be applied to either side of a
CCM. The GDLs may be applied by any suitable means. Suitable GDLs
include those stable at the electrode potentials of use. For
example, the cathode GDL can contain particulate carbon black or
carbon fibers since it is operated at low potentials sufficient for
adequate hydrogen evolution, whereas the anode GDL is typically
made of Ti or some other material stable at the high potentials
characteristic of oxygen evolution. Typically, the cathode GDL is a
carbon fiber construction of woven or non-woven carbon fibers.
Exemplary carbon fiber constructions include those available, for
example, under the trade designation "TORAY" (carbon paper) from
Toray, Japan; "SPECTRACARB" (carbon paper) from Spectracarb,
Lawrence, Mass.; and "ZOLTEK" (carbon cloth) from Zoltek, St.
Louis, Mo., as well as from Mitsubishi Rayon Co., Japan and
Freudenberg, Germany. The GDL may be coated or impregnated with
various materials, including carbon particle coatings,
hydrophilizing treatments, and hydrophobizing treatments such as
coating with polytetrafluoroethylene (PTFE).
[0028] Typically, the electrolyzer anode GDL is metal foam or
porous metal screen or mesh comprised, for example, of Pt, Ti, Ta,
Nb, Zr, Hf, or a metal alloy that will not corrode (e.g.,
Ti-10V-5Zr) and yet will have adequate electrical conductivity
(e.g., by sputter deposition or electroplating a layer of Pt onto
the surface in the case of a Ti GDL) for the electrolyzer operation
at the potentials of use above the thermodynamic potential for
water oxidation at 1.23 V.
[0029] In use, MEAs described herein are typically sandwiched
between two rigid plates, known as distribution plates, also known
as end plates (or in case of a multi-cell stack, bipolar plates
(BPPs)). Like the GDL, the distribution plates are electrically
conductive and must be stable at the potentials of the electrode
GDL against which it is placed. The distribution plate is typically
made of materials such as carbon composite, metal, or coated or
plated metals. As for the GDLs, the cathode plate of the
electrolyzer can be any material common to use in fuel cells,
whereas the anode plate of the electrolyzer must be fabricated of a
material that will not corrode above at potentials of 1.23 volt (in
some embodiments, up to 1.5 volt, 2.5 volts, or even higher)
relative to the potential of a reversible hydrogen electrode (RHE).
An exemplary coating for the anode plate comprises Ti-10V-5Zr. The
distribution plate distributes reactant or product fluids to and
from the MEA electrode surfaces, typically through at least one
fluid-conducting channel engraved, milled, molded, or stamped in
the surface(s) facing the MEA(s). These channels are sometimes
designated a flow field. The distribution plate may distribute
fluids to and from two consecutive MEAs in a stack, with one face
directing water to and oxygen from the anode of the first MEA while
the other face directs evolved hydrogen and water (that crosses
over the membrane) away from the cathode of the next MEA.
Alternately, the distribution plate may have channels on one side
only, to distribute fluids to or from an MEA on only that side, in
which case the distribution plate may be termed an "end plate."
[0030] Pt (i.e., at least one of metallic or Pt oxide) is typically
incorporated into the membrane via addition of the Pt containing
salts to the membrane (imbibing), followed by chemical reduction
typically using NaBH.sub.4 or H.sub.2. Supported Pt can also be
incorporated into the membrane via addition of the carbon-supported
Pt, which has been pre-wetted with deionized water, to the liquid
suspension of the ionomer, followed by casting a membrane from the
resultant mixture.
[0031] In some embodiments, the at least one of metallic Pt or Pt
oxide is collectively present in the membrane at a concentration in
a range from 0.05 mg/cm.sup.3 to 100 mg/cm.sup.3 (in some
embodiments, in a range from 0.1 mg/cm.sup.3 to 100 mg/cm.sup.3, 1
mg/cm.sup.3 to 75 mg/cm.sup.3, or even 5 mg/cm.sup.3 to 50
mg/cm.sup.3).
[0032] In some embodiments, the at least one of metallic Pt or Pt
oxide in the membrane is distributed throughout the membrane. In
some embodiments, the membrane has a thickness extending between
the first and second major surfaces, and first, second, and third
regions equally spaced across the thickness, wherein the first
region is the closest region to the first major surface, wherein
the second region is the closest region to the second major
surface, wherein the third region is located between the first and
second regions, wherein the first and third regions are each
essentially free of both metallic Pt and Pt oxide (i.e., no greater
than 0.001 mg/cm.sup.3, calculated as elemental Pt), and wherein
the second region comprises the at least one of metallic Pt or Pt
oxide in the membrane. In some embodiments, the at least one of
metallic Pt or Pt oxide is distributed throughout the second
region.
[0033] In some embodiments, the membrane has a thickness extending
between the first and second major surfaces, wherein the thickness
has a midpoint between the first and second major surfaces, a first
region between the first major surface and the midpoint, and a
second region between the second major surface and the midpoint,
and wherein the first region comprises the at least one of metallic
Pt or Pt oxide in the membrane and the second region is essentially
free of both metallic Pt and Pt oxide. In some embodiments, the at
least one of metallic Pt or Pt oxide is distributed throughout the
first region.
[0034] In some embodiments, the membrane has a thickness extending
between the first and second major surfaces, wherein the thickness
has a midpoint between the first and second major surfaces, a first
region between the first major surface and the midpoint, and a
second region between the second major surface and the midpoint,
and wherein the first region is essentially free of both metallic
Pt and Pt oxide and the second region comprises the at least one of
metallic Pt or Pt oxide in the membrane. In some embodiments, the
at least one of metallic Pt or Pt oxide is distributed throughout
the second region.
[0035] In some embodiments, the membrane has a thickness extending
between the first and second major surfaces, wherein the thickness
has, in order, a first, second, third, and fourth equally spaced
regions, and wherein at least one of the first, second, third, or
fourth regions comprise the at least one of metallic Pt or Pt oxide
in the membrane. In some embodiments, one of said regions comprises
at least one of metallic Pt or Pt oxide, and the remaining three
regions are essentially free of both metallic Pt and Pt oxide. In
some embodiments, two of said regions comprise at least one of
metallic Pt or Pt oxide, and the remaining two regions are
essentially free of both metallic Pt and Pt oxide. In some
embodiments, three of said regions comprise at least one of
metallic Pt or Pt oxide, and the remaining one region is
essentially free of both metallic Pt and Pt oxide. In some
embodiments, the at least one of metallic Pt or Pt oxide present in
a region is distributed throughout the respective region.
[0036] In some embodiments, the membrane has a thickness extending
between the first and second major surfaces, wherein the thickness
has a midpoint between the first and second major surfaces, wherein
the at least one of metallic Pt or Pt oxide in the membrane is
present in and only within 0.05 micrometer to 0.5 micrometer from
the midpoint toward both the first and second major surfaces of the
membrane.
[0037] In some embodiments, at least a portion of the at least one
of metallic Pt or Pt oxide in the membrane is present on a support
(e.g., a carbon support). Carbon supports include at least one of
carbon spheres or carbon particles (in some embodiments, having an
aspect ratio in a range from 1:1 to 2:1, or even 1:1 to 5:1).
Exemplary carbon spheres are available, for example, from Cabot
Corporation, Billerica, Mass., under the trade designations "VULCAN
XC72" and "BLACK PEARLS BP2000." Exemplary carbon supports already
coated with Pt catalysts are available, for example, from Tanaka
Kikinzoku Kogyo K. K., Hiratsuka, Kanagawa, Japan, under the trade
designations "TEC10F50E," "TEC10BA50E," "TEC10EA50E," "TEC10VA50E,"
"TEC10EA20E-HT," and "TEC10VA20E."
[0038] Carbon supports also include at least one of carbon
nanotubes (e.g., single wall carbon nanotubes (SWNT) (sometimes
referred to as "buckytubes"), double walled carbon nanotubes
(DWNT), or multiple wall carbon nanotubes (MWNT)). Carbon nanotubes
are available, for example, from Showa Denko Carbon Sales, Inc.,
Ridgeville, S.C., under the trade designation "VGCF-H."
[0039] Carbon supports include carbon fullerenes (sometimes
referred to as "buckyballs"). Carbon fullerenes are available, for
example, from Frontier Carbon Corporation, Chiyoda-ku, Tokyo,
Japan, under the trade designation "NANOM."
[0040] Carbon supports include at least one of carbon nanofibers or
carbon microfibers. Carbon nanofibers and carbon microfibers are
available, for example, from Pyrograf Products, Inc., Cedarville,
Ohio, under the trade designation "PYROGRAF-III."
[0041] In some embodiments, the supports include nanostructured
whiskers (e.g., perylene red whiskers). Nanostructured whiskers can
be provided by techniques known in the art, including those
described in U.S. Pat. No. 4,812,352 (Debe), U.S. Pat. No.
5,039,561 (Debe), U.S. Pat. No. 5,338,430 (Parsonage et al.), U.S.
Pat. No. 6,136,412 (Spiewak et al.), and U.S. Pat. No. 7,419,741
(Vernstrom et al.), the disclosures of which are incorporated
herein by reference. In general, nanostructured whiskers can be
provided, for example, by vacuum depositing (e.g., by sublimation)
a layer of organic or inorganic material such as perylene red onto
a substrate (e.g., a microstructured catalyst transfer polymer),
and then converting the perylene red pigment into nanostructured
whiskers by thermal annealing. Typically, the vacuum deposition
steps are carried out at total pressures at or below about
10.sup.-3 Torr or 0.1 Pascal. Exemplary microstructures are made by
thermal sublimation and vacuum annealing of the organic pigment
"perylene red," C.I. Pigment Red 149 (i.e.,
N,N'-di(3,5-xylyl)perylene-3,4:9,10-bis(dicarboximide)). Methods
for making organic nanostructured layers are disclosed, for
example, in Materials Science and Engineering, A158 (1992), pp.
1-6; J. Vac. Sci. Technol. A, 5 (4), July/August 1987, pp. 1914-16;
J. Vac. Sci. Technol. A, 6, (3), May/August 1988, pp. 1907-11; Thin
Solid Films, 186, 1990, pp. 327-47; J. Mat. Sci., 25, 1990, pp.
5257-68; Rapidly Quenched Metals, Proc. of the Fifth Int. Conf. on
Rapidly Quenched Metals, Wurzburg, Germany (Sep. 3-7, 1984), S.
Steeb et al., eds., Elsevier Science Publishers B.V., New York,
(1985), pp. 1117-24; Photo. Sci. and Eng., 24, (4), July/August
1980, pp. 211-16; and U.S. Pat. No. 4,340,276 (Maffitt et al.) and
U.S. Pat. No. 4,568,598 (Bilkadi et al.), the disclosures of which
are incorporated herein by reference. Properties of catalyst layers
using carbon nanotube arrays are disclosed in the article "High
Dispersion and Electrocatalytic Properties of Platinum on
Well-Aligned Carbon Nanotube Arrays," Carbon, 42, (2004), 191-197.
Properties of catalyst layers using grassy or bristled silicon are
disclosed in U.S. Pat. App. Pub. No. 2004/0048466 A1 (Gore et
al.).
[0042] Vacuum deposition may be carried out in any suitable
apparatus (see, e.g., U.S. Pat. No. 5,338,430 (Parsonage et al.),
U.S. Pat. No. 5,879,827 (Debe et al.), U.S. Pat. No. 5,879,828
(Debe et al.), U.S. Pat. No. 6,040,077 (Debe et al.), and U.S. Pat.
No. 6,319,293 (Debe et al.), and U.S. Pat. App. Pub. No.
2002/0004453 A1 (Haugen et al.), the disclosures of which are
incorporated herein by reference). One exemplary apparatus is
depicted schematically in FIG. 4A of U.S. Pat. No. 5,338,430
(Parsonage et al.), and discussed in the accompanying text, wherein
the substrate is mounted on a drum that is then rotated over a
sublimation or evaporation source for depositing the organic
precursor (e.g., perylene red pigment) in order to form the
nanostructured whiskers.
[0043] Typically, the nominal thickness of deposited perylene red
pigment is in a range from about 50 nm to 500 nm. Typically, the
whiskers have an average cross-sectional dimension in a range from
20 nm to 60 nm and an average length in a range from 0.3 micrometer
to 3 micrometers.
[0044] In some embodiments, the whiskers are attached to a backing.
Exemplary backings comprise polyimide, nylon, metal foils, or other
material that can withstand the thermal annealing temperature up to
300.degree. C. In some embodiments, the backing has an average
thickness in a range from 25 micrometers to 125 micrometers.
[0045] In some embodiments, the backing has a microstructure on at
least one of its surfaces. In some embodiments, the microstructure
is comprised of substantially uniformly shaped and sized features
at least three (in some embodiments, at least four, five, ten or
more) times the average size of the nanostructured whiskers. The
shapes of the microstructures can, for example, be V-shaped grooves
and peaks (see, e.g., U.S. Pat. No. 6,136,412 (Spiewak et al.), the
disclosure of which is incorporated herein by reference) or
pyramids (see, e.g., U.S. Pat. No. 7,901,829 (Debe et al.), the
disclosure of which is incorporated herein by reference). In some
embodiments, some fraction of the features of the microstructures
extend above the average or majority of the microstructured peaks
in a periodic fashion, such as every 31.sup.st V-groove peak is 25%
or 50% or even 100% taller than those on either side of it. In some
embodiments, this fraction of features that extend above the
majority of the microstructured peaks can be up to 10% (in some
embodiments up to 3%, 2%, or even up to 1%). Use of the occasional
taller microstructure features may facilitate protecting the
uniformly smaller microstructure peaks when the coated substrate
moves over the surfaces of rollers in a roll-to-roll coating
operation. The occasional taller feature touches the surface of the
roller rather than the peaks of the smaller microstructures and so
much less of the nanostructured material or whiskers is likely to
be scraped or otherwise disturbed as the substrate moves through
the coating process. In some embodiments, the nanostructured
whiskers are at least partially embedded in the ion conducting
membrane. In some embodiments, the microstructure features are
substantially smaller than half the thickness of the membrane that
the catalyst will be transferred to in making a membrane electrode
assembly (MEA). This is so that during the catalyst transfer
process, the taller microstructure features do not penetrate
through the membrane where they may overlap the electrode on the
opposite side of the membrane. In some embodiments, the tallest
microstructure features are less than 1/3.sup.rd or 1/4.sup.th of
the membrane thickness. For the thinnest ion exchange membranes
(e.g., about 10 to 15 micrometers in thickness), it may be
desirable to have a substrate with microstructured features no
larger than about 3 to 4.5 micrometers tall. The steepness of the
sides of the V-shaped or other microstructured features or the
included angles between adjacent features in some embodiments may
be desirable to be on the order of 90.degree. for ease in catalyst
transfer during a lamination-transfer process and in order to have
a gain in surface area of the electrode that comes from the square
root of two (1.414) surface area of the microstructured layer
relative to the planar geometric surface of the substrate
backing.
[0046] In some embodiments, the supports include tin oxide. Such
tin oxide is available as already catalyzed Pt/SnO.sub.2 in the
form of finely ground particles for example, from Tanaka Kikinzoku
Kogyo K. K., Hiratsuka, Kanagawa, Japan, under the trade
designation "TEC10(SnO.sub.2/A)10E" and
"TEC10(SnO.sub.2/A)30E."
[0047] In some embodiments, the supports include clay. These clays
can take the form of particles or platelets and may be synthetic or
naturally occurring layered silicates. Such clay is available, for
example, from BYK Additives and Instruments, GmbH, Wesel, Germany,
under the trade designation "LAPONITE RD."
[0048] Platinum can be sputtered onto the support, for example,
using the general teachings in U.S. Pat. No. 5,879,827 (Debe et
al.), U.S. Pat. No. 6,040,077 (Debe et al.), and U.S. Pat. No.
7,419,741 (Vernstrom et al.), and U.S. Pat. Pub. No. 2014/0246304
A1 (Debe et al.), the disclosures of which are incorporated herein
by reference. In some embodiments, sputtering is conducted at least
in part in an atmosphere comprising argon that is flowing into the
sputtering chamber at a rate of at least 120 sccm (i.e., standard
cubic centimeters per minute).
[0049] The anode and cathode can be provided by techniques known in
the art, including those described in PCT Pub. No. WO 2016/191057
A1, published Dec. 1, 2016, the disclosure of which is incorporated
herein by reference. In general, the anode and cathode are each
comprised of layers.
[0050] In some embodiments, the second catalyst consists
essentially of at least one of metallic Ir or Ir oxide (i.e.,
consists essentially of metallic Ir, consists essentially of Ir
oxide, or consists essentially of both metallic Ir and Ir oxide).
In some embodiments, the second catalyst further comprises at least
one of metallic Pt or Pt oxide. In some embodiments, the second
catalyst consists essentially of at least one of metallic Pt or Pt
oxide and at least one of metallic Ir or Ir oxide.
[0051] For catalysts comprising or consisting essentially of at
least one of metallic Ir or Ir oxide and at least one of metallic
Pt or Pt oxide, the iridium and platinum, calculated as elemental
Pt and Ir, respectively, have a collective weight ratio of at least
20:1 (in some embodiments, at least 50:1, 100:1, 500:1, 1000:1,
5,000:1, or even at least 10,000:1; in some embodiments, in a range
from 20:1 to 10,000:1, 20:1 to 5,000:1, 20:1 to 1000:1, 20:1 to
500:1, 20:1 to 100:1, or even 20:1 to 50:1) Ir to Pt.
[0052] In some embodiments, the at least one of metallic Ir or Ir
oxide of the second catalyst collectively has an areal density of
at least 0.01 mg/cm.sup.2 (in some embodiments, at least 0.05
mg/cm.sup.2, 0.1 mg/cm.sup.2, 0.25 mg/cm.sup.2, 0.5 mg/cm.sup.2, 1
mg/cm.sup.2, or even at least 5 mg/cm.sup.2; in some embodiments,
in a range from 0.01 mg/cm.sup.2 to 5 mg/cm.sup.2, 0.05 mg/cm.sup.2
to 2.5 mg/cm.sup.2, 0.1 mg/cm.sup.2 to 1 mg/cm.sup.2, or even 0.25
mg/cm.sup.2 to 0.75 mg/cm.sup.2).
[0053] Typically, the planar equivalent thickness of a catalyst
layer is in a range from 0.5 nm to 5 nm. "Planar equivalent
thickness" means, in regard to a layer distributed on a surface,
which may be distributed unevenly, and which surface may be an
uneven surface (such as a layer of snow distributed across a
landscape, or a layer of atoms distributed in a process of vacuum
deposition), a thickness calculated on the assumption that the
total mass of the layer was spread evenly over a plane covering the
same projected area as the surface (noting that the projected area
covered by the surface is less than or equal to the total surface
area of the surface, once uneven features and convolutions are
ignored).
[0054] In some embodiments, the anode catalyst comprises up to 1
mg/cm.sup.2 (in some embodiments, up to 0.25 mg/cm.sup.2, or even
up to 0.025 mg/cm.sup.2) of the at least one of metallic Ir or Ir
oxide, calculated as elemental Ir. In some embodiments, the cathode
catalyst comprises up to 1 mg/cm.sup.2 (in some embodiments, up to
0.25 mg/cm.sup.2, or even up to 0.025 mg/cm.sup.2) of the at least
one of metallic Pt or Pt oxide, calculated as elemental Pt.
Typically, the catalyst is a continuous layer on each whisker and
may form a bridge to adjacent whiskers.
[0055] In some embodiments where catalyst is coated on
nanostructured whiskers (including perylene red nanostructured
whiskers), the catalyst is coated in-line, in a vacuum, immediately
following the nanostructured whisker growth step on the
microstructured substrate. This may be a more cost-effective
process so that the nanostructured whisker coated substrate does
not need to be re-inserted into the vacuum for catalyst coating at
another time or place. If the Ir catalyst coating is done with a
single target, it may be desirable that the coating layer be
applied in a single step onto the nanostructured whiskers so that
the heat of condensation of the catalyst coating heats the Ir, O,
etc. atoms and substrate surface sufficiently to provide enough
surface mobility that the atoms are well mixed and form
thermodynamically stable domains. If the Pt catalyst coating is
done with a single target, it may be desirable that the coating
layer be applied in a single step onto the nanostructured whiskers
so that the heat of condensation of the catalyst coating heats the
Pt, O, etc. atoms and substrate surface sufficiently to provide
enough surface mobility that the atoms are well mixed and form
thermodynamically stable domains. Alternatively, for perylene red
nanostructured whiskers, the substrate can also be provided hot or
heated to facilitate this atomic mobility, such as by having the
nanostructured whisker coated substrate exit the perylene red
annealing oven immediately prior to the catalyst sputter deposition
step.
[0056] It will be understood by one skilled in the art that the
crystalline and morphological structure of a catalyst described
herein, including the presence, absence, or size of alloys,
amorphous zones, crystalline zones of one or a variety of
structural types, and the like, may be highly dependent upon
process and manufacturing conditions, particularly when three or
more elements are combined.
[0057] Water electrolyzers described herein are useful for
generating hydrogen and oxygen from water, wherein water is in
contact with the anode, and an electrical current is provided
through the membrane with sufficient potential difference across
the membrane to convert at least a portion of the water to hydrogen
and oxygen on the cathode and anode, respectively.
Exemplary Embodiments
[0058] 1A. A water electrolyzer comprising:
[0059] a membrane having first and second opposed major surfaces
and comprising at least one of metallic Pt or Pt oxide;
[0060] a cathode on the first major surface of the membrane, the
cathode comprising a first catalyst consisting essentially of at
least one of metallic Pt or Pt oxide; and
[0061] an anode on the second major surface of the membrane, the
anode comprising a second catalyst, the second catalyst comprising
at least 95 (in some embodiments, at least 96, 97, 98, or even at
least 99) percent by weight of collectively metallic Ir and Ir
oxide, calculated as elemental Ir, based on the total weight of the
second catalyst (understood not to include any support, if any is
present), wherein at least one of metallic Ir or Ir oxide is
present. [0062] 2A. The water electrolyzer of Exemplary Embodiment
1A, wherein the second catalyst consists essentially of at least
one of metallic Ir or Ir oxide. [0063] 3A. The water electrolyzer
of Exemplary Embodiment 1A, wherein the second catalyst further
comprises at least one of metallic Pt or Pt oxide. [0064] 4A. The
water electrolyzer of Exemplary Embodiment 3A, wherein the second
catalyst consists essentially of at least one of metallic Pt or Pt
oxide and at least one of metallic Ir or Ir oxide. [0065] 5A. The
water electrolyzer of either Exemplary Embodiment 3A or 4A, wherein
the at least one of metallic Ir or Ir oxide and at least one of
metallic Pt or Pt oxide have a collective weight ratio, calculated
as elemental Ir and Pt, respectively, of at least 20:1 (in some
embodiments, at least 50:1, 100:1, 500:1, 1000:1, 5,000:1, or even
at least 10,000:1; in some embodiments, in a range from 20:1 to
10,000:1, 20:1 to 5,000:1, 20:1 to 1000:1, 20:1 to 500:1, 20:1 to
100:1, or even 20:1 to 50:1) Ir to Pt. [0066] 6A. The water
electrolyzer of any preceding A Exemplary Embodiment, wherein the
at least one of metallic Ir or Ir oxide of the second catalyst
collectively has an areal density of at least 0.01 mg/cm.sup.2 (in
some embodiments, at least 0.05 mg/cm.sup.2, 0.1 mg/cm.sup.2, 0.25
mg/cm.sup.2, 0.5 mg/cm.sup.2, 1 mg/cm.sup.2, or even at least 5
mg/cm.sup.2; in some embodiments, in a range from 0.01 mg/cm.sup.2
to 5 mg/cm.sup.2, 0.05 mg/cm.sup.2 to 2.5 mg/cm.sup.2, 0.1
mg/cm.sup.2 to 1 mg/cm.sup.2, or even 0.25 mg/cm.sup.2, to 0.75
mg/cm.sup.2). [0067] 7A. The water electrolyzer of any preceding A
Exemplary Embodiment, wherein the membrane further comprises
polymer electrolyte. [0068] 8A. The water electrolyzer of Exemplary
Embodiment 7A, wherein the polymer electrolyte is at least one of
perfluorosulfonic acid or perfluorosulfonimide acid. [0069] 9A. The
water electrolyzer of any preceding A Exemplary Embodiment, wherein
the at least one of metallic Pt or Pt oxide, calculated as
elemental Pt, is collectively present in the membrane at a
concentration in a range from 0.05 mg/cm.sup.3 to 100 mg/cm.sup.3
(in some embodiments, in a range from 0.1 mg/cm.sup.3 to 100
mg/cm.sup.3, 1 mg/cm.sup.3 to 75 mg/cm.sup.3, or even 5 mg/cm.sup.3
to 50 mg/cm.sup.3). [0070] 10A. The water electrolyzer of any
preceding A Exemplary Embodiment, wherein the at least one of
metallic Pt or Pt oxide is distributed throughout the membrane.
[0071] 11A. The water electrolyzer of any of Exemplary Embodiments
1A to 9A, wherein the membrane has a thickness extending between
the first and second major surfaces, and first, second, and third
regions equally spaced across the thickness, wherein the first
region is the closest region to the first major surface, wherein
the second region is the closest region to the second major
surface, wherein the third region is located between the first and
second regions, wherein the first and third regions are each
essentially free of both metallic Pt and Pt oxide, and wherein the
second region comprises the at least one of metallic Pt or Pt oxide
in the membrane. [0072] 12A. The water electrolyzer of Exemplary
Embodiment 11A, wherein the metallic Pt or Pt oxide is distributed
throughout the second region. [0073] 13A. The water electrolyzer of
any of Exemplary Embodiments 1A to 9A, wherein the membrane has a
thickness extending between the first and second major surfaces,
wherein the thickness has a midpoint between the first and second
major surfaces, a first region between the first major surface and
the midpoint, and a second region between the second major surface
and the midpoint, and wherein the first region comprises the at
least one of metallic Pt or Pt oxide in the membrane and the second
region is essentially free of both metallic Pt and Pt oxide. [0074]
14A. The water electrolyzer of Exemplary Embodiment 13A, wherein
the at least one of metallic Pt or Pt oxide is distributed
throughout the first region. [0075] 15A. The water electrolyzer of
any of Exemplary Embodiments 1A to 9A, wherein the membrane has a
thickness extending between the first and second major surfaces,
wherein the thickness has a midpoint between the first and second
major surfaces, a first region between the first major surface and
the midpoint, and a second region between the second major surface
and the midpoint, and wherein the first region is essentially free
of both metallic Pt and Pt oxide and the second region comprises
the at least one of metallic Pt or Pt oxide the membrane. [0076]
16A. The water electrolyzer of Exemplary Embodiment 15A, wherein
the at least one of metallic Pt or Pt oxide is distributed
throughout the second region. [0077] 17A. The water electrolyzer of
any of Exemplary Embodiments 1A to 9A, wherein the membrane has a
thickness extending between the first and second major surfaces,
wherein the thickness has, in order, a first, second, third, and
fourth equally spaced region, and wherein at least one of the
first, second, third, or fourth regions comprises the at least one
of metallic Pt or Pt oxide in the membrane. [0078] 18A. The water
electrolyzer of Exemplary Embodiment 17A, wherein one of said
regions comprises the at least one of metallic Pt or Pt oxide, and
the remaining three regions are essentially free of both metallic
Pt and Pt oxide. [0079] 19A. The water electrolyzer of Exemplary
Embodiment 17A, wherein two of said regions comprise the at least
one of metallic Pt or Pt oxide, and the remaining two regions are
essentially free of both metallic Pt and Pt oxide. [0080] 20A. The
water electrolyzer of Exemplary Embodiment 17A, wherein three of
said regions comprise the at least one of metallic Pt or Pt oxide,
and the remaining one region is essentially free of both metallic
Pt and Pt oxide. [0081] 21A. The water electrolyzer of any of
Exemplary Embodiments 17A to 20A, wherein the at least one of
metallic Pt or Pt oxide present in a region is distributed
throughout the respective region. [0082] 22A. The water
electrolyzer of any of Exemplary Embodiments 1A to 9A, wherein the
membrane has a thickness extending between the first and second
major surfaces, wherein the thickness has a midpoint between the
first and second major surfaces, wherein the at least one of
metallic Pt or Pt oxide in the membrane is present in and only
within 0.05 micrometer to 0.5 micrometer from the midpoint toward
both the first and second major surfaces of the membrane. [0083]
23A. The water electrolyzer of any preceding A Exemplary
Embodiment, wherein the at least a portion of the at least one of
metallic Pt or Pt oxide in the membrane is present on a support.
[0084] 24A. The water electrolyzer of Exemplary Embodiment 23A,
wherein the support comprises carbon. [0085] 25A. The water
electrolyzer of Exemplary Embodiment 23A, wherein the support
comprises at least one of carbon spheres or carbon particles (in
some embodiments, having an aspect ratio in a range from 1:1 to
2:1, or even 1:1 to 5:1). [0086] 26A. The water electrolyzer of
either Exemplary Embodiment 23A or 25A, wherein the support
comprises carbon nanotubes (e.g., single wall carbon nanotubes
(SWNT) (sometimes referred to as "buckytubes") or multiple wall
carbon nanotubes (MWNT)). [0087] 27A. The water electrolyzer of any
of Exemplary Embodiments 23A, 25A, or 26A, wherein the support
comprises carbon fullerenes (sometimes referred to as
"buckyballs"). [0088] 28A. The water electrolyzer of any of
Exemplary Embodiments 23A or 25A to 27A, wherein the support
comprises at least one of carbon nanofibers or carbon microfibers.
[0089] 29A. The water electrolyzer of any of Exemplary Embodiments
23A or 25A to 28A, wherein the support comprises nanostructured
whiskers. [0090] 30A. The water electrolyzer of Exemplary
Embodiment 29A, wherein the nanostructured whiskers comprise
perylene red. [0091] 31A. The water electrolyzer of Exemplary
Embodiment 23A, wherein the support comprises tin oxide. [0092]
32A. The water electrolyzer of Exemplary Embodiment 23A, wherein
the support comprises clay. [0093] 1B. A method of generating
hydrogen and oxygen from water, the method comprising:
[0094] providing a water electrolyzer of any preceding A Exemplary
Embodiment;
[0095] providing water in contact with the anode; and
[0096] providing an electrical potential difference across the
membrane with sufficient current to convert at least a portion of
the water to hydrogen and oxygen on the cathode and anode,
respectively.
[0097] Advantages and embodiments of this invention are further
illustrated by the following examples, but the particular materials
and amounts thereof recited in these examples, as well as other
conditions and details, should not be construed to unduly limit
this invention. All parts and percentages are by weight unless
otherwise indicated.
EXAMPLES
[0098] Materials for preparing the Examples include those in Table
1, below.
TABLE-US-00001 TABLE 1 Abbreviation or Trade Designation Source
"PR149" Perylene red pigment (i.e., N,N'-di(3,5-
xylyl)perylene-3,4:9,10-bis(dicarboximide)), obtained under the
trade designation "C.I. PIGMENT RED 149," also known as "PR149,"
from Clariant, Charlotte, NC. "NAFION 117" A polymeric
perfluorosulfonic acid (PFSA) cation exchange membrane, obtained
under the trade designation "NAFION 117" from DuPont, Wilmington,
DE. "3M825EW 825 g/mol equivalent weight polymeric MEMBRANE"
perfluorosulfonic acid proton exchange membrane (PEM), obtained
under the trade designation "3M825EW MEMBRANE" from 3M Company, St.
Paul, MN. "3M825EW 825 g/mol equivalent weight polymeric POWDER"
perfluorosulfonic acid ion exchange resin, obtained under the trade
designation "3M825EW POWDER" from 3M Company. "3M825EW 825 g/mol
equivalent weight polymeric SOLUTION" perfluorosulfonic acid ion
exchange resin dispersion (34 wt. % in a 75:25 mix of ethanol and
water), obtained under the trade designation "3M825EW SOLUTION"
from 3M Company. "LAPONITE RD" Clay particles obtained under the
trade designation "LAPONITE RD" from BYK Additives, Inc., Wesel,
Germany. "Ir-NSTF" 0.5 mg/cm.sup.2 iridium/iridium oxide
nanostructured thin film (NSTF) catalyst supported on perylene red
whiskers, prepared as described below under the heading
"Preparation of Nanostructured Thin Film (NSTF) Catalyst."
"Pt-NSTF" 0.25 mg/cm.sup.2 nanostructured thin film (NSTF) catalyst
supported on perylene red whiskers, prepared as described below
under the heading "Preparation of Nanostructured Thin Film (NSTF)
Catalyst." "Pt-PRWF" 50 micrograms/cm.sup.2 Pt-NSTF perylene red
whisker fragments, prepared as described below in Example 2.
"SnO.sub.210E" Tin oxide supported platinum catalyst, obtained
under the trade designation "TEC10(SnO.sub.2/A)10E" from Tanaka
Kikinzoku Kogyo K. K., Hiratsuka, Kanagawa, Japan. "SnO.sub.230E"
Tin oxide supported platinum catalyst, obtained under the trade
designation "TEC10(SnO.sub.2/A)30E" from Tanaka Kikinzoku Kogyo K.
K., Hiratsuka, Kanagawa, Japan. "F50E" Carbon-supported platinum
catalyst, obtained under the trade designation "TEC10F50E" from
Tanaka Kikinzoku Kogyo K. K. BA50E" Carbon-supported platinum
catalyst, obtained under the trade designation "TEC10BA50E" from
Tanaka Kikinzoku Kogyo K. K. "EA50E" Carbon-supported platinum
catalyst, obtained under the trade designation "TEC10EA50E" from
Tanaka Kikinzoku Kogyo K. K. "VA50E" Carbon-supported platinum
catalyst, obtained under the trade designation "TEC10VA50E" from
Tanaka Kikinzoku Kogyo K. K. EA20E" Carbon-supported platinum
catalyst, obtained under the trade designation "TEC10EA20E-HT" from
Tanaka Kikinzoku Kogyo K. K. "VA20E Carbon-supported platinum
catalyst, obtained under the trade designation "TEC10VA20E" from
Tanaka Kikinzoku Kogyo K. K. "KAPTON" Polyimide film, obtained
under the trade designation "KAPTON" from DuPont, Wilmington,
DE.
Preparation of Nanostructured Whiskers
[0099] Nanostructured whiskers were prepared by thermally annealing
a layer of perylene red pigment (PR 149), which was sublimation
vacuum coated onto microstructured catalyst transfer polymer
substrates (MCTS) with a nominal thickness of 200 nm, as described
in detail in U.S. Pat. No. 4,812,352 (Debe), the disclosure of
which is incorporated herein by reference.
[0100] A roll-good web of the MCTS (made on a polyimide film
("KAPTON")) was used as the substrate on which the PR149 was
deposited. The MCTS substrate surface had V-shaped features with
about 3 micrometer tall peaks, spaced 6 micrometers apart. A
nominally 100 nm thick layer of Cr was then sputter deposited onto
the MCTS surface using a DC magnetron planar sputtering target and
typical background pressures of Ar and target powers known to those
skilled in the art sufficient to deposit the Cr in a single pass of
the MCTS web under the target at the desired web speed.
[0101] The Cr coated MCTS web then continued over a sublimation
source containing the perylene red pigment (PR 149). The perylene
red pigment (PR 149) was heated to a controlled temperature near
500.degree. C. so as to generate sufficient vapor pressure flux to
deposit 0.022 mg/cm.sup.2, or an approximately 220 nm thick layer
of the perylene red pigment (PR 149) in a single pass of the web
over the sublimation source. The mass or thickness deposition rate
of the sublimation can be measured in any suitable fashion known to
those skilled in the art, including optical methods sensitive to
film thickness, or quartz crystal oscillator devices sensitive to
mass. The perylene red pigment (PR 149) coating was then converted
to the whisker phase by thermal annealing, as described in detail
in U.S. Pat. No. 5,039,561 (Debe), the disclosure of which is
incorporated herein by reference, by passing the perylene red
pigment (PR 149) coated web through a vacuum having a temperature
distribution sufficient to convert the perylene red pigment (PR
149) as-deposited layer into a layer of oriented crystalline
whiskers at the desired web speed, such that the whisker layer has
an average whisker areal number density of 68 whiskers per square
micrometer, determined from scanning electron microscopy (SEM)
images, with an average length of 0.6 micrometer.
Preparation of Nanostructured Thin Film (NSTF) Catalyst
[0102] Nanostructured thin film (NSTF) Ir-based catalyst was
prepared by sputter coating Ir catalyst films onto the layer of
nanostructured whiskers (prepared as described above under the
heading "Preparation of Nanostructured Whiskers").
[0103] Nanostructured thin film (NSTF) catalyst layers were
prepared by sputter coating catalyst films using a DC-magnetron
sputtering process onto the layer of nanostructured whiskers. A
roll-good of nanostructured whiskers on MCTS substrate were loaded
into a vacuum sputter deposition system similar to that described
in FIG. 4A of U.S. Pat. No. 5,338,430 (Parsonage et al.), but
equipped with additional capability to allow coatings on roll-good
substrate webs. The coatings were sputter deposited by using ultra
high purity Ar as the sputtering gas at approximately 5 mTorr
pressure. Ir-NSTF catalyst layers were deposited onto the roll-good
by first exposing all sections of the roll-good substrate to an
energized 5 inch.times.15 inch (13 cm.times.38 cm) planar Ir
sputtering target (obtained from Materion, Clifton, N.J.),
resulting in the deposition of Ir onto the substrate. The magnetron
sputtering target deposition rate and web speed were controlled to
give the desired areal loading of Ir on the substrate. The DC
magnetron sputtering target deposition rate and web speed were
measured by standard methods known to those skilled in the art. The
substrate was repeatedly exposed to the energized Ir sputtering
target, resulting in additional deposition of Ir onto the
substrate, until the desired Ir areal loading was obtained. An
analogous process was used for formation of Pt-NSTF catalyst
layers, but a pure 5 inch.times.15 inch (13 cm.times.38 cm) planar
Pt sputter target (obtained from Materion, Clifton, N.J.) was used
in place of Ir.
Preparation of Catalyst-Coated Membrane (CCM)
[0104] A catalyst-coated-membrane (CCM) was made by transferring
the catalyst coated whiskers described above onto both surfaces
(full CCM) of the proton exchange membrane (PEM) ("NAFION 117")
using the processes as described in detail in U.S. Pat. No.
5,879,827 (Debe et al.). A Pt-NSTF catalyst layer was laminated to
one side (intended to become the cathode side) of the PEM, and an
Ir-NSTF catalyst layer was laminated to the other (anode) side of
the PEM. The catalyst transfer was accomplished by hot roll
lamination of the NSTF catalysts onto the PEM: the hot roll
temperatures were 350.degree. F. (177.degree. C.) and the gas line
pressure fed to force laminator rolls together at the nip ranged
from 150 psi to180 psi (1.03 MPa to 1.24 MPa). The catalyst coated
MCTSs were precut into 13.5 cm.times.13.5 cm square shapes and
sandwiched onto (one or) both side(s) of a larger square of PEM.
The PEM with catalyst coated MCTS on one or both side(s), was
placed between 2 mil (51 micrometer) thick polyimide film and then
placed, paper on the outside, prior to passing the stacked assembly
through the nip of the hot roll laminator at a speed of 1.2
ft./min. (37 cm/min.). Immediately after passing through the nip,
while the assembly was still warm, the layers of polyimide and
paper were quickly removed and the Cr-coated MCTS substrates were
peeled off the CCM by hand, leaving the catalyst coated whiskers
stuck to the PEM surface(s).
Full CCM Test
[0105] The full CCM fabricated as described above was tested in an
H.sub.2/O.sub.2 electrolyzer single cell. The full CCM was
installed with appropriate gas diffusion layers directly into a 50
cm.sup.2 single fuel cell test station (obtained under the trade
designation "50SCH" from Fuel Cell Technologies, Albuquerque, N.
Mex.), with quad serpentine flow fields. The normal graphite flow
field block on the anode side was replaced with a Pt plated Ti flow
field block of the same dimensions and flow field design (obtained
from Giner, Inc., Auburndale, Mass.) to withstand the high anode
potentials during electrolyzer operation. Purified water with a
resistivity of 18 Mohms was supplied to the anode at 75 mL/min. A
potentiostat (obtained under the trade designation "VMP-3," Model
VMP-3 from Bio-Logic Science Instruments SAS, Seyssinet-Pariset,
France) coupled with a 100 A/5V booster (obtained under the trade
designation "VMP-300," from Bio-Logic Science Instruments SAS) was
connected to the cell and was used to control the applied cell
voltage or current density.
[0106] The anode output was connected to a gas chromatograph
(obtained under the trade designation "MICR0490," Model 490 Micro
GC from Agilent, Santa Clara, Calif.) for analysis of the output
gas for hydrogen content. All tests were carried out at a
temperature of 80.degree. C. with deionized water (18 M.OMEGA. cm)
flowing at a rate of 75 mL/min. to the anode. The gas composition
at the anode compartment was measured using gas chromatography.
Under ambient pressure condition (i.e., 1 bar at the cathode
compartment and 1 bar at the anode compartment), the level of
H.sub.2 crossover through each membrane to the anode was measured
by measuring the mole percent of H.sub.2 in O.sub.2 at 80.degree.
C., varying current densities ranging from 2.0 to 0.05
A/cm.sup.2.
Comparative Example A (CE A)
[0107] A catalyst-coated membrane (CCM) for a water electrolyzer
was prepared using a 183-micrometer thick ion conducting membrane
("NAFION 117"). The CCM was prepared by hot roll laminating the
membrane to a platinum-based hydrogen evolution reaction (HER)
cathode catalyst layer and an iridium/iridium oxide based oxygen
evolution reaction (OER) anode catalyst layer. These catalyst
layers comprised nanostructured thin film (NSTF) catalysts, which
were prepared as described below under the heading "Preparation of
Nanostructured Thin Film (NSTF) Catalyst."
[0108] The resulting CCM was installed in a small single cell water
electrolyzer and tested for hydrogen crossover through the membrane
from the hydrogen-producing cathode to the oxygen-generating anode
compartment by analyzing the effluent of the anode compartment with
a gas chromatograph adapted to detect hydrogen gas. The test is
further described under the heading "Full CCM Test."
[0109] The level of hydrogen crossover detected was 0.52 mol. %
H.sub.2 in O.sub.2 when the cell was operated at a cathode
(hydrogen side) pressure of 1 bar (0.1 MPa) and 1.79 mol. % H.sub.2
in O.sub.2 when the cell was operated at a cathode (hydrogen side)
pressure of 30-bar (3 MPa). For efficiency, for example, it is
often desired to operate electrolyzer cells at a hydrogen side
pressure of 30 bar while staying far below the explosion limit of 4
mol. % H.sub.2 in O.sub.2. The average values of the mole percent
of H.sub.2 measured at 0.1 A/cm.sup.2 over one hour are listed in
Table 2, below.
TABLE-US-00002 TABLE 2 Description Pt/Support type; Pt loading
(mg/cm.sup.3); Mol. % H.sub.2 in O.sub.2 Total membrane thickness
at 1 bar at 30 bars (micrometers) (0.1 MPa) (3 MPa) CE A "NAFION
117" (183) 0.52 1.79 CE B "3M825EW" Double layer (100) 0.81
>2.00 CE C "3M825EW" Triple layer (125) 0.356 -- CE D "3M825EW"
Triple layer (150) 0.349 -- CE E "3M825EW," clay interlayer 0.663
-- (<110) Example 1 2.5 wt % Pt on Clay--Triple layer 0.066 --
(<110) Example 2 "Pt-PRWF"--Triple layer (143) 0.003 -- Example
3 "Pt-PRWF"--Triple layer (125) 0.028 -- Example 4
"Pt-PRWF"--Triple layer (112) 0.011 -- Example 5
"SnO.sub.230E"-4-Triple layer (150) 0.002 -- Example 6
"SnO.sub.230E"-12-Double layer (100) 0.001 -- Example 7
"Pt-PRWF"--Double layer (125) 0.048 -- Example 8 "Pt-PRWF"--Single
layer (43) 0.012 -- Example 9 "SnO.sub.210E"-50-Single layer (100)
<10 ppm -- Example 10 "SnO.sub.210E"-25-Single layer (100)
<10 ppm -- Example 11 "SnO.sub.230E"-50-Single layer (100)
<10 ppm -- Example 12 "SnO.sub.230E"-25-Single layer (100)
<10 ppm -- Example 13 "BA50E"-50-Single layer (100) <10 ppm
0.18 Example 14 "BA50E"-12-Single layer (100) 0.004 -- Example 15
"BA50E"-6-Double layer (100) 0.032 -- Example 16 "EA50E"-50-Single
layer (100) -- 0.24 Example 17 "EA50E"-25-Double layer (100) --
<10 ppm Example 18 "EA50E"-12-Double layer (100) -- <10 ppm
Example 19 "EA50E"-6-Double layer (100) 0.019 -- Example 20
"EA20E"-25-Double layer (100) 0.01 -- Example 21 "EA20E"-25-Single
layer (100) <10 ppm -- Example 22 "EA20E"-12-Double layer (100)
0.002 -- Example 23 "EA20E"-12-Single layer (100) <10 ppm --
Example 24 "F50E"-6-Double layer (100) 0.019 -- Example 25
"VA50E"-6-Double layer (100) 0.037 -- Example 26 "VA20E"-6-Double
layer (100) 0.01 -- Example 27 "EA20E"-17-Triple layer (150)
0.003
Comparative Example B (CE B)
[0110] A full CCM was prepared and tested as in Comparative Example
A, except that the membrane was made using two 50-micrometer thick
825 g/mol equivalent weight polymeric perfluorosulfonic acid proton
exchange membranes ("3M825EW MEMBRANE") that were laminated
together. The two membranes were combined into a single membrane
through hot roll lamination (laminator temperature, 350.degree. F.
(177.degree. C.); applied pressure, 150 psi (1 MPa); and roller
speed: 0.5 feet per minute (2.54 mm/second)).
[0111] The values of the mole percent of H.sub.2 measured at 0.1
A/cm.sup.2 are listed in Table 2, above.
Comparative Example C (CE C)
[0112] A full CCM was prepared and tested as in Comparative Example
B, except that a 125-micrometer thick membrane was used. The
membrane was made by hot roll laminating two 50-micrometer and one
25-micrometer 825 g/mol equivalent weight polymeric
perfluorosulfonic acid proton exchange membranes ("3M825EW
MEMBRANE").
[0113] The values of the mole percent of H.sub.2 measured at 0.1
A/cm.sup.2 are listed in Table 2, above.
Comparative Example D (CE D)
[0114] A full CCM was prepared and tested as in Comparative Example
B, except that a 150-micrometer thick membrane was used. The
membrane was made by hot roll laminating three 50 micrometer thick
825 g/mol equivalent weight polymeric perfluorosulfonic acid proton
exchange membranes ("3M825EW MEMBRANE").
[0115] The values of the mole percent of H.sub.2 measured at 0.1
A/cm.sup.2 are listed in Table 2, above.
Comparative Example E (CE E)
[0116] Comparative Example E was prepared by making a triple-layer
composite containing a thin, platinum-free, clay-containing central
layer. A CCM was prepared using two 50-micrometer thick 825 g/mol
equivalent weight polymeric perfluorosulfonic acid proton exchange
membranes (PEMs) ("3M825EW MEMBRANE") with a composite layer of
perfluorosulfonic acid (PFSA) ionomer ("3M825EW") and clay
("LAPONITE RD") sandwiched between the PEMs. The clay layer was
made by coating onto a 2 mil (51 micrometer) thick polyimide film
("KAPTON") a mixture of 1.00 gram of a 2.5 wt. % ethanol suspension
of clay ("LAPONITE RD") with 10.5 grams of PFSA ionomer ("3M825EW
SOLUTION"). The clay layer was then laminated first to one of the
50-micrometer thick PFSA membranes, and the "KAPTON" liner was
removed. Laminations were done on a heated roller laminator with
150 psi (1 MPa) applied pressure, at 0.5 feet per minute (fpm)
(2.54 mm per second minute), and at 350.degree. F. (177.degree.
C.). Finally, the combined membrane was laminated to the second 50
micrometer thick PFSA membrane using the same laminating
conditions, with the clay layer facing the second membrane.
[0117] The values of the mole percent of H.sub.2 measured at 0.1
A/cm.sup.2 are listed in Table 2, above.
Example 1
[0118] A full CCM was prepared and tested as described in
Comparative Example E, except that the membrane was made using two
50-micrometer thick 825 g/mol equivalent weight polymeric
perfluorosulfonic acid proton exchange membranes ("3M825EW
MEMBRANES") with a composite layer of PFSA ionomer ("3M825EW
SOLUTION") and clay ("LAPONITE RD") which had been sputter coated
with 2.5 wt. % platinum, sandwiched between the PEMs. The
three-layer construction of this membrane is shown in Table 3,
below, following the layer labeling convention of FIG. 2, in which
platinum-bearing Layer 1 corresponds to: single layer membrane 210
in FIG. 2A; membrane layer 221 in double-layer membrane 220 of FIG.
2B; central layer 231 in membrane 230 of FIG. 2C (for all triple
layer membranes except Example 27); and (anode) side layer 241 in
triple layer membrane 240 of FIG. 2D for Example 27. Layer 2 of
Table 3 corresponds to layers 222, 232, and 242 in FIGS. 2B-2D,
respectively. Layer 3 in Table 3 corresponds to membrane layers 233
and 243 in FIGS. 2C and 2D, respectively.
TABLE-US-00003 TABLE 3 Layer 1 Formulation Membrane Layer 1 Layer 2
Layer 3 PFSA solution Wet film Dried film "PFSA "PFSA PFSA
Pt/Support suspension thickness, thickness, 825EW," 825EW,"
Solution Type grams Pt/Support Type grams micrometers micrometers
micrometers micrometers Example 1 34 wt. % 10.5 2.5 wt. % Pt on
Clay 1.00 50 <10 50 50 Example 2 34 wt. % 28.83 "Pt-PRWF" 1.65
381 43 50 50 Example 3 34 wt. % 28.83 "Pt-PRWF" 1.65 254 25 50 50
Example 4 34 wt. % 28.83 "Pt-PRWF" 1.65 127 12 50 50 Example 5 42
wt. % 18.75 "SnO.sub.230E" 1.87 381 50 50 50 Example 6 42 wt. %
18.75 "SnO.sub.230E" 3.74 381 50 50 0 Example 7 34 wt. % 28.83
"Pt-PRWF" 1.65 254 25 100 0 Example 8 34 wt. % 28.83 "Pt-PRWF" 1.65
381 43 0 0 Example 9 42 wt. % 17.98 "SnO.sub.210E" 5.22 762 100 0 0
Example 10 42 wt. % 17.98 "SnO.sub.210E" 2.61 762 100 0 0 Example
11 42 wt. % 18.75 "SnO.sub.230E" 7.48 762 100 0 0 Example 12 42 wt.
% 18.75 "SnO.sub.230E" 3.74 762 100 0 0 Example 13 42 wt. % 18.52
"BA50E" 4.62 762 100 0 0 Example 14 42 wt. % 18.52 "BA50E" 1.15 762
100 0 0 Example 15 42 wt. % 17.90 "BA50E" 1.10 381 50 50 0 Example
16 42 wt. % 18.52 "EA50E" 4.40 762 100 0 0 Example 17 42 wt. %
18.52 "EA50E" 4.40 381 50 50 0 Example 18 42 wt. % 18.52 "EA50E"
2.20 381 50 50 0 Example 19 42 wt. % 17.90 "EA50E" 1.10 381 50 50 0
Example 20 42 wt. % 19.96 "EA20E" 21.56 381 50 50 0 Example 21 42
wt. % 19.96 "EA20E" 10.78 762 100 0 0 Example 22 42 wt. % 19.96
"EA20E" 10.78 381 50 50 0 Example 23 42 wt. % 19.96 "EA20E" 5.39
762 100 0 0 Example 24 42 wt. % 17.90 "F50E" 1.10 381 50 50 0
Example 25 42 wt. % 17.90 "VA50E" 1.10 381 50 50 0 Example 26 42
wt. % 17.90 "VA20E" 1.10 381 50 50 0 Example 27 42 wt. % 19.96
"EA20E" 10.78 381 50 50 50
Example 2
[0119] The membrane of Example 2 was prepared and tested as in
Example 1, except that the three-layer construction (see Table 3,
above, and FIG. 2C) was produced by laminating three separate
membranes together, with the platinum in the middle layer (Layer
1), was supported on whiskers of perylene red pigment (PR 149).
These whiskers were prepared as described under the heading
"Preparation of Nanostructured Thin Film (NSTF) Catalyst" above,
except that the whiskers had only one fifth of the 0.25 mg/cm.sup.2
platinum loading of the Pt-NSTF whiskers used in the CCM cathodes
of these experiments. Fragments of these low-loading
platinum-coated perylene red whisker fragments ("Pt-PRWF")
containing a platinum loading of 50 micrograms/cm.sup.2 (measured
geometrically as deposited on the MCTS substrate) were removed from
the MCTS with a brush and collected.
[0120] A 9 wt. % suspension of the supported platinum catalyst
("Pt-PRWF" in this example) was prepared by stirring 0.9 gram of
the supported catalyst into 9 grams of deionized water, with
continued stirring overnight.
[0121] To prepare the platinum-bearing membrane for Layer 1, 1.62
gram of the 9 wt. % suspension of the supported platinum catalyst
and 28.83 grams of 34 wt. % polymeric perfluorosulfonic acid ion
exchange resin solution ("3M825EW SOLUTION") were mixed together
and the composite mixture slowly stirred at 100 rpm overnight to
obtain a homogeneous mixture. The resulting mixture (i.e.,
composite formulation) was then immediately used to cast a
membrane. A 5 inch (12.7 cm) wide microfilm applicator (wet film
thickness: 15 mils (0.38 millimeter) Paul N. Gardner Company, Inc.)
was used to coat a 2 mil (51 micrometer) thick polyimide film
("KAPTON") with the composite mixture. The coated sample was dried
at 70.degree. C. for 15 minutes and then at 120.degree. C. for 30
minutes, followed by annealing at 160.degree. C. for 10 minutes.
The annealed sample was then cooled down to room temperature.
[0122] To prepare a triple-layer membrane, the resulting annealed
membrane was laminated with two 50 micrometer-thick 825 g/mol
equivalent weight polymeric perfluorosulfonic acid proton exchange
membranes ("3M825EW MEMBRANE") so that the annealed Pt-PRWF
membrane was sandwiched between the two 825 g/mol equivalent weight
polymeric perfluorosulfonic acid proton exchange membranes
("3M825EW MEMBRANE") (laminator temperature, 350.degree. F.
(177.degree. C.); applied pressure, 150 psi (1 MPa); and roller
speed, 0.5 feet per minute (2.54 mm per second minute)).
[0123] The test results are listed in Table 3, above.
Example 3
[0124] The membrane of Example 3 was prepared and tested as in
Example 2, except that the membrane for Layer 1 was coated at a wet
thickness of only 10 mils (0.25 mm) resulting in a thinner membrane
(25 micrometers) and a correspondingly lower total platinum content
(see Table 3, above).
[0125] The test results are listed in Table 3, above.
Example 4
[0126] The membrane of Example 4 was prepared and tested as in
Example 2, except that the membrane for Layer 1 was coated at a wet
thickness of only 5 mils (0.13 mm) resulting in a thinner membrane
(12 micrometers) and a correspondingly lower total platinum content
(see Table 3, above).
[0127] The test results are listed in Table 3, above.
Example 5
[0128] The membrane of Example 5 was prepared and tested as in
Example 2, except that the membrane for Layer 1 was prepared from a
blend composed of 18.75 grams of a 42 wt. % PFSA solution (prepared
as described below) and 1.87 gram of a 9 wt. % suspension of
platinum supported on tin oxide ("SnO.sub.230E") prepared as
described in Example 2 (see Table 3, above).
[0129] The 42 wt. % PFSA solution was prepared by stirring 40 grams
of 825 g/mol equivalent weight polymeric perfluorosulfonic acid ion
exchange resin ("3M825EW POWDER") into in 55.4 grams of an 80:20 by
weight percent ethanol (EtOH) to water.
[0130] The test results are listed in Table 3, above.
Example 6
[0131] The membrane of Example 6 was prepared and tested as in
Example 5, except that this was a two-layer construction, in which
the membrane forming the layer containing platinum catalyst tin
oxide ("SnO.sub.230E") was laminated to only one
50-micrometer-thick 825 g/mol equivalent weight polymeric
perfluorosulfonic acid proton exchange membrane ("3M825EW
MEMBRANE") (see Table 3, above). During preparation of the full
CCM, the membrane layer containing the platinum, Layer 1, was
laminated to the iridium anode catalyst that comprised Ir-NSTF.
[0132] The test results are listed in Table 3, above.
Example 7
[0133] The two-layer membrane of Example 7 was prepared and tested
as in Example 6, except that the platinum-containing membrane for
Layer 1 was cast from a blend of 28.83 grams of 34 wt. % polymeric
perfluorosulfonic acid ion exchange resin solution ("3M825EW
SOLUTION") and 1.65 gram of the 9 wt. % suspension of 50
micrograms/cm.sup.2 Pt-NSTF perylene red whisker fragments
("Pt-PRWF") from Example 2, using a 254 micrometer (10 mil) wet
coating thickness, resulting in a 25-micrometer thick layer. The
platinum-containing membrane (Layer 1) was laminated to a
100-micrometer thick 825 g/mol equivalent weight polymeric
perfluorosulfonic acid proton exchange membrane ("3M825EW
MEMBRANE"), resulting in a total thickness of 125 micrometers.
[0134] The test results are listed in Table 32, above.
Example 8
[0135] The single-layer membrane of Example 8 was prepared and
tested as in Example 7, except that the platinum-containing
membrane for Layer 1 was cast using a 15 mil (0.38 mm) wet coating
thickness, resulting in a 43-micrometer thick Layer 1.
[0136] This layer was tested by itself, rather than laminating it
to one or more PFSA membranes before testing. The test results are
listed in Table 3, above.
Example 9
[0137] The single-layer membrane of Example 9 was prepared and
tested as in Example 8, except that it was cast from a blend made
up of 17.98 grams of a 42 wt. % polymeric perfluorosulfonic acid
ion exchange resin solution, prepared as described in Example 5,
and 5.22 grams of 42.5 wt. % suspension of tin oxide supported
platinum catalyst ("SnO.sub.210E") in deionized water with a wet
thickness of 30 mils (0.76 mm) resulting in a final membrane
thickness of 100 micrometers. The 42.5 wt. % suspension of the
supported platinum catalyst was prepared by stirring 2.22 grams of
supported catalyst ("SnO.sub.210E") into 3.0 grams of deionized
water, with continued stirring overnight. The composition and
resulting structure is given in Table 3, above.
[0138] The test results are listed in Table 3, above.
Example 10
[0139] The single-layer membrane of Example 10 was prepared and
tested as in Example 9, except that it was cast from a blend
composed 17.98 grams of the 42 wt. % PFSA solution and 2.61 grams
of the 42.5 wt. % suspension of "supported platinum catalyst"
("SnO.sub.210E") in deionized water, resulting in another
100-micrometer thick membrane having only half of the platinum
concentration of Example 9.
[0140] The test results are listed in Table 3, above.
Example 11
[0141] The single-layer membrane of Example 11 was prepared and
tested as in Example 10, except that the platinum-bearing membrane
was made from a mixture containing 18.75 grams of the 42 wt. % PFSA
solution and 7.48 grams of a 9 wt. % suspension of a different tin
oxide-supported platinum catalyst ("SnO.sub.230E"), as listed in
Table 3, above.
[0142] The test results are listed in Table 3, above.
Example 12
[0143] The single-layer membrane of Example 12 was prepared and
tested as in Example 10, except that the platinum-bearing membrane
was made from a blending containing 18.75 grams of the 42% PFSA
solution and 3.74 grams of a 9 wt. % suspension of the tin
oxide-supported platinum catalyst ("SnO.sub.230E") in deionized
water, only half of the platinum of Example 11.
[0144] The test results are listed in Table 3, above.
Example 13
[0145] The ion-conducting membrane of Example 13 was prepared as a
single-layer homogeneous construction containing a carbon-supported
platinum catalyst ("BA50E"). 100 micrometer-thick PFSA-based
composite membranes, having 50 mg Pt loading per a 1 cm.sup.3
volume of the membrane (as listed in Table 2, above), was prepared
by mixing together 4.62 grams of a 9 wt. % catalyst ("BA50E")
suspension (prepared as in Example 2) and 18.52 grams of a 42 wt. %
PFSA solution (prepared as in Example 5). The mixture was slowly
stirred at 100 rpm overnight to obtain a homogeneous mixture. The
resulting mixture (i.e., composite formulation) was then
immediately used to cast a membrane. A 5 inch (12.7 cm) wide
microfilm applicator (wet film thickness: 30 mils (0.76 mm), Paul
N. Gardner Company, Inc.) was used to coat a 2 mil (51 micrometer)
thick substrate ("KAPTON") with the composite mixture. The coated
sample was dried at 70.degree. C. for 15 minutes and then at
120.degree. C. for 30 minutes, followed by annealing at 160.degree.
C. for 10 minutes. The annealed sample was then cooled down to room
temperature. The resultant membrane is described in Table 3, above,
and represented in FIG. 2A.
[0146] The resulting membrane was used to make a CCM for a hydrogen
crossover test. The corresponding CCM was prepared as follows: Nano
Structured Thin Film (NSTF) catalyst whiskers on a support film
("KAPTON") (as prepared in the section "Preparation of
Nanostructured Thin Film (NSTF) Catalyst," above) were transferred
from the support film to a final membrane article through hot roll
lamination (temperature, 350.degree. F. (177.degree. C.); applied
pressure, 150 psi (1 MPa); and roller speed: 1.2 fpm (37 cm per
minute)), following the procedure described in the section
"Preparation of Catalyst-Coated Membrane (CCM)," above. The
as-prepared membrane was dried at 110.degree. C. for 2 minutes
under nitrogen prior to lamination. The Pt-deposited NSTF
("Pt-NSTF," Pt mass loading, 0.25 mg/cm.sup.2) was used as the
cathode and Iridium (Ir)-deposited NSTF ("Ir-NSTF," Ir mass
loading, 0.50 mg/cm.sup.2) was used as the anode.
[0147] The test results are listed in Table 3, above.
Example 14
[0148] Example 14 was prepared and tested in the same manner as
Example 13 above, except that it used 1.15 gram of the 9 wt. %
catalyst ("BA50E") suspension with the 18.52 grams of the 42 wt. %
PFSA solution, resulting in a lower platinum concentration in the
ion-conducting membrane.
[0149] The test results are listed in Table 3, above.
Example 15
[0150] Example 15 was a double-layer laminated composite membrane,
as represented in FIG. 2B, that was prepared and tested in a manner
similar to that of Example 14. To prepare this double layer
PFSA-based composite membrane having 6 mg Pt loading per a 1
cm.sup.3 volume of the membrane (as listed in Table 2, above), 1.10
gram of a 9 wt. % "BA50E" suspension (prepared as in Example 2) and
17.90 grams of a 42 wt. % PFSA solution (prepared as in Example 5)
were mixed together and the composite mixture was slowly stirred at
100 rpm overnight to obtain a homogeneous mixture. The resulting
mixture (i.e., composite formulation) was then immediately used to
cast a membrane. A 5 inch (12.7 cm) wide microfilm applicator (wet
film thickness: 15 mils (0.38 mm), Paul N. Gardner Company, Inc.)
was used to coat a 2 mil (51 micrometer) substrate ("KAPTON") with
the composite mixture. The coated sample was dried at 70.degree. C.
for 15 minutes and then at 120.degree. C. for 30 minutes, followed
by annealing at 160.degree. C. for 10 minutes. The annealed sample
was then cooled down to room temperature. The double-layer
membrane, consisting of a 50 micrometer-thick conventional PFSA
membrane ("3M825EW MEMBRANE") and the 50 micrometer-thick composite
film containing supported Pt, was prepared through hot roll
lamination (laminator temperature, 350.degree. F. (177.degree. C.);
applied pressure, 150 psi (1 MPa); and roller speed, 0.5 fpm (2.54
mm/s)). The same preparation method was used to prepare the
corresponding CCM as described in Example 13. However, care was
taken to assure that the Ir-NSTF was attached to the membrane
surface having the film layer containing catalyst ("BA50E"), so
that the catalyst ("BA50E") could be positioned nearer to the anode
than to the cathode.
[0151] The test results are listed in Table 3.
Example 16
[0152] Example 16 was a single layer membrane prepared and tested
as in Example 13, except that a different carbon-supported platinum
catalyst ("EA50E") was used. As shown in Table 3 above, 18.52 grams
of the 42 wt. % PFSA solution was mixed with 4.40 grams of a 9 wt.
% catalyst ("EA50E") suspension. This mixture was cast into a
membrane of the form shown in FIG. 2A.
[0153] The test results are listed in Table 3, above.
Example 17
[0154] Example 17 was a double layer membrane prepared and tested
as in Example 15, except that a different catalyst ("EA50E") was
used, and the two-layer composite membrane was made by top-coating
a 50-micrometer thick PFSA membrane onto the Pt-containing layer,
rather than by lamination. The catalyst ("EA50E") suspension and
the PFSA solution were mixed together using 4.40 grams of the 9 wt.
% catalyst ("EA50E") suspension with 18.52 grams of the 42 wt. %
PFSA solution. The composite mixture was slowly stirred at 100 rpm
overnight to obtain a homogeneous mixture. The resulting mixture
(i.e., composite formulation) was then immediately used to cast a
membrane. An 8-inch (20.32 cm) wide microfilm applicator (wet film
thickness: 15 mils (0.38 mm), Paul N. Gardner Company, Inc.) was
used to coat a 2 mil (51 micrometer) substrate ("KAPTON") with the
composite mixture. The coated samples were dried at 70.degree. C.
for 15 minutes and then at 120.degree. C. for 30 minutes, followed
by annealing at 160.degree. C. for 10 minutes. The annealed sample
was then cooled down to room temperature. The resulting annealed
composite film was coated with a 34 wt. % of PFSA solution
("3M825EW SOLUTION") using an 8 inch (20.32 cm) wide microfilm
applicator (wet film thickness: 15 mils (0.38 mm)). The coated
samples were dried at 70.degree. C. for 15 minutes and then at
120.degree. C. for 30 minutes, followed by annealing at 160.degree.
C. for 10 minutes. The resulting double-layer membrane, consisting
of a 50 micrometer-thick conventional PFSA "3M825EW MEMBRANE"
membrane and the 50 micrometer-thick composite film, were used to
make a CCM for hydrogen crossover tests. The same preparation
method was used to prepare the corresponding CCM as described in
Example 13. The Ir-deposited NSTF was attached to the surface of
the film layer containing catalyst ("EA50E") so that the catalyst
("EA50E") would be positioned nearer to the anode than to the
cathode.
[0155] The test results are listed in Table 3, above.
Example 18
[0156] Example 18 was a double layer membrane prepared and tested
as in Example 17, except that only half as much of the 9 wt. %
catalyst ("EA50E") suspension was used to make Layer 1 of the
composite membrane, as is shown in Table 3, above.
[0157] The test results are listed in Table 3, above.
Example 19
[0158] Example 19 was a double layer membrane prepared and tested
as in Example 15, except that catalyst "EA50E" was used, and the
composite membrane was made by lamination, rather than top-coating.
1.10 gram of the 9 wt. % catalyst ("EA50E") suspension was combined
with 17.90 grams of the 42 wt. % PFSA solution to cast Layer 1.
Layer 1 was then laminated to a 50-micrometer thick membrane
("3M825EW MEMBRANE") according to the procedure described in
Comparative Example B above, to form a double layer composite
membrane as shown in FIG. 2B. Note that this laminated membrane is
the same as the top-coated composite membrane in Example 17, except
that only one quarter as much "EA50E" catalyst was used in Layer 1
of the composite membrane (1.10 gram vs. 4.40 grams).
[0159] The test results are listed in Table 3, above.
Example 20
[0160] Example 20 was a double layer membrane prepared and tested
as in Example 19, except that a different carbon-supported platinum
catalyst ("EA20E") was used, at a higher concentration. The
formulation for coating Layer 1 was a mixture of 21.56 grams of a 9
wt. % catalyst suspension ("EA20E") with 19.96 grams of the 42 wt.
% PFSA solution that was prepared in Example 5.
[0161] The test results are listed in Table 3, above.
Example 21
[0162] Example 21 was a single layer membrane prepared and tested
as in Examples 13, 14, and 16, except that a different catalyst
("EA20E") was used, and at a higher weight loading of catalyst.
10.78 grams of a 9 wt. % catalyst ("EA20E") suspension was mixed
with 19.96 grams of the 42 wt. % PFSA solution from Example 5 to
produce the formulation used for casting Layer 1.
[0163] The test results are listed in Table 3, above.
Example 22
[0164] Example 22 was a laminated double layer membrane prepared
and tested as in Example 15, except that a different catalyst
("EA20E") was used. The formulation for preparing Layer 1 was
obtained by mixing 10.78 grams of catalyst ("EA20E") suspension
with 19.96 grams of the 42 wt. % PFSA solution from Example 5.
[0165] The test results are listed in Table 3, above.
Example 23
[0166] Example 23 was a single layer membrane prepared and tested
as in Example 13, except that a different catalyst ("EA20E") was
used, and at a higher weight loading of catalyst. This example is
very comparable to Example 21, except with approximately half of
the catalyst loading of Example 21. The formulation for casting
Layer 1 was produced by mixing 5.39 grams of 9 wt. % aqueous
suspension of catalyst ("EA20E") with 19.96 grams of the 42 wt. %
PFSA solution prepared in Example 5.
[0167] The test results are listed in Table 3, above.
Example 24
[0168] Example 24 was a laminated double layer membrane prepared
and tested as in Example 15, except that a different catalyst
("F50E") was used. The formulation for casting Layer 1 was prepared
by mixing 1.10 gram of a 9 wt. % aqueous suspension of
carbon-supported platinum catalyst ("F50E") with 17.90 grams of the
42 wt. % PFSA solution from Example 5.
[0169] The test results are listed in Table 3, above.
Example 25
[0170] Example 25 was a laminated double layer membrane prepared
and tested as in Example 15, except that a different catalyst
("VA50E") was used. The formulation used for casting Layer 1 was
prepared by mixing 1.10 gram of a 9 wt. % aqueous suspension of
carbon-supported Pt catalyst ("VA50E") with 17.90 grams of the 42
wt. % PFSA solution prepared in Example 5.
[0171] The test results are listed in Table 3, above.
Example 26
[0172] Example 26 was a laminated double layer membrane prepared
and tested as in Example 15, except that a different
carbon-supported platinum catalyst ("VA20E") was used. The
formulation used to cast Layer 1 was prepared by mixing 1.10 gram
of a 9 wt. % aqueous suspension of the carbon-supported platinum
catalyst ("VA20E") with 17.90 grams of the 42 wt. % PFSA solution
prepared in Example 5.
[0173] The test results are listed in Table 3, above.
Example 27
[0174] The membrane of Example 27 was prepared and tested as in
Example 2, except that the equally spaced composite membrane for
Layer 1 was prepared from a blend composed of 19.96 grams of a 42
wt. % PFSA solution and 10.78 grams of a 9 wt. % suspension of
platinum supported on carbon ("EA20E") (see Table 3, above) and
Layer 1 was located adjacent to the anode side in the resulting
CCM, as shown in FIG. 2D.
[0175] The 42 wt. % PFSA solution was prepared by stirring 40 grams
of 825 g/mol equivalent weight polymeric perfluorosulfonic acid ion
exchange resin ("3M825EW POWDER") into 55.4 grams of an 80:20 by
weight percent ethanol (EtOH) to water solution.
[0176] The 9 wt. % suspension of the supported platinum catalyst
("EA20E") was prepared by stirring 0.9 gram of the supported
catalyst into 9 grams of deionized water, with continue stirring
overnight.
[0177] The test results are listed in Table 3, above.
[0178] Foreseeable modifications and alterations of this disclosure
will be apparent to those skilled in the art without departing from
the scope and spirit of this invention. This invention should not
be restricted to the embodiments that are set forth in this
application for illustrative purposes.
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