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Hydrogen production via the electrolysis of water has gained a lot of attention in the last couple of years. Research related to electrolysers is mostly aimed towards decreasing the noble–metal catalyst content. In this study the presently used catalyst application techniques were reviewed and critically examined to find commercially applicable and effective methods. Selected methods were then practically applied to determine their feasibility and to gain “know–how” related to the practical application of these techniques. The selected techniques were the hand paint, inkjet print, screen print and spray paint techniques. Meaningful comparisons were made between the methods in terms of parameters such as practicality, waste of catalyst and microstructure. The results point out that the hand paint and spray paint methods are feasible methods although there are improvements to be made. The hand paint method was improved by applying a carbon micro porous layer to the gas diffusion layer before the painting is carried out. The addition of the carbon layer reduced the soaking of the catalyst–containing ink through the gas diffusion layer. A method not initially investigated was identified an evaluated and showed promising results in lowering the mass of catalyst applied. This method comprised of sputtering a layer of catalyst material onto a prepared gas diffusion layer. It also came to light from the results that electrodes, and therefore membrane electrode assemblies, can be produced at a much lower cost than the commercial available membrane electrode assemblies. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2012.

Hydrogen production via the electrolysis of water has gained a lot of attention in the last couple of years. Research related to electrolysers is mostly aimed towards decreasing the noble–metal catalyst content. In this study the presently used catalyst application techniques were reviewed and critically examined to find commercially applicable and effective methods. Selected methods were then practically applied to determine their feasibility and to gain “know–how” related to the practical application of these techniques. The selected techniques were the hand paint, inkjet print, screen print and spray paint techniques. Meaningful comparisons were made between the methods in terms of parameters such as practicality, waste of catalyst and microstructure. The results point out that the hand paint and spray paint methods are feasible methods although there are improvements to be made. The hand paint method was improved by applying a carbon micro porous layer to the gas diffusion layer before the painting is carried out. The addition of the carbon layer reduced the soaking of the catalyst–containing ink through the gas diffusion layer. A method not initially investigated was identified an evaluated and showed promising results in lowering the mass of catalyst applied. This method comprised of sputtering a layer of catalyst material onto a prepared gas diffusion layer. It also came to light from the results that electrodes, and therefore membrane electrode assemblies, can be produced at a much lower cost than the commercial available membrane electrode assemblies. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2012.

Diese Dissertation befasst sich mit der industrienahen Herstellung von Katalysatorschichten für Polymer-Elektrolyt-Membran-Brennstoffzellen mit Hilfe des Tiefdrucks als Fertigungsverfahren. Um die Anforderungen an die Katalysatorschicht hinsichtlich der Schichtdicke zu erreichen, wird ein Linienraster für den Tiefdruck entwickelt. Das patentierte und verifizierte Designkonzept des Linienrasters ermöglicht es, trotz Tinten mit geringem Feststoffgehalt hohe Trockenschichtdicken zu erzeugen. Aufgrund des verwendeten Tiefdruckrasters sind Optimierungsschritte an der Fertigungsanlage notwendig, um eine hohe Schichtqualität zu erreichen. Schließlich werden kontinuierlich und industrienah Katalysatorschichten gefertigt, die als Membran-Elektroden-Einheit in einer Polymer-Elektrolyt-Membran-Brennstoffzelle erfolgreich eingesetzt werden. / This work presents an industrial close manufacturing process of active electrodes for Polymer Electrolyte Fuel Cells utilizing an adapted gravure printing process. To meet the requirements of the electrodes regarding the layer thickness (weight) and quality a novel line screen with maximized dipping volume for gravure printing was developed and investigated. A design rule for this kind of screens was realized and verified by a successful manufacturing of electrodes with different dried layer thicknesses. Due to the rough structure and the high dipping volumes of these line screens an adaption and optimization of the machinery and the whole process was necessary to achieve high quality electrodes. Finally, it is shown that it is possible to manufacture continuiously in an industrial close roll-to-roll process platinum loaded electrodes, working successful as cathode in a Membran-Electrode-Assembly.