Abstract: Apparatus is described for rapidly coating a large area, or for rapidly producing a powder. In one embodiment, a liquid having a coating chemical is pumped from a liquid reservoir to a distribution manifold. From the distribution manifold, the liquid is carried under pressure to a geometric array, e.g., linear, of atomization nozzles. Flow equalization means are provided for equalizing the flow of the liquid delivered to each nozzle, and, preferably, means are provided for equalizing the temperature of the liquid delivered to each nozzle. The liquid, upon exiting the nozzles with the attendant pressure drop atomizes. The atomized liquid coats a substrate either in non-reacted or reacted form, or forms a powder. In a preferred embodiment, a solution of precursor chemical is reacted in a geometric array of flames produced at the nozzles, and a coating material produced in the flame coats the substrate, or a powder is formed.

Abstract: To form an ionomer-based catalytic layer on a porous substrate, a heat source (40) is used to dry an ionomer-containing spray (46) so that it does not substantially liquid flow on the substrate (14). The ionomer spray (46) may contain a catalyst. A spray (46) of mixed material for forming the catalytic layer is entrained by a gas stream and is heated and directed to a substrate surface (12). For hydrogen/oxygen fuel cells, catalytic material is incorporated into the proton-conducting membrane (56) to convert diffusing oxygen and hydrogen to water to reduce potential loss at the electrodes and maintain hydration of the proton-conducting membrane (56).