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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Solid oxidized fuel cells seals leakage setup and testing

As the world s reserves of fossil fuels are depleted, the U.S. Government, as well as other countries and private industries, is researching solutions for obtaining power, answers that would be more efficient and environmentally friendly. For a long time engineers have been trying to obtain the benefits of clean electric power without heavy batteries or pollution-producing engines. While some of the inventions proved to be effective (i.e. solar panels or windmills) their applications are limited due to dependency on the energy source (i.e. sun or wind). Currently, as energy concerns increase, research is being carried out on the development of a Solid Oxide Fuel Cell (SOFC). The United States government is taking a proactive role in expanding the technology through the Solid State Energy Conversion Alliance (SECA) Program, which is coordinated by the Department of Energy. into an electrical energy. This occurs by the means of natural tendency of oxygen and hydrogen to chemically react. While controlling the process, it is possible to harvest the energy given off by the reaction. SOFCs use currently available fossil fuels and convert a variety of those fuels with very high efficiency (about 40% more efficient than modem thermal power plants). At the same time they are almost entirely nonpolluting and due to their size they can be placed in remote areas. The main fields where the application of the fuel cells appears to be the most useful for are stationary energy sources, transportation, and military applications. structure and materials must be resolved. All the components must be operational in harsh environments including temperatures reaching 800 C and cyclic thermal- mechanical loading. Under these conditions, the main concern is the requirement for hermetic seals to: (1) prevent mixing of the fuel and oxidant within the stack, (2) prevent parasitic leakage of the fuel from the stack, (3) prevent contamination of the anode by air leaking into the stack, (4) electrically isolate the individual cells within the stack, and (5) mechanically bond the cell components. The sealing challenges are aggravated by the need to maintain hermetic boundaries between the different flow paths within the fuel cell throughout cycled operation. Within the timeframe of my tenure, the main objective is to assist in building a state-of-art test facility.

Bastrzyk, Marta B.↗
DOE OSTI2017

Effect of Rubidium Incorporation on the Structural, Electrical, and Photovoltaic Properties of Methylammonium Lead Iodide-Based Perovskite Solar Cells

We report the electrical properties of rubidium-incorporated methylammonium lead iodide ((Rb x MA 1-x )PbI 3 ) films and the photovoltaic performance of (Rb x MA 1-x )PbI 3 film-based p-i-n-type perovskite solar cells (PSCs). The incorporation of a small amount of Rb + (x = 0.05) increases both the open circuit voltage (V oc ) and the short circuit photocurrent density (J sc ) of the PSCs, leading to an improved power conversion efficiency (PCE). However, a high fraction of Rb + incorporation (x = 0.1 and 0.2) decreases the J sc and thus the PCE, which is attributed to the phase segregation of the single tetragonal perovskite phase to a MA-rich tetragonal perovskite phase and a RbPbI 3 orthorhombic phase at high Rb fractions. Conductive atomic force microscopic and admittance spectroscopic analyses reveal that the single-phase (Rb 0.05 MA 0.95 )PbI 3 film has a high electrical conductivity because of a reduced deep-level trap density. We also found that Rb substitution enhances the diode characteristics of the PSC, as evidenced by the reduced reverse saturation current (J 0 ). The optimized (Rb x MA 1-x )PbI 3 PSCs exhibited a PCE of 18.8% with negligible hysteresis in the photocurrent-voltage curve. The results from this work enhance the understanding of the effect of Rb incorporation into organic-inorganic hybrid halide perovskites and enable the exploration of Rb-incorporated mixed perovskites for various applications, such as solar cells, photodetectors, and light-emitting diodes.

14 SOLAR ENERGY↗
DOE OSTI2021

Transverse thermal energy conversion using spin and topological structures

Conversion of thermal to electrical energy has been a subject of intense study for well over two centuries. Despite steady progress throughout the past several decades, solid-state thermoelectric (TE) energy conversion devices remain adequate only for niche applications. One appealing option for circumventing the limits of conventional TE physics is to utilize phenomena where flows of heat and charge are perpendicular, the so-called “transverse” geometry. In this Tutorial, we discuss recent advances behind new ways to generate large transverse thermoelectric voltages, such as the spin Seebeck and Nernst effects, as well as Weyl physics. We provide suggestions for how these mechanisms might be enhanced and implemented into high-efficiency, next generation transverse TE devices. Furthermore, we also discuss best practices for accurate measurement and reporting of transverse thermoelectric material properties, including a case study of a round robin spin Seebeck coefficient measurement.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Efficient electrochemical CO 2 conversion powered by renewable energy

Here, the catalytic conversion of CO 2 into industrially relevant chemicals is one strategy for mitigating greenhouse gas emissions. Along these lines, electrochemical CO 2 conversion technologies are attractive because they can operate with high reaction rates at ambient conditions. However, electrochemical systems require electricity, and CO 2 conversion processes must integrate with carbon-free, renewable-energy sources to be viable on larger scales. We utilize Au 25 nanoclusters as renewably powered CO 2 conversion electrocatalysts with CO 2 → CO reaction rates between 400 and 800 L of CO 2 per gram of catalytic metal per hour and product selectivities between 80 and 95%. These performance metrics correspond to conversion rates approaching 0.8–1.6 kg of CO 2 per gram of catalytic metal per hour. We also present data showing CO 2 conversion rates and product selectivity strongly depend on catalyst loading. Optimized systems demonstrate stable operation and reaction turnover numbers (TONs) approaching 6 × 10 6 mol CO 2 molcatalyst–1 during a multiday (36 hours total hours) CO 2 electrolysis experiment containing multiple start/stop cycles. TONs between 1 × 10 6 and 4 × 10 6 molCO 2 molcatalyst–1 were obtained when our system was powered by consumer-grade renewable-energy sources. Daytime photovoltaic-powered CO 2 conversion was demonstrated for 12 h and we mimicked low-light or nighttime operation for 24 h with a solar-rechargeable battery. This proof-of-principle study provides some of the initial performance data necessary for assessing the scalability and technical viability of electrochemical CO 2 conversion technologies. Specifically, we show the following: (1) all electrochemical CO 2 conversion systems will produce a net increase in CO 2 emissions if they do not integrate with renewable-energy sources, (2) catalyst loading vs activity trends can be used to tune process rates and product distributions, and (3) state-of-the-art renewable-energy technologies are sufficient to power larger-scale, tonne per day CO 2 conversion systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2015

Efficient quasi-monoenergetic ion beams from laser-driven relativistic plasmas

Table-top laser–plasma ion accelerators have many exciting applications, many of which require ion beams with simultaneous narrow energy spread and high conversion efficiency. However, achieving these requirements has been elusive. We report the experimental demonstration of laser-driven ion beams with narrow energy spread and energies up to 18 MeV per nucleon and ~5% conversion efficiency (that is 4 J out of 80-J laser). Using computer simulations we identify a self-organizing scheme that reduces the ion energy spread after the laser exits the plasma through persisting self-generated plasma electric (~1012 V m -1 ) and magnetic (~104 T) fields. Furthermore, these results contribute to the development of next generation compact accelerators suitable for many applications such as isochoric heating for ion-fast ignition and producing warm dense matter for basic science.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Power generation from nanostructured PbTe-based thermoelectrics: comprehensive development from materials to modules

In this work, we demonstrate the use of high performance nanostructured PbTe-based materials in high conversion efficiency thermoelectric modules. We fabricated the samples of PbTe-2% MgTe doped with 4% Na and PbTe doped with 0.2% PbI2 with high thermoelectric figure of merit (ZT) and sintered them with Co-Fe diffusion barriers for use as p- and n-type thermoelectric legs, respectively. Transmission electron microscopy of the PbTe legs reveals two shapes of nanostructures, disk-like and spherical. The reduction in lattice thermal conductivity through nanostructuring gives a ZT of similar to 1.8 at 810 K for p-type PbTe and similar to 1.4 at 750 K for n-type PbTe. Nanostructured PbTe-based module and segmented-leg module using Bi2Te3 and nanostructured PbTe were fabricated and tested with hot-side temperatures up to 873 K in a vacuum. The maximum conversion efficiency of similar to 8.8% for a temperature difference (Delta T) of 570 K and B11% for a Delta T of 590 K have been demonstrated in the nanostructured PbTe-based module and segmented Bi2Te3/nanostructured PbTe module, respectively. Three-dimensional finite-element simulations predict that the maximum conversion efficiency of the nanostructured PbTe-based module and segmented Bi2Te3/nanostructured PbTe module reaches 12.2% for a Delta T of 570 K and 15.6% for a Delta T of 590 K respectively, which could be achieved if the electrical and thermal contact between the nanostructured PbTe legs and Cu interconnecting electrodes is further improved.

Hu, Xiaokai↗
DOE OSTI2018

Production of Synthetic Natural Gas From Carbon Dioxide and Renewably Generated Hydrogen: A Techno-Economic Analysis of a Power-to-Gas Strategy

Power-to-gas to energy systems are of increasing interest for low carbon fuels production and as a low-cost grid-balancing solution for renewables penetration. However, such gas generation systems are typically focused on hydrogen production, which has compatibility issues with the existing natural gas pipeline infrastructures. This study presents a power-to-synthetic natural gas (SNG) plant design and a techno-economic analysis of its performance for producing SNG by reacting renewably generated hydrogen from low-temperature electrolysis with captured carbon dioxide. The study presents a 'bulk' methanation process that is unique due to the high concentration of carbon oxides and hydrogen. Carbon dioxide, as the only carbon feedstock, has much different reaction characteristics than carbon monoxide. Thermodynamic and kinetic considerations of the methanation reaction are explored to design a system of multistaged reactors for the conversion of hydrogen and carbon dioxide to SNG. Heat recuperation from the methanation reaction is accomplished using organic Rankine cycle (ORC) units to generate electricity. The product SNG has a Wobbe index of 47.5?MJ/m3 and the overall plant efficiency (H2/CO2 to SNG) is shown to be 78.1% LHV (83.2% HHV). The nominal production cost for SNG is estimated at 132 $/MWh (38.8 $/MMBTU) with 3 $/kg hydrogen and a 65% capacity factor. At U.S. DOE target hydrogen production costs (2.2 $/kg), SNG cost is estimated to be as low as 97.6 $/MWh (28.6 $/MMBtu or 1.46 $/kgSNG).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2016

Electrohydrodynamic-assisted Assembly of Hierarchically Structured, 3D Crumpled Nanostructures for Efficient Solar Conversions

The tantalizing prospect of harnessing the unique properties of graphene crumpled nanostructures continues to fuel tremendous interest in energy storage and harvesting applications. However, the paper ball-like, hard texture, and closed-sphere morphology of current 3D graphitic nanostructure production not only constricts the conductive pathways but also limits the accessible surface area. Here, we report new insights into electrohydrodynamically-generated droplets as colloidal nanoreactors in that the stimuli-responsive nature of reduced graphene oxide can lead to the formation of crumpled nanostructures with a combination of open structures and doubly curved, saddle-shaped edges. In particular, the crumpled nanostructures dynamically adapt to non-spherical, polyhedral shapes under continuous deposition, ultimately assembling into foam-like microstructures with a highly accessible surface area and spatially interconnected transport pathways. The implementation of such crumpled nanostructures as three-dimensional rear contacts for solar conversion applications realize benefits of a high aspect ratio, electrically addressable and energetically favorable interfaces, and substantial enhancement of both short-circuit currents and fill-factors compared to those made of planar graphene counterparts. Further, the 3D crumpled nanostructures may shed lights onto the development of effective electrocatalytic electrodes due to their open structure that simultaneously allows for efficient water flow and hydrogen escape.

25 ENERGY STORAGE↗
DOE OSTI2024

An Advanced Cooling Device for Concentrated Photovoltaic Systems

Concentrated photovoltaics (CPV) have the potential to significantly enhance the energy conversion utilization of solar panels and reduce solar generation costs, making them a crucial area of advancement in solar power generation technology. However, the concentration of sunlight can lead to overheating of solar panels, resulting in a notable reduction in both the efficiency of solar power generation and the lifespan of the panels. This challenge remains the predominant technical hurdle that hinders the application of concentrated photovoltaic power generation technology. In this study, we propose a new cooling method for concentrated photovoltaic power generation systems via an integrated approach of incorporating Phase-Change Thermal Storage (PCTS) and Thermoelectric Generator (TEG) technology. This new method not only enhances the overall system's electricity generation efficiency but also effectively resolves the technical challenge of concentrated photovoltaic panel overheating issues, ensuring the continuity of concentrated photovoltaic power generation and extending the lifespan of solar panels and their components. In order to make full use of the wasted heat generated by photovoltaic power generation and effectively improve the power generation efficiency of the system, this work developed a phase change heat storage device based on a phase change material. This device uses the temperature difference between day and night to recover wasted heat from photovoltaic power generation. Through integration with the thermoelectric power generation system, thermal energy can be converted into electrical energy. In addition, the Peltier effect of thermoelectric materials is used to construct a photovoltaic panel overheating protection system, which significantly improves the reliability and service life of the system.

14 SOLAR ENERGY↗
DOE OSTI2016

A dual-mode operation overmoded coaxial millimeter-wave generator with high power capacity and pure transverse electric and magnetic mode output

An overmoded coaxial millimeter-wave generator with high power capacity and pure transverse electric and magnetic (TEM) mode output is designed and presented, by using a kind of coaxial slow wave structure (SWS) with large transversal dimension and small distance between inner and outer conductors. The generator works in dual-mode operation mechanism. The electron beam synchronously interacts with 7π/8 mode of quasi-TEM, at the meanwhile exchanges energy with 3π/8 mode of TM{sub 01}. The existence of TM{sub 01} mode, which is traveling wave, not only increases the beam-wave interaction efficiency but also improves the extraction efficiency. The large transversal dimension of coaxial SWS makes its power capacity higher than that of other reported millimeter-wave devices and the small distance between inner and outer conductors allows only two azimuthally symmetric modes to coexist. The converter after the SWS guarantees the mode purity of output power. Particle-in-cell simulation shows that when the diode voltage is 400 kV and beam current is 3.8 kA, the generation of microwave at 32.26 GHz with an output power of 611 MW and a conversion efficiency of 40% is obtained. The power percentage carried by TEM mode reaches 99.7% in the output power.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2005

Novel Space-based Solar Power Technologies and Architectures for Earth and Beyond

Research, development and studies of novel space-based solar power systems, technologies and architectures for Earth and beyond are needed to reduce the cost of clean electrical power for terrestrial use and to provide a stepping stone for providing an abundance of power in space, i.e., manufacturing facilities, tourist facilities, delivery of power between objects in space, and between space and surface sites. The architectures, technologies and systems needed for space to Earth applications may also be used for in-space applications. Advances in key technologies, i.e., power generation, power management and distribution, power beaming and conversion of beamed power are needed to achieve the objectives of both terrestrial and extraterrestrial applications. Power beaming or wireless power transmission (WPT) can involve lasers or microwaves along with the associated power interfaces. Microwave and laser transmission techniques have been studied with several promising approaches to safe and efficient WPT identified. These investigations have included microwave phased array transmitters, as well as laser transmission and associated optics. There is a need to produce "proof-of-concept" validation of critical WPT technologies for both the near-term, as well as far-term applications. Investments may be harvested in near-term beam safe demonstrations of commercial WPT applications. Receiving sites (users) include ground-based stations for terrestrial electrical power, orbital sites to provide power for satellites and other platforms, future space elevator systems, space vehicle propulsion, and space to surface sites. This paper briefly discusses achieving a promising approach to the solar power generation and beamed power conversion. The approach is based on a unique high-power solar concentrator array called Stretched Lens Array (SLA) for both solar power generation and beamed power conversion. Since both versions (solar and laser) of SLA use many identical components (only the photovoltaic cells need to be different), economies of manufacturing and scale may be realized by using SLA on both ends of the laser power beaming system in a space solar power application. Near-term uses of this SLA-laser-SLA system may include terrestrial and space exploration in near Earth space. Later uses may include beamed power for bases or vehicles on Mars.

Howell, Joe T.↗
DOE OSTI2026

Through‐Plane Conductive Hydrophobic Electrodes for CO 2 Electrolysis to Ethylene

Copper catalyst gas diffusion electrodes (GDEs) have demonstrated unique electrochemical selectivity converting CO 2 to C 2 -hydrocarbons such as ethylene and ethanol but have been challenged by their hydrophobic chemical stability and internal electrical resistance leading to low energy efficiency. Carbon-supported GDEs have low electrical resistance but lack sufficient stability at industrially relevant current densities. While polymer-supported GDEs have improved hydrophobicity, they also display high in-plane electrical resistance, particularly at industrial scales. Here, in this work, we demonstrate a composite gas diffusion layer that combines hydrophobic porous polymers with an electrically conductive backbone addressing these core gas diffusion electrode (GDE) scaling challenges. We investigate the material properties of standalone porous perfluoropolyether (PFPE) polymers, including porosity and surface morphology, under varying processing conditions and then incorporate these polymers into a porous copper foam. This composite enhances the mechanical rigidity necessary for cell assembly and provides a through-plane electrical conduction path to reduce electrical resistive losses. This enhanced PFPE composite GDE displays efficient CO 2 reduction, achieving 15% ethylene energy efficiency at 100 cm 2 . These findings contribute to the development of advanced catalyst materials and electrode architectures and promote scalable strategies for electrochemical conversion of CO 2 into high-value carbon products.

Chemistry↗
DOE OSTI2023

Design, modeling and simulation of nuclear-powered integrated energy systems with cascaded heating applications

Nuclear-renewable integrated energy systems (IES) consist of a variety of energy generation and conversion technologies and can be used to meet heterogeneous end uses (e.g., electricity, heat, and cooling demands). In addition to supply-demand balance, end-use heat demands usually require heat supply of certain temperature ranges. The effective and efficient utilization of heat produced within an IES is, therefore, a critical challenge. Here, this paper examines design options of an IES that includes heating processes of multiple temperature grades. We investigate a cascaded design configuration, where the remaining residual heat after high-grade heating processes [e.g., hydrogen production through high-temperature steam electrolysis (HTSE)] is recovered to meet the low-grade heating needs [e.g., district heating (DH)]. Additionally, a thermal energy storage system is integrated into the DH system to address the imbalance between heat supply and demand. This paper primarily focuses on the design and modeling of the proposed system and evaluates its operation with a 24-h transient process simulation using a DH demand profile with hourly resolution. The results indicate that the residual heat from the HTSE exhaust is insufficient for the DH demand, and additional topping heat directly from the reactor process steam is needed. Furthermore, the inclusion of thermal energy storage within the DH system provides the necessary balance between thermal generation and demand, thereby ensuring a consistent rated temperature of the DH supply water. This approach helps minimize the control actions needed on the reactor side.

08 HYDROGEN↗
NASA NTRS1981

The application of simulation modeling to the cost and performance ranking of solar thermal power plants

A computer simulation code was employed to evaluate several generic types of solar power systems (up to 10 MWe). Details of the simulation methodology, and the solar plant concepts are given along with cost and performance results. The Solar Energy Simulation computer code (SESII) was used, which optimizes the size of the collector field and energy storage subsystem for given engine-generator and energy-transport characteristics. Nine plant types were examined which employed combinations of different technology options, such as: distributed or central receivers with one- or two-axis tracking or no tracking; point- or line-focusing concentrator; central or distributed power conversion; Rankin, Brayton, or Stirling thermodynamic cycles; and thermal or electrical storage. Optimal cost curves were plotted as a function of levelized busbar energy cost and annualized plant capacity. Point-focusing distributed receiver systems were found to be most efficient (17-26 percent).

Rosenberg, L. S.↗
NASA NTRS1983

Photovoltaic conversion of laser to electrical power

Transmission of power in space using lasers will require devices for converting the laser power to electrical power. One such type of device for accomplishing this is the photovoltaic converter. This paper reviews photovoltaic converters and their application for conversion of monochromatic laser power to electrical power. Laser power densities greater than 1000 W/sq cm are considered. For a converter operated at 300 K a lower bandgap limit of 0.67 eV (1.80 micron) is defined. For ideal conditions, an efficiency of 47.8 percent is calculated for Nd/Liquid laser radiation incident on an Si converter. Several types of photovoltaic converters are discussed. Series resistance is identified as a major problem. Vertical multijunction converters are the most promising photovoltaic devices for use as laser to electric power converters.

Walker, G. H.↗
NASA NTRS2006

Alpha-Voltaic Sources Using Diamond as Conversion Medium

A family of proposed miniature sources of power would exploit the direct conversion of the kinetic energy of a particles into electricity in diamond semiconductor diodes. These power sources would function over a wide range of temperatures encountered in terrestrial and outer-space environments. These sources are expected to have operational lifetimes of 10 to 20 years and energy conversion efficiencies >35 percent. A power source according to the proposal would include a pair of devices like that shown in the figure. Each device would contain Schottky and p/n diode devices made from high-band-gap, radiation-hard diamond substrates. The n and p layers in the diode portion would be doped sparsely (<1014 cm-3) in order to maximize the volume of the depletion region and thereby maximize efficiency. The diode layers would be supported by an undoped diamond substrate. The source of a particles would be a thin film of 244Cm (half-life 18 years) sandwiched between the two paired devices. The sandwich arrangement would force almost every a particle to go through the active volume of at least one of the devices. Typical a particle track lengths in the devices would range from 20 to 30 microns. The a particles would be made to stop only in the undoped substrates to prevent damage to the crystalline structures of the diode portions. The overall dimensions of a typical source are expected to be about 2 by 2 by 1 mm. Assuming an initial 244Cm mass of 20 mg, the estimated initial output of the source is 20 mW (a current of 20 mA at a potential of 1 V).

Patel, Jagadish U.↗
DOE OSTI2018

Revealing the Impact of F4‐TCNQ as Additive on Morphology and Performance of High‐Efficiency Nonfullerene Organic Solar Cells

Abstract Fluorinated molecule 2,3,5,6‐tetrafluoro‐7,7,8,8‐tetracyanoquinodimethane (F4‐TCNQ) and its derivatives have been used in polymer:fullerene solar cells primarily as a dopant to optimize the electrical properties and device performance. However, the underlying mechanism and generality of how F4‐TCNQ affects device operation and possibly the morphology is poorly understood, particularly for emerging nonfullerene organic solar cells. In this work, the influence of F4‐TCNQ on the blend film morphology and photovoltaic performance of nonfullerene solar cells processed by a single halogen‐free solvent is systematically investigated using a set of morphological and electrical characterizations. In solar cells with a high‐performance polymer:small molecule blend FTAZ:IT‐M, F4‐TCNQ has a negligibly small effect on the molecular packing and surface characteristics, while it clearly affects the electronic properties and mean‐square composition variation of the bulk. In comparison to the control devices with an average power conversion efficiency (PCE) of 11.8%, inclusion of a trace amount of F4‐TCNQ in the active layer has improved device fill factor and current density, which has resulted into a PCE of 12.4%. Further increase in F4‐TCNQ content degrades device performance. This investigation aims at delineating the precise role of F4‐TCNQ in nonfullerene bulk heterojunction films, and thereby establishing a facile approach to fabricate highly optimized nonfullerene solar cells.

Xiong, Yuan↗
NASA NTRS2005

Improved Anode for a Direct Methanol Fuel Cell

A modified chemical composition has been devised to improve the performance of the anode of a direct methanol fuel cell. The main feature of the modified composition is the incorporation of hydrous ruthenium oxide into the anode structure. This modification can reduce the internal electrical resistance of the cell and increase the degree of utilization of the anode catalyst. As a result, a higher anode current density can be sustained with a smaller amount of anode catalyst. These improvements can translate into a smaller fuel-cell system and higher efficiency of conversion. Some background information is helpful for understanding the benefit afforded by the addition of hydrous ruthenium oxide. The anode of a direct methanol fuel cell sustains the electro-oxidation of methanol to carbon dioxide in the reaction CH3OH + H2O--->CO2 + 6H(+) + 6e(-). An electrocatalyst is needed to enable this reaction to occur. The catalyst that offers the highest activity is an alloy of approximately equal numbers of atoms of the noble metals platinum and ruthenium. The anode is made of a composite material that includes high-surface-area Pt/Ru alloy particles and a proton-conducting ionomeric material. This composite is usually deposited onto a polymer-electrolyte (proton-conducting) membrane and onto an anode gas-diffusion/current-collector sheet that is subsequently bonded to the proton-conducting membrane by hot pressing. Heretofore, the areal density of noble-metal catalyst typically needed for high performance has been about 8 mg/cm2. However, not all of the catalyst has been utilized in the catalyzed electro-oxidation reaction. Increasing the degree of utilization of the catalyst would make it possible to improve the performance of the cell for a given catalyst loading and/or reduce the catalyst loading (thereby reducing the cost of the cell). The use of carbon and possibly other electronic conductors in the catalyst layer has been proposed for increasing the utilization of the catalyst by increasing electrical connectivity between catalyst particles. However, the relatively low density of carbon results in thick catalyst layers that impede the mass transport of methanol to the catalytic sites. Also, the electrical conductivity of carbon is less than 1/300th of typical metals. Furthermore, the polymer-electrolyte membrane material is acidic and most metals are not chemically stable in contact with it. Finally, a material that conducts electrons (but not protons) does not contribute to the needed transport of protons produced in the electro-oxidation reaction.

Valdez, Thomas↗