Systems and methods for direct coating of electrodes on porous substrates for electrolyzers

Abstract

A membrane electrode assembly for one of a proton exchange membrane electrolyzer or an alkaline electrolyzer includes a corrosion resistant substrate coated with an anode catalyst ink to form an anode catalyst layer, wherein the anode catalyst layer includes ionomer strands that protrude into the corrosion resistant substrate, a porous substrate coated with a cathode catalyst ink to form a cathode catalyst layer, wherein the cathode catalyst layer includes ionomer strands that protrude into the porous substrate, and a membrane disposed between the anode catalyst layer of the corrosion resistant substrate and the cathode catalyst layer of the porous substrate.

What is claimed is: 
     
         1 . A membrane electrode assembly for one of a proton exchange membrane electrolyzer or an alkaline electrolyzer to generate hydrogen for use as fuel in a vehicle, the membrane electrode assembly comprising:
 a corrosion resistant substrate coated with an anode catalyst ink via one of slot die, spray coating methods, or sputtering to form an anode catalyst layer, wherein the anode catalyst layer includes ionomer strands that protrude into the corrosion resistant substrate;   a porous substrate coated with a cathode catalyst ink via one of slot die, spray coating methods, or sputtering to form a cathode catalyst layer, wherein the cathode catalyst layer includes ionomer strands that protrude into the porous substrate; and   a membrane disposed between the anode catalyst layer of the corrosion resistant substrate and the cathode catalyst layer of the porous substrate.   
     
     
         2 . The membrane electrode assembly of  claim 1 , wherein the depth of the ionomer strands of the anode catalyst layer protruding into the corrosion resistant substrate is between approximately 1-80% of the total thickness of the corrosion resistant substrate. 
     
     
         3 . The membrane electrode assembly of  claim 1 , wherein the depth of the ionomer strands of the cathode catalyst layer protruding into the porous substrate is between approximately 1-80% of the total thickness of the porous substrate. 
     
     
         4 . The membrane electrode assembly of  claim 1 , wherein the corrosion resistant substrate is a porous transport layer. 
     
     
         5 . The membrane electrode assembly of  claim 4 , wherein the porous transport layer is formed from titanium-based components. 
     
     
         6 . The membrane electrode assembly of  claim 1 , wherein the porous substrate is a gas diffusion layer. 
     
     
         7 . The membrane electrode assembly of  claim 6 , wherein the gas diffusion layer is formed from carbon-based components. 
     
     
         8 . A membrane electrode assembly for one of a proton exchange membrane electrolyzer or an alkaline electrolyzer, the membrane electrode assembly comprising:
 a corrosion resistant substrate coated with an anode catalyst ink to form an anode catalyst layer, wherein the anode catalyst layer includes ionomer strands that protrude into the corrosion resistant substrate;   a porous substrate coated with a cathode catalyst ink to form a cathode catalyst layer, wherein the cathode catalyst layer includes ionomer strands that protrude into the porous substrate; and   a membrane disposed between the anode catalyst layer of the corrosion resistant substrate and the cathode catalyst layer of the porous substrate.   
     
     
         9 . The membrane electrode assembly of  claim 8 , wherein the depth of the ionomer strands of the anode catalyst layer protruding into the corrosion resistant substrate is between approximately 1-80% of the total thickness of the corrosion resistant substrate. 
     
     
         10 . The membrane electrode assembly of  claim 8 , wherein the depth of the ionomer strands of the cathode catalyst layer protruding into the porous substrate is between approximately 1-80% of the total thickness of the porous substrate. 
     
     
         11 . The membrane electrode assembly of  claim 8 , wherein the corrosion resistant substrate is a porous transport layer. 
     
     
         12 . The membrane electrode assembly of  claim 11 , wherein the porous transport layer is formed from titanium-based components. 
     
     
         13 . The membrane electrode assembly of  claim 8 , wherein the porous substrate is a gas diffusion layer. 
     
     
         14 . The membrane electrode assembly of  claim 13 , wherein the gas diffusion layer is formed from carbon-based components. 
     
     
         15 . A method for making a membrane electrode assembly comprising:
 providing a corrosion resistant substrate;   providing a membrane;   providing a porous substrate;   applying an anode catalyst ink to the corrosion resistant substrate;   applying a cathode catalyst ink to the porous substrate; and   laminating the corrosion resistant substrate coated with the anode catalyst ink and the porous substrate coated with the cathode catalyst ink with the membrane.   
     
     
         16 . The method of  claim 15 , wherein the anode catalyst ink includes ionomer strands that protrude into the corrosion resistant substrate, and the depth of the ionomer strands protruding into the corrosion resistant substrate is between approximately 1-80% of the total thickness of the corrosion resistant substrate. 
     
     
         17 . The method of  claim 15 , wherein the cathode catalyst ink includes ionomer strands that protrude into the porous substrate, and the depth of the ionomer strands protruding into the porous substrate is between approximately 1-80% of the total thickness of the porous substrate. 
     
     
         18 . The method of  claim 15 , wherein the corrosion resistant substrate is a porous transport layer. 
     
     
         19 . The method of  claim 18 , wherein the porous transport layer is formed from titanium-based components. 
     
     
         20 . The method of  claim 15 , wherein the porous substrate is a gas diffusion layer.