METHOD OF COATING A CATALYST ON FLAT OR TEXTURED SUBSTRATES
According to the invention there is a method of applying a catalyst layer to a surface, the method comprising the steps of: providing a donor substrate having opposing first and second surfaces and providing a catalyst ink disposed as a layer on the second surface, wherein the catalyst ink comprises a catalyst and a solvent; providing an acceptor substrate, wherein the second surface of the donor substrate faces towards the acceptor substrate; and irradiating the catalyst ink with laser radiation at a wavelength which is absorbed by the catalyst ink so as to transfer the catalyst ink from the donor substrate to the acceptor substrate.
1 . A method of applying a catalyst layer to a surface, the method comprising the steps of:
providing a donor substrate having opposing first and second surfaces and providing a catalyst ink disposed as a layer on the second surface, wherein the catalyst ink comprises a catalyst and a solvent;
providing an acceptor substrate, wherein the second surface of the donor substrate faces towards the acceptor substrate; and
irradiating the catalyst ink with laser radiation at a wavelength which is absorbed by the catalyst ink so as to transfer the catalyst ink from the donor substrate to the acceptor substrate.
2 . The method according to claim 1 , wherein the method further comprises a step of drying the catalyst ink on the acceptor substrate so as to remove substantially all the solvent.
3 . The method according to claim 1 , wherein the catalyst comprises a reformer catalyst.
4 . The method according to claim 1 , wherein the acceptor substrate comprises a non-flat surface.
5 . The method according to claim 1 , wherein the acceptor substrate comprises a textured surface.
6 . The method according to claim 1 , wherein the acceptor substrate comprises a surface with raised and depressed sections.
7 . The method according to claim 1 , wherein the acceptor substrate comprises a surface with dimples.
8 . The method according to claim 1 , wherein the acceptor substrate comprises a surface with ridges.
9 . The method according to claim 1 , wherein the acceptor substrate comprises a plate for a solid oxide fuel cell.
10 . The method according to claim 1 , wherein the catalyst ink is applied to the acceptor substrate in a pre-determined pattern.
11 . The method according to claim 1 , wherein the catalyst ink is applied to the acceptor substrate in a pre-determined pattern corresponding to a texture of the acceptor substrate surface.
12 . The method according to claim 1 , wherein the catalyst layer comprises at least one region having a first thickness and at least one region having a second thickness, wherein the first and second thicknesses are different.
13 . The method according to claim 1 , wherein the acceptor substrate has a textured surface comprising depressed and raised surfaces, and wherein the catalyst ink is applied to the acceptor substrate in a pre-determined pattern corresponding to a texture of the acceptor substrate surface, such that the depressed surfaces are coated and the raised surfaces are not coated.
14 . The method according to claim 1 , wherein the acceptor substrate has a textured surface comprising depressed and raised surfaces, and wherein the catalyst ink is applied to the acceptor substrate in a pre-determined pattern corresponding to a texture of the acceptor substrate surface, such that the raised surfaces are coated and the depressed surfaces are not coated.
15 . The method according to claim 1 , wherein the acceptor substrate comprises a flat surface.
16 . The method according to claim 1 , wherein the solvent has a boiling point of at least 80° C., at least 95° C., at least 100° C., or at least 110° C.
17 . The method according to claim 1 , wherein the solvent comprises water, ethanol, n-propanol, iso-propanol, n-butanol, methanol, ethylene glycol, propylene glycol, dipropylene glycol, poly(ethylene glycol), poly(propylene glycol), ethylene carbonate, propylene carbonate, diethyl carbonate, dimethyl carbonate, or a combination thereof.
18 . The method according to claim 17 , wherein the solvent consists essentially of water.
19 . A catalyst layer obtained using a method according to claim 1 .
20 . A catalyst-coated plate comprising the catalyst layer according to claim 19 .