CN-122003296-A - Method for coating catalyst on flat or textured substrate

Abstract

According to the present invention there is a method of applying a catalyst layer to a surface comprising the steps of providing a donor substrate having opposed first and second surfaces, and providing a catalyst ink disposed as a layer on the second surface, wherein the catalyst ink comprises a catalyst and a solvent, providing an acceptor substrate, wherein the second surface of the donor substrate faces the acceptor substrate, and irradiating the catalyst ink with laser radiation at a wavelength absorbed by the catalyst ink to transfer the catalyst ink from the donor substrate to the acceptor substrate.

Inventors

• J. A. Edgar
• E. R. Price
• S. D. Kaufman
• J. S. Dalton
• J. Nisbet
• H.Dong
• M. B.M. Theodore
• K. A. Hardstone

Assignees

• 庄信万丰股份有限公司

Dates

Publication Date

20260508

Application Date

20241009

Priority Date

20231010

Claims (20)

1. 1. A method of applying a catalyst layer to a surface, the method comprising the steps of: Providing a donor substrate having opposed first and second surfaces, and providing a catalyst ink disposed as a layer on the second surface, wherein the catalyst ink comprises a catalyst and a solvent; providing an acceptor substrate, wherein the second surface of the donor substrate faces the acceptor substrate, and Irradiating the catalyst ink with laser radiation at a wavelength absorbed by the catalyst ink to transfer the catalyst ink from the donor substrate to the acceptor substrate.
2. 2. The method of claim 1, wherein the method further comprises the step of drying the catalyst ink on the receptor substrate to remove substantially all of the solvent.
3. 3. The method of any one of the preceding claims, wherein the catalyst comprises a reformer catalyst.
4. 4. The method of any one of the preceding claims, wherein the receptor substrate comprises a non-planar surface.
5. 5. The method of any of the preceding claims, wherein the receptor substrate comprises a textured surface.
6. 6. The method of any one of the preceding claims, wherein the receptor substrate comprises a surface having raised sections and recessed sections.
7. 7. The method of any of the preceding claims, wherein the receptor substrate comprises a surface having pits.
8. 8. The method of any one of the preceding claims, wherein the receptor substrate comprises a surface having ridges.
9. 9. The method of any one of the preceding claims, wherein the receptor substrate comprises a plate for a solid oxide fuel cell.
10. 10. The method of claim 5, wherein the catalyst ink is applied to the textured surface at a uniform coating layer thickness.
11. 11. The method of claim 5, wherein the catalyst ink is applied to the textured surface at a predetermined non-uniform coating layer thickness.
12. 12. The method of any one of the preceding claims, wherein the catalyst ink is applied to the receptor substrate in a predetermined pattern.
13. 13. The method of any one of the preceding claims, wherein the catalyst ink is applied to the receiver substrate in a predetermined pattern corresponding to the texture of the receiver substrate surface.
14. 14. The method of any one of claims 1 to 9 or 11 to 13, wherein the catalyst layer comprises at least one region having a first thickness and at least one region having a second thickness, wherein the first thickness is different from the second thickness.
15. 15. The method of any of the preceding claims, wherein the receiver substrate has a textured surface comprising a concave surface and a convex surface, and wherein the catalyst ink is applied to the receiver substrate in a predetermined pattern corresponding to the texture of the receiver substrate surface such that the concave surface is coated and the convex surface is uncoated.
16. 16. The method of any of the preceding claims, wherein the receiver substrate has a textured surface comprising a concave surface and a convex surface, and wherein the catalyst ink is applied to the receiver substrate in a predetermined pattern corresponding to the texture of the receiver substrate surface such that the convex surface is coated and the concave surface is uncoated.
17. 17. The method of any one of claims 1 to 3, 9 or 12, wherein the receptor substrate comprises a planar surface.
18. 18. The method of any one of the preceding claims, wherein the solvent has a boiling point of at least 80 ℃, at least 95 ℃, at least 100 ℃, or at least 110 ℃.
19. 19. The method of any of the preceding claims, wherein the solvent comprises water, ethanol, n-propanol, isopropanol, n-butanol, methanol, ethylene glycol, propylene glycol, dipropylene glycol, poly (ethylene glycol), poly (propylene glycol), ethylene carbonate, propylene carbonate, diethyl carbonate, dimethyl carbonate, or a combination thereof.
20. 20. The method of claim 17, wherein the solvent consists essentially of water.

Description

Method for coating catalyst on flat or textured substrate Technical Field The present invention relates to a method of preparing a catalyst layer on a flat and/or textured surface, such as a reformer catalyst plate for a Solid Oxide Fuel Cell (SOFC). The reformer catalyst interconnect plates convert methane, natural gas, or biofuel to hydrogen, and then the hydrogen is used to generate electricity within the SOFC. The present invention also relates to a method of making a catalyst coated flat and/or textured surface, and associated catalyst layers and catalyst coated substrates, such as interconnect boards made using such methods. Background Catalyst coated substrates, such as metal plates, are useful in a variety of applications, including fuel cells and electrolyzers. Conventional methods of catalyst coating include spraying and ultrasonic spraying. However, such methods have limited ability to control the coating location and layer thickness, coat catalysts in unique patterns, coat flat or textured surfaces, and they may also lead to catalyst wastage through overspray. With the expanded application of the use of catalyst coated plates, it is desirable to correct these deficiencies of conventional coating methods. The method and associated product of the present invention addresses these needs by providing more precise control of the coating location, coating layer thickness, coating in a predetermined pattern, coating with enhanced resolution, coating a flat or textured surface, and reducing catalyst wastage. Disclosure of Invention According to some aspects of the present invention, a method of applying a catalyst layer to a surface includes the steps of providing a donor substrate having opposed first and second surfaces, and providing a catalyst ink disposed as a layer on the second surface, wherein the catalyst ink comprises a catalyst and a solvent, providing an acceptor substrate, wherein the second surface of the donor substrate faces the acceptor substrate, and irradiating the catalyst ink with laser radiation at a wavelength absorbed by the catalyst ink to transfer the catalyst ink from the donor substrate to the acceptor substrate. The method may further comprise the step of drying the catalyst ink on the receptor substrate to remove substantially all of the solvent. In some aspects, the catalyst comprises a reformer catalyst. In certain aspects, the receiver substrate includes a non-planar surface, a textured surface, a surface having raised sections and recessed sections, a surface having pits, and/or a surface having ridges. In certain aspects, the receptor substrate comprises a planar surface. In some aspects, the acceptor substrate comprises a plate for a solid oxide fuel cell. In certain aspects, the catalyst ink is applied to the textured surface at a uniform coating layer thickness. In some aspects, the catalyst ink is applied to the textured surface at a predetermined non-uniform coating layer thickness. The catalyst ink may be applied to the receiver substrate in a predetermined pattern, and in some aspects, may be applied in a predetermined pattern corresponding to the texture of the receiver substrate surface. In some aspects, the catalyst layer includes at least one region having a first thickness and at least one region having a second thickness, wherein the first thickness is different from the second thickness. In certain aspects, the receiver substrate has a textured surface comprising a concave surface and a convex surface, wherein the catalyst ink is applied to the receiver substrate in a predetermined pattern corresponding to the texture of the receiver substrate surface such that the concave surface is coated and the convex surface is uncoated. In some aspects, the receiver substrate has a textured surface comprising a concave surface and a convex surface, wherein the catalyst ink is applied to the receiver substrate in a predetermined pattern corresponding to the texture of the receiver substrate surface such that the convex surface is coated and the concave surface is uncoated. The solvent may have a boiling point of at least 80 ℃, at least 95 ℃, at least 100 ℃, at least 110 ℃. The solvent may include, for example, water, ethanol, n-propanol, isopropanol, n-butanol, methanol, ethylene glycol, propylene glycol, dipropylene glycol, poly (ethylene glycol), poly (propylene glycol), ethylene carbonate, propylene carbonate, diethyl carbonate, dimethyl carbonate, or combinations thereof. In some aspects, the solvent consists essentially of water. 19. The method of any one of the preceding claims, wherein the catalyst ink comprises the catalyst in an amount of at least 5 wt%, at least 10 wt%, at least 15 wt%, at least 20 wt%, at least 25 wt%, at least 30 wt%, at least 40 wt%, or at least 50wt%, based on the total weight of the catalyst ink. In some aspects, the catalyst layer has a substantially uniform catalyst loading. In other aspects, the catalyst layer may have a substantial