GAS DIFFUSION LAYER

Abstract

A gas diffusion layer for an electrolyser or for a fuel cell comprises a first nonwoven layer of metal fibers provided for contacting a proton exchange membrane, a second nonwoven layer of metal fibers, and a third porous metal layer. The first nonwoven layer of metal fibers comprises metal fibers of a first equivalent diameter. The second nonwoven layer of metal fibers comprises metal fibers of a second equivalent diameter. The second equivalent diameter is larger than the first equivalent diameter. The third porous metal layer comprises open pores. The open pores of the third porous metal layer are larger than the open pores of the second nonwoven layer of metal fibers. The second nonwoven layer is provided in between and contacting the first nonwoven layer and the third porous metal layer. The second nonwoven layer is metallurgically bonded to the first nonwoven layer and to the third porous metal layer. The thickness of the third porous metal layer is at least two timesand preferably at least three timesthe thickness of the first nonwoven layer.

Claims

1-15. (canceled)

16. Gas diffusion layer for an electrolyser or for a fuel cell; comprising a first nonwoven layer of metal fibers provided for contacting a proton exchange membrane, wherein the first nonwoven layer of metal fibers comprises metal fibers of a first equivalent diameter; a second nonwoven layer of metal fibers, wherein the second nonwoven layer of metal fibers comprises metal fibers of a second equivalent diameter; wherein the second equivalent diameter is larger than the first equivalent diameter; and a third porous metal layer; wherein the third porous metal layer comprises open pores; wherein the open pores of the third porous metal layer are larger than the open pores of the second nonwoven layer of metal fibers; wherein the second nonwoven layer is provided in between and contacting the first nonwoven layer and the third porous metal layer; wherein the second nonwoven layer is metallurgically bonded to the first nonwoven layer and to the third porous metal layer; wherein the thickness of the third porous metal layer is at least two times the thickness of the first nonwoven layer.

17. Gas diffusion layer as in claim 16, wherein the first equivalent diameter is less than 35 m.

18. Gas diffusion layer as in claim 16, wherein the thickness of the second nonwoven layer is at least double the thickness of the first nonwoven layer.

19. Gas diffusion layer as in claim 16, wherein the thickness of the first nonwoven layer is less than 0.15 mm.

20. Gas diffusion layer as in claim 16, wherein the first nonwoven layer and the second nonwoven layer comprise titanium fibers; and wherein the third porous layer comprises titanium.

21. Gas diffusion layer as in claim 16; wherein the metal fibers of the first nonwoven layer have a discrete length; and have a cross section, wherein the cross section has two neighbouring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides.

22. Gas diffusion layer as in claim 16; wherein the third porous metal layer comprises or consists out of a third nonwoven layer of metal fibers, wherein the third nonwoven layer of metal fibers comprises metal fibers of a third equivalent diameter; and wherein the third equivalent diameter is larger than the second equivalent diameter.

23. Gas diffusion as in claim 22, wherein the first nonwoven layer, the second nonwoven layer and the third nonwoven layer have the same porosity.

24. Gas diffusion layer as in claim 22, wherein the third equivalent diameter is larger than 50 m.

25. Gas diffusion layer as in claim 22, wherein the metal fibers of the third nonwoven layer have a discrete length; and have a cross section, wherein the cross section has two neighboring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides.

26. Gas diffusion layer as in claim 22, wherein the metal fibers of the third nonwoven layer have a quadrangular cross section.

27. Gas diffusion layer as in claim 19; wherein the third porous metal layer comprises or consists out of one or a stack of expanded metal sheets or woven wire meshes.

28. Gas diffusion layer as in claim 27, wherein the third porous metal layer comprises a first expanded metal sheet and a second expanded metal sheet, wherein the direction of the large dimension of the diamond sized openings of the first expanded metal sheet makes an angle of at least 30 with the direction of the large dimension of the diamond sized openings of the second expanded metal sheet.

29. Stack for an electrolyser or a fuel cell, comprising a gas diffusion layer as in claim 16, and a bipolar plate; wherein the bipolar plate contacts the third porous metal layer.

30. Assembly of a gas diffusion layer as in claim 16 and a proton exchange membrane wherein the first nonwoven layer contacts the proton exchange membrane.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0036] FIG. 1 shows schematically a cross section of a gas diffusion layer according to the invention.

[0037] FIG. 2 shows an enlarged picture of a cross section of a gas diffusion layer according to the invention.

[0038] FIG. 3 compares the electrical resistance through the thickness of a gas diffusion layer with a two layer gas diffusion layer.

MODE(S) FOR CARRYING OUT THE INVENTION

[0039] A first exemplary gas diffusion layer 10 according to the invention is schematically shown in FIG. 1. A magnified picture of the cross section of this first exemplary gas diffusion layer 40 is shown in FIG. 2. The first exemplary gas diffusion layer 10, 40 consists out of a first nonwoven layer 12, 42 of titanium fibers, a second nonwoven layer 22, 52 of titanium fibers and a third nonwoven layer 32, 62 of titanium fibers. The first nonwoven layer of titanium fibers is provided for contacting a proton exchange membrane in an electrolyser. The first nonwoven layer of titanium fibers comprises titanium fibers of 22 m equivalent diameter. The titanium fibers of the first nonwoven layer have 14 mm length; and have a cross section, wherein the cross section has two neighbouring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides. The first nonwoven layer has a specific mass of 250 g/m.sup.2 and a thickness d.sub.1 0.11 mm.

[0040] The second nonwoven layer of titanium fibers consists out of 800 g/m.sup.2 of titanium fibers with equivalent diameter 50 m; the fibers have a quadrangular cross section. The thickness d.sub.2 of the second nonwoven layer is 0.35 mm. Because of the larger equivalent diameter of fibers in the second nonwoven layer compared to the first nonwoven layer, the open pores are larger in the second nonwoven layer than in the first nonwoven layer. The third nonwoven layer of titanium fibers consists out of 2600 g/m.sup.2 of titanium fibers of equivalent diameter 80 m. The third nonwoven layer has a thickness d.sub.3 1.14 mm. the open pores in the third nonwoven layer are larger than the open pores in the second nonwoven layer. The titanium fibers of the first nonwoven layer have a discrete length; and have a cross section, wherein the cross section has two neighbouring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides.

[0041] The second nonwoven layer is provided in between and contacting the first nonwoven layer and the third nonwoven layer. The second nonwoven layer is sintered to the first nonwoven layer and to the third nonwoven layer. The total thickness d of the gas diffusion layer is 1.6 mm.

[0042] The first exemplary gas diffusion layer according to the invention has been compared with a two-layer gas diffusion layer.

[0043] The two-layer gas diffusion layer consisted out of a first nonwoven layer of 22 m equivalent diameter titanium fiber. The first layer had a specific mass of 650 g/m.sup.2 and a thickness of 0.28 mm. Sintered to the first nonwoven is another nonwoven of 3000 g/m.sup.2 consisting out of 80 m equivalent diameter titanium fibers and the thickness of the another nonwoven is 1.32 mm; the total thickness of this gas diffusion layer was 1.6 mm; which is the same total thickness as the first exemplary gas diffusion layer according to the invention.

[0044] The electrical resistance has been measured through the thickness of the gas diffusion layer, as a function of the compressive forces on the gas diffusion layer. Gas diffusion layers operate in electrolysers and in fuel cells under compressive forces, e.g. under 4 MPa or even under higher compressive forces. FIG. 3 shows in Y-axis (in mOhm) the measured electrical resistance through the thickness of the inventive gas diffusion layer (curve A) and of the two-layer gas diffusion layer (curve B), as a function of the compressive forces on the gas diffusion layer (in X-axis, compressive forces expressed in MPa). The results show a significantly reduced electrical resistance through the gas diffusion layer under compressive forces (in X-axis, expressed in MPa) as used in an electrolyser or in a fuel cell for the inventive gas diffusion layer (curve A).

[0045] A second exemplary gas diffusion layer according to the invention consists out of a first nonwoven layer of titanium fibers, a second nonwoven layer of titanium fibers and a stack of titanium expanded metal sheets. The first nonwoven layer of titanium fibers is provided for contacting a proton exchange membrane in an electrolyser. The first nonwoven layer of titanium fibers comprises titanium fibers of 14 m equivalent diameter. The titanium fibers of the first nonwoven layer have 10 mm length; and have a cross section, wherein the cross section has two neighbouring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides. The first nonwoven layer has a specific mass of 150 g/m.sup.2 and a thickness of 0.15 mm.

[0046] The second nonwoven layer of titanium fibers consists out of 150 g/m.sup.2 of titanium fibers with equivalent diameter 22 m. The titanium fibers of the second nonwoven layer have 14 mm length; and have a cross section, wherein the cross section has two neighbouring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides. The thickness of the second nonwoven layer is 0.15 mm. Because of the larger equivalent diameter of fibers in the second nonwoven layer compared to the first nonwoven layer, the open pores are larger in the second nonwoven layer than in the first nonwoven layer. The second nonwoven layer is sintered to the first nonwoven layer.

[0047] The third porous layer consists out of a stack of 6 expanded titanium sheets (or meshes), sintered or welded to each other and to the second nonwoven layer. A first mesh 0.125 mm thick with diamond opening size 0.8 mm by 1.2 mm contacts the second nonwoven layer. This first mesh is followed by a second expanded metal sheet identical to the first mesh. Further, the stack comprises two expanded metal sheets of 0.3 mm thickness each and having diamond opening size 1.0 by 2.0 mm; and two expanded metal sheets of 0.68 mm thickness each and having diamond opening size 2.0 by 4.0 mm.

[0048] The total thickness of the gas diffusion layer is 2.5 mm.

[0049] A third exemplary gas diffusion layer according to the invention consists out of a first nonwoven layer of titanium fibers, a second nonwoven layer of titanium fibers and a stack of titanium expanded metal sheets. The first nonwoven layer of titanium fibers is provided for contacting a proton exchange membrane in an electrolyser. The first nonwoven layer of titanium fibers comprises titanium fibers of 14 m equivalent diameter. The titanium fibers of the first nonwoven layer have 10 mm length; and have a cross section, wherein the cross section has two neighbouring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides. The first nonwoven layer has a specific mass of 150 g/m.sup.2 and a thickness of 0.15 mm.

[0050] The second nonwoven layer of titanium fibers consists out of 150 g/m.sup.2 of titanium fibers with equivalent diameter 22 m. The titanium fibers of the second nonwoven layer have 14 mm length; and have a cross section, wherein the cross section has two neighbouring straight lined sides with an included angle of less than 90 degrees and one or more irregularly shaped curved sides. The thickness of the second nonwoven layer is 0.15 mm. Because of the larger equivalent diameter of fibers in the second nonwoven layer compared to the first nonwoven layer, the open pores are larger in the second nonwoven layer than in the first nonwoven layer. The second nonwoven layer is sintered to the first nonwoven layer.

[0051] The third porous layer consists out of a stack of five expanded titanium sheets (or meshes), sintered or welded to each other and to the second nonwoven layer. A first mesh 0.1 mm thick with diamond opening size 0.8 mm by 1.2 mm contacts the second nonwoven layer. This first mesh is followed by a second expanded metal sheet 0.3 mm thick with diamond opening size 1 mm by 2 mm. Further, the stack comprises three expanded metal sheets of 2 mm thickness each and having diamond opening size 7 by 14 mm.

[0052] The total thickness of the gas diffusion layer is 6 mm.