Method for making oxygen-reducing catalyst layers

Coating processes – Electrical product produced – Fuel cell part

Reexamination Certificate

Rate now

  [ 0.00 ] – not rated yet Voters 0   Comments 0

Details

C427S248100, C427S376600, C204S192100

Reexamination Certificate

active

07740902

ABSTRACT:
Methods are provided for making oxygen-reducing catalyst layers, which include simultaneous or sequential stops of physical vapor depositing an oxygen-reducing catalytic material onto a substrate, the catalytic material comprising a transition metal that is substantially free of platinum; and thermally treating the catalytic material. At least one of the physical vapor deposition and the thermal treatment is performed in a processing environment comprising a nitrogen-containing gas.

REFERENCES:
patent: 4333916 (1982-06-01), Iwai et al.
patent: 4340276 (1982-07-01), Maffitt et al.
patent: 4568598 (1986-02-01), Bilkadi et al.
patent: 4578135 (1986-03-01), Ueno et al.
patent: 4812352 (1989-03-01), Debe
patent: 4985386 (1991-01-01), Tsurumi et al.
patent: 5039561 (1991-08-01), Debe
patent: 5079107 (1992-01-01), Jalan
patent: 5176786 (1993-01-01), Debe
patent: 5240893 (1993-08-01), Witherspoon
patent: 5336558 (1994-08-01), Debe
patent: 5338430 (1994-08-01), Parsonage et al.
patent: 5593934 (1997-01-01), Stonehart
patent: 5643343 (1997-07-01), Selifanov et al.
patent: 5645951 (1997-07-01), Johnssen
patent: 5711773 (1998-01-01), Selifanov et al.
patent: 5872074 (1999-02-01), Schulz et al.
patent: 5879827 (1999-03-01), Debe et al.
patent: 5879828 (1999-03-01), Debe et al.
patent: 6040077 (2000-03-01), Debe et al.
patent: 6136412 (2000-10-01), Spiewak et al.
patent: 6150569 (2000-11-01), Hamann et al.
patent: 6319293 (2001-11-01), Debe et al.
patent: 6403245 (2002-06-01), Hunt
patent: 6425993 (2002-07-01), Debe et al.
patent: 6475653 (2002-11-01), Gomez
patent: 6610436 (2003-08-01), Dearnaley et al.
patent: 6624328 (2003-09-01), Guerra
patent: 6835489 (2004-12-01), Venkatesan et al.
patent: 7005401 (2006-02-01), Lu et al.
patent: 2002/0004453 (2002-01-01), Haugen et al.
patent: 2002/0144394 (2002-10-01), Uchida et al.
patent: 2003/0004058 (2003-01-01), Li et al.
patent: 2003/0124717 (2003-07-01), Awano et al.
patent: 2004/0048466 (2004-03-01), Gore et al.
patent: 2004/0058808 (2004-03-01), Lu et al.
patent: 2004/0081880 (2004-04-01), Chang
patent: 2004/0116742 (2004-06-01), Guerra
patent: 2004/0121210 (2004-06-01), Hamrock et al.
patent: 2004/0121221 (2004-06-01), Suzuki et al.
patent: 2004/0197638 (2004-10-01), McElrath et al.
patent: 2004/0197641 (2004-10-01), Visco et al.
patent: 2005/0031921 (2005-02-01), Ovshinsky et al.
patent: 2005/0069755 (2005-03-01), Vernstrom et al.
patent: 2005/0095189 (2005-05-01), Brey et al.
patent: 2005/0095355 (2005-05-01), Leistra et al.
patent: 2005/0176990 (2005-08-01), Coleman et al.
patent: 2005/0200040 (2005-09-01), Hara et al.
patent: 2005/0221155 (2005-10-01), McLean et al.
patent: 2006/0088739 (2006-04-01), Ovshinsky
patent: 2006/0194092 (2006-08-01), Kanai et al.
patent: 2006/0264319 (2006-11-01), Yoo et al.
patent: 2007/0082814 (2007-04-01), Debe et al.
patent: 2007/0248875 (2007-10-01), O'Brien et al.
patent: 2008/0113257 (2008-05-01), Hampden-Smith et al.
patent: 2008/0274269 (2008-11-01), Bose et al.
patent: 2009/0226796 (2009-09-01), Atanasoski et al.
patent: 100 38 800 (2002-06-01), None
patent: 2004/217977 (2004-08-01), None
Chemistry World “Less platinum for cheaper fuel cells”. Aug. 2, 2005 (no page numbers).
Chemical & Engineering News, “Nanotube Catalysts: Nitrogen-doped carbon nanotubes could make fuel cells more affordable”. vol. 87, No. 6, Feb. 9, 2009 p. 7.
Hitachi Australia: New catalyst for oxygen-reducing reactions from Hitachi Maxell. (Apr. 4, 2008) no page numbers.
“Platinum-Nickel Alloy Found to be Most Active Oxygen-Reducing Catalyst Ever Reported”. Jan. 30, 2007, no citation, no page numbers.
M. K. Debe, “Novel Catalysts, Catalysts Support and Catalysts Coated Membrane Methods,”Handbook of Fuel Cells, Fundamentals, Technology and Applications, vol. 3, (pp. 576-589).
Markovic, et al., Oxygen Reduction Reaction on Pt and Pt Bimetallic Surfaces: A Selective Review,Fuel Cells, vol. 1, No. 2, 2001, (pp. 105-116).
Paulus, et al., “Oxygen Reduction on Carbon-Supported Pt-Ni and Pt-Co Alloy Catalysts”J. Phys. Chem. B, No. 106, 2002, (pp. 4181-4191).
Lefevre, et al., “O2 Reduction in PEM Fuel Cells: Activity and Active Site Structural Information Catalysts Obtained by the Pyrolysis at High Temperature of Fe Precursors”,J. Phys. Chem. B, Sep. 7, 2000, (pp. 11238-11247).
Jaouen, et al., “Oxygen Reduction Catalysts for Polymer Electrolyte Fuel Cells From the Pyrolysis of Iron Acetate Adsorbed on Various Carbon Supports”,J. Phys. Chem. B, vol. 107, Oct. 18, 2002, (pp. 1376-1386).
N. J. Kim, “Structure and Properties of Rapidly Solidified Al-Li-Cu-Mg-Zr Alloys with a High Zirconium Content”,Materials Science and Engineering, A158, 1992, (pp. 103-110).
Kam, et al., “Summary Abstract: Dramatic Variation of the Physical Microstructure of a Vapor Deposited Organic Thin Film”,J. Vac. Sci. Technol. A, 5 (4), Jul./Aug. 1987, (pp. 1914-1916).
Debe, et al., Vacuum Vapor Deposited Thin Films of a Perylene Dicarboximide Derviative: Microstructure Versus Deposition Parameters:,J. Vac. Sci. Technol.A, 6 (3), May/Aug. 1988, (pp. 1907-1911).
Debe et al., “Effect of Gravity on Copper Phthalocyanine Thin Films III: Microstructure Comparisons of Copper Phthalocyanine Thin Films Grown in Microgravity and Unit Gravity”,Thin Solid Films, 186, 1990, (pp. 327-347).
Sadaoka et al., “Effects of Morphology on NO2Detection in Air at Room Temperature With Phthalocyanine Thin Films”,J. Mat. Sci., 25, 1990, (pp. 5257-5268).
Ohnuma et al., “Amorphous Ultrafine Metallic Particles Prepared by Sputtering Method”, Rapidly Quenched Metals,( Steeb, et al. Eds.); from the Proc. of the Fifth Int. Conf. on Rapidly Quenched Metals in Wurzburg, Germany, Sep. 3-7, 1984.Elsevier Science Publishers B.V., New York, 1985, (pp. 1117-1124).
Lee et al., “Measurement and Modeling of the Reflectance-Reducing Properties of Gradient Index Microstructured Surfaces”,Photo. Sci. and Eng., 24, (4), Jul./Aug. 1980, (pp. 211-216).
Tang et al., “High Dispersion and Electrocatalytic Properties of Platinum on Well-Aligned Carbon Nanotube Arrays,” Carbon, 42 2004, (pp. 191-197).
Stanishevsky, “Quaziamorphous Carbon and Carbon Nitride Films Deposited from the Plasma of Pulsed Cathodic Arc Discharge,”Chaos, Solitons and Fractals, vol. 10, No. 12, 1999, (pp. 2045-2066).
Dahn, et al., “Economical Sputtering System to Produce Large-Size Composition-Spread Libraries Having Linear and Orthogonal Stoichiometry Variations”,Chemistry of Materials, 14 (8), 2002, (pp. 3519-3523).
Easton, et al., “Preparation and Characterization of Sputtered Fe1-XNXFilms”,Thin Solid Films, 493, 2005, (pp. 60-66).
Villers, et al., “Fe-Based Catalysts for Oxygen Reduction in PEM Fuel Cells: Pretreatment of the Carbon Support”,J. Electrochem. Soc. 151, (9), 2004, (pp. A1507-A1515).
Lefevre, et al., “Fe-Based Catalysts for the Reduction of Oxygen in Polymer Electrolyte Membrane Fuel Cell Conditions: Determination of the Amount of Peroxide Released During Electroreduction and its Influence on the Stability of the Catalysts”,Electrochimica Acta, 48, 2003, (pp. 2749-2760).
Paik, et al., “Extent of PEMFC Cathode Surface Oxidation by Oxygen and Water Measured by CV”,Electrochemical and Solid-State Letters, 7, (4), 2004, (pp. A82-A84).
Atanasoski, “2004 DOE Hydrogen, Fuel Cells, and Infrastructure Technologies Program Review Meeting”, May 24-27, 2004, Philadelphia, PA, Presentation FC17, (pp. 1-16).
Faubert, et al., “Oxygen Reduction Catalysts for Polymer Electrolyte Fuel Cells From the Pyrolysis of FeIIAcetate Adsorbed on 3,4,9,10-Perylenetetracarboxylic Dianhydride”,Electrochimica Acta, 44, 1999, (pp. 2589-2603).
Chow et al.; “Fabrication of Biologically Based Microstructure Composites for Vacuum Field Emission”,Materials Science and Engineering, A158 (1992), pp. 1-6.
J.P. Dodelet, “Oxygen Reduction by N

LandOfFree

Say what you really think

Search LandOfFree.com for the USA inventors and patents. Rate them and share your experience with other people.

Rating

Method for making oxygen-reducing catalyst layers does not yet have a rating. At this time, there are no reviews or comments for this patent.

If you have personal experience with Method for making oxygen-reducing catalyst layers, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method for making oxygen-reducing catalyst layers will most certainly appreciate the feedback.

Rate now

     

Profile ID: LFUS-PAI-O-4210963

  Search
All data on this website is collected from public sources. Our data reflects the most accurate information available at the time of publication.