Claims
- 1. A catalytic layer suitable for use in a fuel cell, said catalytic layer contacting a proton diffusion layer of the fuel cell, at least said proton diffusion layer-contacting surface portion of said layer being a material comprising,
at least about 30 wt % platinum or gold particulates of mean particulate size of 5 nanometers or less, carbon particulates at a Pt:C or Au:C weight ratio of between about 5:1 and about 2:1, balance organic material, said organic material comprising between about 80 wt % and 100 wt % gas permeable ionomer and from 0 wt % to about 20 wt % particulates of hydrophobic polymer.
- 2. The catalytic layer of claim 1 wherein at least said proton diffusion layer-contacting surface portion of said layer is formed of material having at least about 40 wt % platinum or gold particulates of mean particle size of 5 nanometers or less, at least at said proton diffusion layer-contacting surface portion.
- 3. The catalytic layer of claim 1 wherein said platinum or gold particulates have mean particulate sizes of 3 nanometers or less.
- 4. The catalytic layer of claim 2 wherein said platinum or gold particulates have mean particulate sizes of 3 nanometers or less.
- 5. The catalytic layer of claim 1 wherein the Pt:C or Au:C weight ration is between about 3:1 and about 2:1.
- 6. The catalytic layer of claim 1 containing not more than about 80 wt % particulates of Pt or Au.
- 7. The catalytic layer of claim 1 wherein at least a portion of said layer is effectively gas impermeable.
- 8. The catalytic layer of claim 1 wherein said layer is predominantly gas impermeable.
- 9. The catalytic layer of claim 1 having a uniform composition throughout.
- 10. The catalytic layer of claim 1 having a highest Pt or Au concentration at a proton diffusion layer-contacting surface portion and a gradient of lower Pt or Au concentrations away from said proton diffusion layer-contacting surface portion.
- 11. The catalytic layer of claim 1 bonded to a proton diffusion layer.
- 12. The catalytic layer of claim 1 bonded to a cathode.
- 13. A fuel cell comprising an anode, an anodic catalytic layer, a proton diffusion layer, the catalytic layer of claim 1 as the catalytic layer and a cathode.
- 14. A method of forming a catalytic layer comprising, providing a combustion chemical vapor deposition flame that produces platinum or gold particulates, providing a non-flame spray or sprays, said non-flame spray comprising a solvent system, dissolved ionomer, and suspended carbon particulates, and causing said non-flame spray or sprays and platinum or gold particulates produced by said flame to co-deposit on a substrate surface.
- 15. A catalyst layer suitable for use in conjunction with an anode in a fuel cell formed of material, said catalyst layer having a surface portion for contacting a proton conduction layer, said material comprising at least about 30 wt % platinum particulates of mean particle size of 5 nanometers or less at at least said proton conduction layer-contacting portion, co-deposited ruthenium in metallic and/or oxide form or alloyed with the platinum, and an ionomer.
- 16. The catalyst layer according to claim 15 wherein said particulates have a mean particulate size of 3 nanometers or less.
- 17. The catalyst layer of claim 15 having at least about 40 wt % platinum particulates of mean particle size of 5 nanometers or less, at least at said proton conduction layer-contacting surface portion.
- 18. The catalyst layer of claim 17 wherein said particulates have a mean particulate size of 3 nanometers or less.
- 19. The catalyst layer of claim 11 bonded to a proton conduction layer.
- 20. The catalyst layer of claim 11 bonded to an anode.
- 21. A fuel cell comprising an anode; the catalyst layer of claim 11 as the anodic catalyst layer; a proton conduction layer; a cathodic catalyst layer; and a cathode.
- 22. A method of forming an anode catalytic layer comprising, providing a combustion chemical vapor deposition flame that produces platinum particulates and which co-deposits ruthenium in metallic and/or oxide form or alloyed to the platinum,
providing a non-flame spray comprising a solvent system and dissolved ionomer, and causing said non-flame spray, and platinum particulates along with said co-deposited ruthenium, in metallic and/or oxide form or alloyed with the platinum, produced by said flame to co-deposit on a substrate surface.
- 23. A catalytic layer comprising platinum particulates, ruthenium in metallic and/or oxidized form, gas permeable ionomer, and carbon particulates at a Pt/C weight ratio of about 6:1 or less down to 0 carbon particulates.
- 24. The catalytic layer according to claim 23 having no carbon particulates.
- 25. Catalytic material comprising at least about 30 wt % platinum particulates of mean particle size of 3 nanometers or less, co-deposited ruthenium in metallic and/or oxide form or alloyed with the platinum, and a gas ionomer.
- 26. The material of claim 23 in powder form.
- 27. The material of claim 26 in wet or dry form.
Priority Claims (2)
Number |
Date |
Country |
Kind |
60243966 |
Oct 2000 |
US |
|
60243883 |
Oct 2000 |
US |
|
Government Interests
[0001] This invention was developed under National Science Foundation grants nos. DMI-9801444 and DMI-9960502; the U.S. government has rights in these invention pursuant thereto.
PCT Information
Filing Document |
Filing Date |
Country |
Kind |
PCT/US01/48581 |
10/26/2001 |
WO |
|