Electrode reservoir for a fuel cell

Claim 2

An electrolyte reservoir layer for use adjacent the catalyst layer of a fuel cell, said reservoir layer being porous and including a catalyst facing surface and a noncatalyst facing surface, said catalyst facing surface including first impregnations of hydrophobic material to a shallow depth over a major portion of its area, said catalyst facing surface also including uniformly distributed areas not impregnated with hydrophobic material, said reservoir layer also including uniformly distributed nonelectrolyte retaining portions leading from said noncatalyst facing surface to said impregnations of hydrophobic material at said other surface, said nonelectrolyte retaining portions comprising only a small portion of the volume of said reservoir layer, said reservoir layer being hydrophilic in all portions other than said nonelectrolyte retaining portions and said first impregnations, said reservoir layer also including impregnations of an electrolyte retaining matrix material extending from said areas of said catalyst facing surface not impregnated with hydrophobic material into said hydrophilic portions, said matrix material impregnating less than half of said hydrophilic portions.

Claim 3

The reservoir layer according to claim 1 wherein said nonelectrolyte retaining portions are second impregnations of hydrophobic material extending from said noncatalyst facing surface to said first impregnations of hydrophobic material.

Claim 4

The reservoir layer according to claim 2 wherein said impregnation of matrix material extends from said catalyst facing surface to said noncatalyst facing surface.

Claim 5

The reservoir layer according to claim 1 wherein the area of said catalyst facing surface not impregnated with hydrophobic material is at least 2% of the total area of said catalyst facing surface, said depth of said first impregnations is no more than 50% of the thickness of said reservoir layer and no less than 3 mils, and the minimum total cross-sectional area of said nonelectrolyte retaining portions is 2% of the total cross-sectional area of said noncatalyst facing surface.

Claim 6

The electrolyte reservoir layer according to claim 4 wherein said reservoir layer comprises carbon paper.

Claim 7

The electrolyte reservoir layer according to claim 4 wherein said matrix material comprises silicon carbide.

Claim 8

A fuel cell electrode comprising an electrolyte reservoir layer and a catalyst layer, said catalyst layer including hydrophobic material, said reservoir layer being porous throughout and including a catalyst facing surface and a noncatalyst facing surface, said catalyst facing surface including first impregnations of hydrophobic material to a shallow depth over a major portion of its area, said catalyst facing surface also including uniformly distributed areas not impregnated with hydrophobic material, said reservoir layer further including uniformly distributed nonelectrolyte retaining portions leading from said noncatalyst facing surface to said impregnations of hydrophobic material at said other surface, said nonelectrolyte retaining portions comprising only a small portion of the volume of said reservoir layer, said reservoir layer being hydrophilic in all portions other than said nonelectrolyte retaining portions and said first impregnations, said reservoir layer including impregnations of an electrolyte retaining matrix material extending from said areas of said catalyst facing surface not impregnated with hydrophobic material into said hydrophilic portions, said matrix material impregnating less than half of said hydrophilic portions, said catalyst layer being bonded to said catalyst facing surface and including holes therethrough in communication with said impregnations of electrolyte retaining matrix material.

Claim 9

A fuel cell electrode comprising an electrolyte reservoir layer and a catalyst layer, said catalyst layer including hydrophobic material, said reservoir layer being porous throughout and including a catalyst facing surface and a noncatalyst facing surface, said catalyst facing surface including first impregnations of hydrophobic material to a shallow depth over a major portion of its area, said catalyst facing surface also including uniformly distributed areas not impregnated with hydrophobic material, said reservoir layer further including uniformly distributed nonelectrolyte retaining portions leading from said noncatalyst facing surface to said impregnations of hydrophobic material at said other surface, said nonelectrolyte retaining portions comprising only a small portion of the volume of said reservoir layer, said reservoir layer being hydrophilic in all portions other than said nonelectrolyte retaining portions and said first impregnations, said reservoir layer including impregnations of an electrolyte retaining matrix material extending from said areas of said catalyst facing surface not impregnated with hydrophobic material into said hydrophilic portions, said matrix material impregnating less than half of said hydrophilic portions, said catalyst layer being bonded to said catalyst facing surface and including holes therethrough in communication with said impregnations of electrolyte retaining matrix material.

Claim 10

The fuel cell electrode according to claim 7 wherein said impregnations of matrix material extend from said catalyst facing surface to said noncatalyst facing surface.

Claim 11

The fuel cell electrode according to claim 7 wherein said area of said catalyst facing surface not impregnated with hydrophobic material is at least 2% of the total area of said catalyst facing surface, said depth of said first impregnations is no more than 50% of the thickness of said reservoir layer and no less than 3 mils, and the minimum total cross-sectional area of said nonelectrolyte retaining portions is 2% of the total cross-sectional area of said noncatalyst facing surface.

Claim 12

In a fuel cell comprising an electrolyte retaining matrix, an anode catalyst layer disposed on one side of and in contact with said matrix and a cathode catalyst layer disposed on the other side of and in contact with said matrix each of said catalyst layers including hydrophobic material, the improvement comprising: an electrolyte reservoir layer in contact with the nonmatrix facing side of at least one of said catalyst layers, said reservoir layer being porous throughout and including a catalyst facing surface and a noncatalyst facing surface, said catalyst facing surface including first impregnations of hydrophobic material to a shallow depth over a major portion of its area, said catalyst facing surface also including uniformly distributed areas not impregnated with hydrophobic material, said reservoir layer also including second impregnations of hydrophobic material leading from said noncatalyst facing surface to said first impregnations of hydrophobic material, said second impregnations comprising only a small portion of the volume of said reservoir layer, said reservoir layer being hydrophilic in all portions other than said first and second impregnations, said reservoir layer including third impregnations of a material essentially the same as the material of said matrix, said third impregnations extending from said areas of said catalyst facing surface not impregnated with hydrophobic material into said hydrophilic portions, said third impregnations impregnating less than half of said hydrophilic portions, said hydrophilic portions having substantially no pores smaller than the largest pores of said matrix.

Claim 13

In a fuel cell comprising an electrolyte retaining matrix, an anode catalyst layer disposed on one side of and in contact with said matrix and a cathode catalyst layer disposed on the other side of and in contact with said matrix each of said catalyst layers including hydrophobic material, the improvement comprising: an electrolyte reservoir layer in contact with the nonmatrix facing side of at least one of said catalyst layers, said reservoir layer being porous throughout and including a catalyst facing surface and a noncatalyst facing surface, said catalyst facing surface including first impregnations of hydrophobic material to a shallow depth over a major portion of its area, said catalyst facing surface also including uniformly distributed areas not impregnated with hydrophobic material, said reservoir layer also including second impregnations of hydrophobic material leading from said noncatalyst facing surface to said first impregnations of hydrophobic material, said second impregnations comprising only a small portion of the volume of said reservoir layer, said reservoir layer being hydrophilic in all portions other than said first and second impregnations, said reservoir layer including third impregnations of a material essentially the same as the material of said matrix, said third impregnations extending from said areas of said catalyst facing surface not impregnated with hydrophobic material into said hydrophilic portions, said third impregnations impregnating less than half of said hydrophilic portions, said hydrophilic portions having substantially no pores smaller than the largest pores of said matrix.

Claim 14

The improvement according to claim 10 wherein said one catalyst layer is said anode catalyst layer.

Claim 15

The improvement according to claim 11 wherein said anode catalyst layer is bonded to said reservoir layer.

Claim 16

The improvement according to claim 11 wherein said catalyst layer includes a plurality of uniformly distributed holes therethrough aligned with said third impregnations, said holes being filled with essentially the same material of which said matrix is made.

Claim 17

The improvement according to claim 13 wherein said reservoir layer comprises carbon paper.

Claim 18

The improvement according to claim 14 wherein said matrix comprises silicon carbide with a hydrophobic polymer binder.

Claim 19

The improvement according to claim 12 wherein said areas of said catalyst facing surface not impregnated with hydrophobic material are at least 2% of the total area of said catalyst facing surface, said depth of said first impregnations are no more than 50% of the thickness of said reservoir layer and no less than 3 mils, and the minimum total cross-sectional area of said second impregnations is 2% of the total cross-sectional area of said noncatalyst facing surface.

Claim 20

The improvement according to claim 16 wherein said third impregnations extend from said catalyst facing surface to said noncatalyst facing surface.