Abstract: The invention is directed to highly porous catalyst coated membranes and to sprayable inks and processes for forming catalyst coated membranes. In one aspect, the invention is to a sprayable ink, comprising catalyst particles, polymer electolyte ionomer, and a vehicle for dispersing the catalyst particles and polymer electolyte ionomer. In another aspect, the process comprises the steps of depositing an ink comprising catalyst particles and a vehicle onto a membrane and vaporizing from 40 to 95 weight percent of the vehicle from the sprayed ink under conditions effective to form a catalyst layer on the membrane. Preferably, the depositing and vaporizing steps are alternated to form multiple stacked catalyst layers on the membrane.

Abstract: A process for preparing catalyst coated membranes and membrane electrode assemblies for use in direct methanol fuel cells is provided. Cathode and anode layers are formed by spraying catalyst-containing inks onto a novel framed electrolytic membrane to form a catalyst coated membrane. The spraying process optionally employs one or more masks, which carefully control where the catalyst-containing ink is deposited. Following application of the cathode and anode layers, diffusion layers are prepared and inserted onto the catalyst coated membranes, and pressed to form membrane electrode assemblies.

Abstract: In a method of producing an electrode comprising a layer of an electrocatalytic material on a substrate, at least one liquid medium containing a precursor to the electrocatalytic material is atomized to produce droplets containing the precursor and the droplets are entrained in a stream of carrier gas moving in a first direction. The droplets entrained in the carrier gas stream are then heated to remove the liquid medium and convert the precursor to particles of the electrocatalytic material. The electrocatalytic material particles entrained in said carrier gas stream are then brought into contact with the substrate, whereby the electrocatalytic particles are separated from the carrier gas and collected on the substrate. By imparting relative movement between the substrate and the carrier gas stream in a second direction substantially perpendicular to the first direction a continuous layer of the electrocatalytic material can be progressively deposited on the substrate.

Abstract: Electrocatalyst powders and energy devices fabricated using electrocatalyst powders and methods for making energy devices. The energy devices, such as fuel cells, have improved performance over a range of operating conditions.

Abstract: Provided is an aerosol manufacture facility including an aerosol generator (600), an aerosol heater (604), an aerosol cooler (604), a particle collector (606), a precursor liquid supply system (608), a carrier gas supply system (610), and a cooling gas supply system (612), and optionally other components. Also provided is an aerosol method for manufacturing particles in the aerosol manufacture facility, which, in one embodiment, involves automated process control.

Abstract: Dental glass powders, methods for producing the powders and dental compositions including the glass powders. The powders preferably have a well-controlled particle size, narrow size distribution and a spherical morphology. The method includes forming the particles by a spray pyrolysis technique. The invention also includes dental filler and restorative compositions that include the glass powders.

Abstract: Dental glass powders, methods for producing the powders and dental compositions including the glass powders. The powders preferably have a well-controlled particle size, narrow size distribution and a spherical morphology. The method includes forming the particles by a spray pyrolysis technique. The invention also includes dental filler and restorative compositions that include the glass powders.

Abstract: A process for making particles, the process including generating an aerosol stream which includes droplets of a precursor liquid dispersed in a carrier gas, the precursor liquid including a liquid vehicle and a precursor material, separating the precursor liquid into two portions during the generating step, a first portion exiting the generator in the droplets of the aerosol stream and a second portion exiting as effluent at least a portion of which is recycled to the generator, and also during the generating step adding additional liquid vehicle to at least one of the carrier gas supply, the precursor liquid supply, and the aerosol generator, to at least partially compensate for the tendency of the precursor liquid to become more concentrated in the precursor material over time, and then removing at least a portion of the liquid vehicle from the droplets and forming particles in the aerosol stream.

Abstract: Electrocatalyst powders and energy devices fabricated using electrocatalyst powders and methods for making energy devices. The energy devices, such as fuel cells, have improved performance over a range of operating conditions.

Abstract: Dental glass powders, methods for producing the powders and dental compositions including the glass powders. The powders preferably have a well-controlled particle size, narrow size distribution and a spherical morphology. The method includes forming the particles by a spray pyrolysis technique. The invention also includes dental filler and restorative compositions that include the glass powders.