Electrolysis of Water and Fuel Cell Coating

1. Electrolysis of Water Coating

• The importance of electrode material spraying: In the process of electrolysis of water, the performance of the electrode plays a key role in the efficiency of electrolysis. By spraying the catalyst on the surface of the electrode, the reaction activity of the electrode can be greatly improved. For example, for hydrogen evolution reaction (HER) and oxygen evolution reaction (OER), commonly used catalysts such as platinum (Pt), iridium (Ir), ruthenium (Ru) and its oxides, etc., spraying these catalysts on electrodes (such as titanium electrodes, carbon electrodes, etc.) in a suitable manner can reduce the overpotential of the reaction and improve the energy conversion efficiency of water electrolysis.
• Spraying methods and advantages:
  – Thermal spraying: Thermal spraying technology can heat the catalyst material to a molten or semi-molten state, and then spray it onto the electrode surface at high speed. This method can form a dense coating with good bonding with the electrode. For example, when preparing an oxygen evolution electrode, plasma thermal spraying technology is used to spray iridium oxide on a titanium electrode. The high density of the coating helps to improve the stability and corrosion resistance of the electrode, thereby extending the service life of the electrode.
  – Chemical solution spraying: A chemical solution containing a catalyst precursor is sprayed onto the electrode surface, and then converted into a target catalyst through post-treatment steps such as thermal annealing. This method can precisely control the composition and thickness of the coating. For example, for the preparation of some non-precious metal catalysts, a solution containing a transition metal salt (such as nickel salt, cobalt salt) is sprayed on a carbon electrode. After appropriate annealing, a catalyst coating with good hydrogen evolution performance can be obtained, and the catalytic performance of the coating can be adjusted by the solution concentration and the number of spraying times.
• Application of membrane material spraying: In proton exchange membrane water electrolysis (PEM water electrolysis) or anion exchange membrane water electrolysis (AEM water electrolysis) systems, spraying functional materials on the membrane can improve the performance of the membrane. For example, in PEM water electrolysis, spraying materials such as perfluorosulfonic acid resin on the proton exchange membrane can increase the proton conductivity of the membrane, reduce the resistance of the membrane, and thus improve the overall efficiency of water electrolysis.

2. Fuel Cell Coating

• The key role of electrode spraying: The electrode reactions of fuel cells (such as hydrogen oxidation and oxygen reduction reactions in hydrogen fuel cells) require efficient catalysts to accelerate the reaction process. Spraying catalysts onto electrodes is a key step in improving fuel cell performance. For example, in proton exchange membrane fuel cells (PEMFCs), spraying platinum-based catalysts onto carbon paper or carbon cloth electrodes can effectively reduce the polarization loss of the electrodes and improve the power output and energy conversion efficiency of the batteries.
• Spraying process and characteristics:
  – Ultrasonic spraying: Ultrasonic spraying technology has unique advantages in the preparation of fuel cell electrodes. It can evenly atomize and spray catalyst ink (usually a mixture containing catalyst particles, binders and solvents) onto electrodes. Ultrasonic spraying can produce smaller and uniform droplets, making the catalyst more evenly distributed on the electrode, which is beneficial to improving the reaction activity of the electrode. For example, when preparing the cathode electrode of PEMFC, ultrasonic spraying can better disperse the platinum-carbon catalyst on the electrode surface, reduce agglomeration, and thus improve the efficiency of the oxygen reduction reaction.
  – Electrostatic spraying: Electrostatic spraying is the use of electrostatic action to adsorb charged catalyst particles to the electrode surface. This method can make the catalyst particles more closely arranged on the electrode, forming a high-quality coating. In the preparation of electrodes for metal-air fuel cells, electrostatic spraying can effectively spray metal oxide catalysts (such as manganese oxide) on the air electrode to improve the oxygen reduction and oxygen evolution performance of the air electrode.
  – Impact of membrane spraying: In fuel cells, the performance of proton exchange membranes or ion exchange membranes is also crucial. Spraying functional materials on the membrane can enhance the selectivity, conductivity and stability of the membrane. For example, in direct methanol fuel cells (DMFCs), spraying some materials that block methanol penetration on the proton exchange membrane can reduce the penetration of methanol from the anode to the cathode and improve the performance and efficiency of the battery.

Hydrogen production by electrolysis of water is the most advantageous method for producing hydrogen. Utrasonic coating systems are ideal for spraying carbon-based catalyst inks onto electrolyte membranes used for hydrogen generation. This technology can improve the stability and conversion efficiency of the diaphragm in the electrolytic water hydrogen production device. Cheersonic has extensive expertise coating proton exchange membrane electrolyzers, creating uniform, effective coatings possible for electrolysis applications.

Cheersonic ultrasonic coating systems are used in a number of electrolysis coating applications. The high uniformity of catalyst layers and even dispersion of suspended particles results in very high efficiency electrolyzer coatings, either single or double sided.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

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