Fuel Cell Catalyst Ink Dispersion and Coating

Fuel Cell Catalyst Ink Dispersion and Coating – Cheersonic

Throughout the history of energy research, fuel cells have offered high energy efficiency, high power density, low operating temperatures and superior durability. And polymer electrolyte membrane fuel cells, which can convert hydrogen fuel directly into electricity, offer high advantages in the alternative variety of internal combustion engines. The catalyst, the active component of the coating, forms the core of the polymer electrolyte membrane fuel cell. In order to obtain the best possible performance of the fuel cell, it is essential to obtain the right structure and functionality of the catalyst layer. The catalyst layer precursors therefore need to be adapted and then applied to the membrane to form the cladding film.

The membrane electrode assembly forms the heart of the fuel cell and typically consists of an anode and cathode catalyst layer, a polymer electrolyte membrane and a gas diffusion layer. The catalyst layer is the seat of the critical redox and hydroxide reactions. In particular, the cathode catalyst layer, which favours the redox reaction, is a bottleneck, which makes the cathode catalyst layer an important performance and cost-controlling component of the fuel cell. As a solution, increasing the loading of platinum catalysts can accelerate the reaction, but issues of scalability and economic viability limit high platinum loading. As a result, much research on fuel cells has focused on developing optimised catalyst coatings and membrane electrode assembly layouts.

High power density fuel cell cathodes are typically made of catalyst inks consisting of carbon black, forming a backbone. This high surface area framework is decorated with platinum particles as electrocatalysts. The fuel cell catalyst ink is usually dispersed in a liquid, but this is only a transitional state, and in operation the catalyst ink is ultimately applied as a coating to the substrate or film. The Pt/C catalyst powder in the cathodic catalyst layer is dispersed in a continuous phase containing a solvent (mixture) and an ionomer.

Cheersonic ultrasonic coating systems suitable for R & D, small and medium-sized batch production. It produce highly durable, uniform, coatings of carbon-based catalyst inks onto both fuel cell and electrolysis processes for proton exchange membrane (PEM) electrolyzers such as Nafion, without deformation of the membrane. Cheersonic’s UAL100 is ideal for deagglomeration of nanoparticles and catalyst slurries specially used to disperse clump and particles which are difficult to keep evenly dispersed in suspension. Programmed continual high frequency ultrasonic vibrations disperse agglomerated particles quicker and more uniformly than magnetic stirring or sonic baths commonly used for the same applications. Great for carbon black fuel cell catalyst solutions, ceramic slurries and nanosuspensions.

The advantages of ultrasonic spraying include：
1.Full range of ultrasonic nozzles
2.Spray patterns are easily shaped for precise coating applications
3.Up to 80% reduction in material consumption with reduced overspray, conserving expensive catalyst inks.
4.Spray plume can be easily shaped and directed to coat only target area.
5.Self-cleaning nozzle design prevents clogging
6.Extremely easy-to-control spray provides reliable and consistent results
7.Very uniform and durable coating (even on electrolyte substrates).

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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