Multi-layer porous transport layer for a membrane electrode assembly and method of manufaturing the same

Abstract

A multi-layer porous transport layer (PTL) comprising a first layer comprising a first surface and a second surface opposite the first surface, the first layer being made of one or more first particles, and a second layer comprising a first surface and a second surface opposite the first surface, the second surface of the second layer being coupled to the first surface of the first layer, the second layer being made of one or more second particles.

What is claimed is: 
     
         1 . A multi-layer porous transport layer (PTL), comprising:
 a first layer comprising a first surface and a second surface opposite the first surface, the first layer being made of one or more first particles; and   a second layer comprising a first surface and a second surface opposite the first surface, the second surface of the second layer being coupled to the first surface of the first layer, the second layer being made of one or more second particles.   
     
     
         2 . The multi-layer PTL of  claim 1 , wherein the one or more second particles are smaller in diameter than the one or more first particles. 
     
     
         3 . The multi-layer PTL of  claim 2 , wherein the one or more first particles and the one or more second particles are made of titanium. 
     
     
         4 . The multi-layer PTL of  claim 1 , further comprising a protrusion barrier arranged between the first surface of the second layer and the second surface of the first layer. 
     
     
         5 . The multi-layer PTL of  claim 4 , wherein the protrusion barrier includes both the one or more first particles and the one or more second particles. 
     
     
         6 . The multi-layer PTL of  claim 5 , wherein the one or more first particles are interlocked with the one or more second particles. 
     
     
         7 . The multi-layer PTL of  claim 1 , wherein the first layer includes a first thickness and the second layer includes a second thickness, the first thickness being greater than the second thickness. 
     
     
         8 . The multi-layer PTL of  claim 7 , wherein the first thickness is between 100 micrometers (μm) and 500 μm and the second thickness is between 10 μm and 100 μm. 
     
     
         9 . The multi-layer PTL of  claim 1 , wherein some of the one or more second particles are embedded in between some of the one or more first particles. 
     
     
         10 . The multi-layer PTL of  claim 1 , wherein the second layer has a lower surface roughness than the first layer. 
     
     
         11 . A proton exchange membrane (PEM) electrolyzer for generating hydrogen for use as fuel in a vehicle, the PEM electrolyzer comprising:
 a first distribution plate and a second distribution plate spaced from the first distribution plate;   a membrane arranged between the first distribution plate and the second distribution plate;   a cathode compartment arranged between the second distribution plate and the membrane; and   an anode compartment arranged between the first distribution plate and the membrane, comprising:
 an anode catalyst layer arranged adjacent to the membrane, and 
 a multi-layer porous transport layer (PTL) arranged between the anode catalyst layer and the first distribution plate, the multi-layer PTL comprising:
 a first layer being made of one or more first particles, and 
 a second layer being made of one or more second particles, the one or more second particles being fused with some of the one or more first particles. 
 
   
     
     
         12 . The PEM electrolyzer of  claim 11 , wherein the one or more second particles are smaller in diameter than the one or more first particles. 
     
     
         13 . The PEM electrolyzer of  claim 12 , wherein the one or more first particles include a diameter between 50 micrometers (μm) and 100 μm and the one or more second particles include a diameter between 1 μm and 45 μm. 
     
     
         14 . The PEM electrolyzer of  claim 11 , wherein the multi-layer PTL further includes a protrusion barrier including some of the one or more first particles and some of the one or more second particles. 
     
     
         15 . The PEM electrolyzer of  claim 11 , wherein some of the one or more second particles are embedded in between some of the one or more first particles. 
     
     
         16 . The PEM electrolyzer of  claim 11 , wherein the second layer has a lower surface roughness than the first layer. 
     
     
         17 . The PEM electrolyzer of  claim 11 , wherein the multi-layer PTL has an arithmetic mean height (Ra) of between 3.0 μm and 6 μm, the second layer being configured to make substantial contact with the anode catalyst layer. 
     
     
         18 . A method of manufacturing a multi-layer porous transport layer (PTL), comprising:
 providing a first layer having one or more first particles;   applying a slurry having one or more second particles onto the first layer;   drying the slurry on the first layer; and   fusing the slurry to the first layer so that at least some of the one or more second particles fuse to the one or more first particles.   
     
     
         19 . The method of  claim 18 , wherein applying the slurry having the one or more second particles onto the first layer further includes mixing the one or more second particles with water, solvents, and binders. 
     
     
         20 . The method of  claim 18 , wherein fusing the slurry to the first layer further includes sintering the slurry and the first layer at a temperature greater than 600 degrees Celsius (° C.) and less than 1400° C.