Abstract: Oxygen electrodes, production methods and reversible, alkaline or anion exchange membrane (AEM) electrochemical devices are provided. The oxygen electrodes are operable in the reversible devices both as cathodes of a fuel cell supporting an oxygen reduction reaction (ORR), and as anodes of an electrolyzer supporting an oxygen evolution reaction (OER). The oxygen electrodes comprise a substrate layer which may be a porous transport layer (PTL), possibly coated and/or hydrophobized, or a membrane; and a blend of catalysts which is deposited on the substrate layer to form a catalyst layer, and includes ORR catalyst (e.g., a platinum group metal), OER catalyst (e.g., nickel-based particles), and possibly binders such as ionomers, PTFE or other polymers that are resistant in alkaline environment, but with the catalyst layer and the substrate layer being devoid of elemental carbon.

Abstract: Methods of preparing cell element(s) that are operable in alkaline or anion exchange electrochemical devices are provided, as well as corresponding cell elements and electrochemical devices such as fuel cells, electrolyzers and reversible dual devices. Binder material is mixed with catalyst material and optionally ionomer material, and coated on support layer(s) and/or one or both side of a membrane, and the catalyst layers are hot-pressed briefly, to improve the adhesion of the layer and its cohesivity. Membrane electrode assemblies are prepared from the cell elements in various configurations of the catalyst layers with respect to the cell elements, and the added binder and hot pressing improve the long-term performance and durability of the electrochemical devices.

Abstract: Methods of making alkaline exchange catalytic electrodes for electrochemical devices are provided, as well as fuel cells, electrolyzers and dual reversible devices with provided electrodes and/or membrane-electrode assemblies. Methods comprise preparing a catalyst dispersion by mixing catalyst nanoparticles and polymer precursor dispersion in a solvent. The polymer precursor(s) comprise multiple types of monomer units with multiple types of functional groups that include non-cationic functional group(s) and anion-conductive functional group(s). Consecutively, the catalyst dispersion is deposited on a functional substrate and the solvent is evaporated to form a catalyst layer, and then the non-cationic functional group(s) and/or the anion-conductive group(s) are crosslinked to stabilize the catalyst layer. Membrane-electrode assemblies may be formed by the provided methods, and used in various types of electrochemical devices.