Abstract: A method of forming a catalyst layer for a fuel cell includes electrospinning a first solution of an ionomer, a binder, and a first solvent to form a porous mat having an interior and an exterior and including a plurality of ionomer nanofibers intertwined with one another to define a plurality of pores within the interior. A portion of the plurality of ionomer nanofibers define the exterior and have an internal surface facing the interior and an external surface facing away from the interior. The method also includes electrospraying a second solution of a catalyst and a second solvent onto the porous mat such that the catalyst is disposed on each external surface and is not embedded within the plurality of pores to thereby form the catalyst layer. A catalyst layer and a fuel cell are also described.

Abstract: A membrane-electrode assembly (MEA) for use in electrical applications, for example in polymer electrolyte fuel cells (PEFCs), includes a protective high-stiffness interlayer coating interposed between a gas diffusion layer and an ion conducting membrane layer, and includes also a catalyst layer. The interlayer mitigates electrical shorting across the ion conducting membrane layer, for example by providing mechanical support against fiber protrusions from the gas diffusion layers into the ion conducting membrane layer or by smoothing the roughness of the gas diffusion layer. The interlayer is typically a mixture of carbon black and one or more ionomers, and its properties are controlled by modulating its thickness, mechanical modulus, ionomer loading, and electrical conductivity.

Abstract: The present invention relates generally to textile fabrics, and more particularly, to a stretchable, nonwoven nanofiber fabric which is impermeable to water but allows vapor transport, capable of conforming to body parts, and is particularly useful in high performance apparels and personal care products. The fabric is combined with different substrates to form a laminate. The fabric and its laminate can retain their dimensional integrity on repeated stretching, have relatively high air permeability while maintaining liquid repellency, and have high stretching recovery. Methods of preparing and applying the nanofiber fabric and its laminate are also provided.