Disclosed are an apparatus for manufacturing a membrane electrode assembly to provide excellent mass transfer characteristics and durability and a manufacturing method using the same. A porosity gradient may be continuously imparted to electrodes of the membrane electrode assembly in a thickness direction thereby improving reactivity with external gas and transfer of internal ions.

A direct isopropanol fuel cell adapted for use in ambient conditions and utilizing as fuel isopropanol and water preferably with isopropanol at relatively high concentrations representing 30% to 90% isopropanol.

A method for forming an electrode catalyst layer by putting catalyst ink within an insulative container having a conductive nozzle in communication with the interior of the container and applying an electrospray voltage to the nozzle to cause electrospray of the catalyst ink through the tip end of the nozzle and thereby to form an electrode catalyst layer, the method includes preparing catalyst ink containing a mixture of at least electrode catalyst, polymer electrolyte binder and volatile organic compound and/or water, putting the catalyst ink within the container with a space remaining inside thereof and air-tightly sealing the container, and electrospraying with the space inside of the air-tightly sealed container being conditioned to have a negative pressure of a level at which the catalyst ink cannot drip off from the nozzle.

An electrode of an embodiment includes a catalyst layer having pores. A mode diameter of the pores is 10 μm or more and 100 μm or less. The catalyst layer may have a thickness of 0.05 μm or more and 3.0 μm or less. A value of the mode diameter of the pores may three times or more a value of a thickness of the catalyst layer.

An electrolyte membrane of a membrane-electrode assembly has improved chemical durability. The electrolyte membrane includes a composite, which includes an antioxidant in an ionic state and a first ionomer surrounding the antioxidant. The composite is dispersed in a second ionomer, which is a polymer matrix. A manufacturing method for the electrolyte membrane includes preparing an antioxidant solution, mixing the antioxidant solution and a first ionomer dispersion solution, drying the mixture to produce a composite having an antioxidant and a first ionomer surrounding the antioxidant, introducing and mixing the composite with a second ionomer dispersion solution, and applying that mixture to a substrate and drying the mixture to manufacture an electrolyte membrane.

A manufacturing process includes: depositing a first catalyst on a first gas diffusion layer (GDL) to form a first catalyst-coated GDL; depositing a first ionomer on the first catalyst-coated GDL to form a first gas diffusion electrode (GDE); depositing a second catalyst on a second GDL to form a second catalyst-coated GDL; depositing a second ionomer on the second catalyst-coated GDL to form a second GDE; and laminating the first GDE with the second GDE and with an electrolyte membrane disposed between the first GDE and the second GDE to form a membrane electrode assembly (MEA). A MEA includes a first GDL; a second GDL; an electrolyte membrane disposed between the first GDL and the second GDL; a first catalyst layer disposed between the first GDL and the electrolyte membrane; and a second catalyst layer disposed between the second GDL and the electrolyte membrane, wherein a thickness of the electrolyte membrane is about 15 μm or less.

A fuel cell membrane electrode assembly includes a polymer electrolyte membrane and a pair of electrocatalyst layers arranged to have the polymer electrolyte membrane therebetween, at least one of the pair of electrocatalyst layers includes particles supporting a catalyst which is composed of a noble metal component, a polymer electrolyte, and a fibrous oxide-based catalytic material, and the fibrous oxide-based catalytic material includes at least one transition metal element selected from a group consisting of Ta, Nb, Ti, and Zr.

Provided is a method for producing metal nanoparticles, which enables metal nanoparticles to be more conveniently produced.

The method for producing metal nanoparticles includes spraying and drying a mixture to form metal nanoparticles, the mixture containing a metal salt and at least one solvent selected from alcohols having 1 or more and 5 or less carbon atoms.

A proton exchange membrane fuel cell includes an anode catalyst layer, a cathode catalyst layer, a proton exchange membrane separating the anode catalyst layer from the cathode catalyst layer, an oxygen inlet configured to supply oxygen to the cathode catalyst layer, and a hydrogen inlet separate from the oxygen inlet and configured to supply hydrogen to the anode catalyst layer. The fuel cell is operable to convert the hydrogen from the hydrogen inlet to hydrogen ions at the anode catalyst layer and to produce an H2O byproduct at the cathode catalyst layer where the oxygen reacts with the hydrogen ions. The fuel cell includes a water outlet for the H2O byproduct that is separate from the oxygen inlet.

The invention provides noble metal-free electro-catalyst compositions for use in acidic media, e.g., acidic electrolyte. The noble metal-free electro-catalyst compositions include non-noble metal absent of noble metal. The non-noble metal is non-noble metal oxide, and typically in the form of any configuration of a solid or hollow nano-material, e.g., nano-particles, a nanocrystalline thin film, nanorods, nanoshells, nanoflakes, nanotubes, nanoplates, nanospheres and nanowhiskers or combinations of myriad nanoscale architecture embodiments. Optionally, the noble metal-free electro-catalyst compositions include dopant, such as, but not limited to halogen. Acidic media includes oxygen reduction reaction (ORR) in proton exchange membrane (PEM) fuel cells, and direct methanol fuel cells and oxygen evolution reaction (OER) in PEM-based water electrolysis and metal air batteries, and hydrogen generation from solar energy and electricity-driven water splitting.