Abstract: The present technology relates to an improved method for manufacturing anion exchange membranes. The method uses trimethylamine gas for amination of polymer films. The process involves placing polymer film pieces or a roll with thin spacer in a pressure vessel, removing air by applying vacuum, and then filling the vessel with trimethylamine gas at about 1 barg pressure and at about 30° C. temperature. After amination, residual trimethylamine is removed by vacuum and optionally by heat treatment. This gas-based approach eliminates membrane swelling and wrinkling issues associated with aqueous trimethylamine solutions, improves diffusion rates, reduces waste generation, and allows for more efficient and scalable production processes, including the ability to aminate complete rolls of polymer film. The resulting membrane maintains its structural integrity and is more suitable for assembly into electrochemical device stacks.

Abstract: An innovative catalyst layer composition and Anion Exchange Membrane (AEM) electrolyzer structure are disclosed, featuring meso porous particles with open pores that provide a high surface area and conductive support for anode catalysts. The composition includes a less-conductive catalyst, which is either grown on the meso porous particles through deposition processes or admixed and adsorbed by the meso porous particles. The AEM electrolyzer structure includes this catalyst layer composition, along with a cathode side containing a bipolar plate or half plate, a porous transport layer, and a catalyst layer, and an anode side similarly equipped but with a meso porous layer formed from the catalyst composition. The two sides are separated by an anion exchange membrane. Methods for manufacturing the AEM electrolyzer structure using spraying and decal processes are also disclosed, enhancing efficiency and safety for hydrogen and oxygen generation.

Abstract: A membrane electrode assembly (MEA) includes a membrane, a cathode catalyst layer, a cathode co-catalyst layer including a hydrogen reservoir, an anode catalyst layer, and an anode co-catalyst layer including a hydrogen reservoir. The anode co-catalyst layer and the cathode co-catalyst layer cap a cathode potential at lower than 1.5V and an anode potential at lower than 1.0V. The anode co-catalyst layer and the cathode co-catalyst layer can include a platinum doped rare earth oxide, such as platinum doped cerium oxide.

Abstract: A method for manufacturing a catalyst for a fuel cell can include provision of a platinum precursor and a carbon material. The platinum precursor and the carbon material can be mixed to form a platinum carbon mixture. The platinum carbon mixture can be heated to form a porous solid. The porous solid can be milled to form a powder. The powder can be reacted with a reducing agent to form the catalyst.

Abstract: An electrode layer can have an electrically conductive material, a catalyst, an ionomer binder, and a perfluorocarbon compound. The ionomer binder forms hydrophilic regions on the electrically conductive material to support proton and water transport. The perfluorocarbon compound forms hydrophobic regions on the electrically conductive material to support oxygen solubility and transport. The electrode can be used in making a membrane electrode assembly and can be configured as a cathode thereof. Fuel cells and fuel stacks can include such membrane electrode assemblies.

Abstract: A method for manufacturing a catalyst for a fuel cell can include provision of a platinum precursor and a carbon material. The platinum precursor and the carbon material can be mixed to form a platinum carbon mixture. The platinum carbon mixture can be heated to form a porous solid. The porous solid can be milled to form a powder. The powder can be reacted with a reducing agent to form the catalyst.

Abstract: A membrane electrode assembly (MEA) includes a membrane, a cathode catalyst layer, and an anode catalyst layer. The anode catalyst layer includes a Pt/C catalyst layer that has one or more hydrogen bronzes. The hydrogen bronzes include one or more oxides of niobium, molybdenum, and tungsten. The anode catalyst layer does not include ruthenium.

Abstract: An electrode layer can have an electrically conductive material, a catalyst, an ionomer binder, and a perfluorocarbon compound. The ionomer binder forms hydrophilic regions on the electrically conductive material to support proton and water transport. The perfluorocarbon compound forms hydrophobic regions on the electrically conductive material to support oxygen solubility and transport. The electrode can be used in making a membrane electrode assembly and can be configured as a cathode thereof. Fuel cells and fuel stacks can include such membrane electrode assemblies.

Abstract: A membrane electrode assembly (MEA) includes a membrane, a cathode catalyst layer, a cathode co-catalyst layer including a hydrogen reservoir, an anode catalyst layer, and an anode co-catalyst layer including a hydrogen reservoir. The anode co-catalyst layer and the cathode co-catalyst layer cap a cathode potential at lower than 1.5V and an anode potential at lower than 1.0V. The anode co-catalyst layer and the cathode co-catalyst layer can include a platinum doped rare earth oxide, such as platinum doped cerium oxide.