Patterned electrode catalyst
Disclosed herein are embodiments of a patterned electrode comprising regions of catalyst and segregating regions that separate the regions of catalyst. The segregating regions may be regions of non-catalytic material. The catalyst regions may correspond to the channels of a flow field. The electrode provides improved fuel cell performance, particularly at high current densities. The electrode may be for all suitable applications, such as in a membrane electrode assembly and/or a fuel cell. Also disclosed is a method for making the patterned electrode. The method may comprise using masks to apply the catalyst and non-catalyst material to a substrate.
1. An electrode, comprising:
a flow field comprising a flow field channel that is defined by flow field walls;
a substrate layer in direct physical contact with the flow field; and
a plurality of catalyst regions separated by non-catalyst regions and in direct physical contact with the substrate layer, the plurality of catalyst regions being located such that multiple catalyst regions and multiple non-catalyst regions are arranged under the flow field channel, the catalyst regions comprising a catalyst material;
wherein the plurality of catalyst regions are located under the flow field channel and the flow field walls.
2. The electrode of claim 1 , wherein the non-catalyst regions are empty regions.
3. The electrode of claim 1 , wherein the catalyst material comprises platinum and a carbon support.
4. The electrode of claim 3 , wherein the carbon support is a high surface area carbon support.
5. The electrode of claim 1 , wherein the non-catalyst regions comprise non-catalyst material comprising carbon, an ionomer, or a combination thereof.
6. The electrode of claim 1 , wherein:
the catalyst regions each have a first width of from greater than zero to 2 mm;
the non-catalyst regions each have a second width of from greater than zero to 2 mm;
or a combination thereof.
7. A membrane electrode assembly, comprising
a cathode comprising the electrode of claim 1 ;
an anode; and
a membrane.
8. A fuel cell, comprising the electrode of claim 1 .
9. A stationary power device comprising the electrode of claim 1 .
10. The electrode of claim 1 , wherein the substrate layer comprises a gas dispersion layer and a microporous layer, and the flow field directly contact the gas dispersion layer and the plurality of catalyst regions directly contact the microporous layer.
11. An electrode, comprising:
a flow field comprising a flow field channel that is defined by flow field walls;
a substrate layer in direct physical contact with the flow field; and
a plurality of catalyst regions separated by non-catalyst regions and in direct physical contact with the substrate layer, the plurality of catalyst regions being located such that multiple catalyst regions and multiple non-catalyst regions are arranged under the flow field channel, the catalyst regions comprising a catalyst material;
wherein the plurality of catalyst regions are located under the flow field channel, but not under the flow field walls.
12. The electrode of claim 11 , wherein the catalyst material comprises platinum and a carbon support.
13. The electrode of claim 12 , wherein the carbon support is a high surface area carbon support.
14. The electrode of claim 11 , wherein the non-catalyst regions comprise non-catalyst material comprising carbon, an ionomer, or a combination thereof.
15. The electrode of claim 11 , wherein the non-catalyst regions are empty regions.
16. The electrode of claim 11 , wherein the substrate layer comprises a gas dispersion layer and a microporous layer, and the flow field directly contact the gas dispersion layer and the plurality of catalyst regions directly contact the microporous layer.
17. The electrode of claim 11 , wherein:
the catalyst regions each have a first width of from greater than zero to 2 mm;
the non-catalyst regions each have a second width of from greater than zero to 2 mm;
or a combination thereof.
18. A membrane electrode assembly, comprising
a cathode comprising the electrode of claim 11 ;
an anode; and
a membrane.
19. A fuel cell, comprising the electrode of claim 11 .
20. A stationary power device comprising the electrode of claim 11 .