US2004241530A1PendingUtilityA1

Method for preparing fuel cell component substrate of flexible graphite material having improved catalytic properties

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Priority: May 31, 2001Filed: May 23, 2002Published: Dec 2, 2004
Est. expiryMay 31, 2021(expired)· nominal 20-yr term from priority
Inventors:Robert Anderson Reynolds, IiiRobert Angelo MercuriRonald Greinke
C04B 2235/444C04B 2235/48H01M 4/8605C04B 2235/3289C04B 35/536H01M 8/0213H01M 4/926H01M 8/0226Y02E60/50
44
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Claims

Abstract

A method enables preparation of a stock or starting material having improved catalytic properties. These materials will be useful in the formation of articles adapted for use in electrochemical fuel cells.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A material useful as a substrate for preparing articles such as an embossed or unembossed flexible graphite sheet, the material comprising: 
 a compressed sheet of graphite comprised of intercalated graphite particles having fuel cell catalyst included therein.    
     
     
         2 . A material of  claim 1  wherein the intercalant comprises a platinum group metal.  
     
     
         3 . A material of  claim 1  wherein the intercalant comprises a platinum group metal selected from the group of platinum, rhodium, palladium and iridium and combinations.  
     
     
         4 . A material of  claim 1  which comprises a platinum group metal at a concentration in the range of from 0.001 to 1.0 mg/cm 2 .  
     
     
         5 . A material of  claim 4  which comprises a platinum group metal at a concentration in the range of from 0.01 to 0.3 mg/cm 2 .  
     
     
         6 . A material of  claim 4  having a thickness of from 0.075 to 1.4 mm.  
     
     
         7 . A material of  claim 4  having a thickness of under 1 mm and greater than 0.01 mm.  
     
     
         8 . A material of  claim 1  which is embossed on one surface.  
     
     
         9 . A material of  claim 1  wherein the sheet contains resin at a level of at least about 5% in the flexible graphite sheet.  
     
     
         10 . A process for preparing a material useful as a substrate for preparing articles such as an embossed or unembossed flexible graphite sheet, comprising: 
 intercalating a sheet of flexible graphite to an extent necessary to form graphite intercalation compounds which increase the thermal and/or electrical conductivity of the graphite sheet; and compressing the sheet following intercalation.    
     
     
         11 . A process of  claim 10  wherein the intercalant comprises a platinum group metal.  
     
     
         12 . A process of  claim 10  wherein the intercalant comprises a platinum group metal selected from the group of platinum, rhodium, palladium and iridium and combinations.  
     
     
         13 . A process of  claim 10  which comprises a platinum group metal at a concentration in the range of from 0.001 to 1.0 mg/cm 2 .  
     
     
         14 . A process of  claim 13  which comprises a platinum group metal at a concentration in the range of from 0.01 to 0.3 mg/cm 2 .  
     
     
         15 . A process of  claim 14  having a thickness of from 0.075 to 1.4 mm.  
     
     
         16 . A process of  claim 14  having a thickness of under 1 mm and greater than 0.01 mm.  
     
     
         17 . A process of  claim 1  including the step of embossing one surface of the sheet following intercalation.  
     
     
         18 . A process of  claim 10  including the step of impregnating with a resin at a level of at least about 5% in the flexible graphite sheet.

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