Abstract: Thermoset polymer composite wires including a multiplicity of substantially continuous fibers embedded in a solidified polymer composite matrix and forming a substantially continuous filament, the solidified polymer composite matrix further including a polymer formed by curing a polymer precursor from a liquid state and a multiplicity of nanoparticles having a median diameter of one micrometer or less substantially uniformly dispersed throughout the polymer composite matrix, and optionally, a corrosion resistant sheath surrounding the substantially continuous filament. In some embodiments, the multiplicity of particles includes surface-modified particles having a core and a surface modifying agent associated with the core and reacted with the polymer cured from a liquid state. Stranded cables including one or more such thermoset polymer composite wires, and methods of making and using such thermoset polymer composite wires and stranded cables are also described.

Abstract: Thermoset polymer composite wires including a multiplicity of substantially continuous fibers embedded in a solidified polymer composite matrix and forming a substantially continuous filament, the solidified polymer composite matrix further including a polymer formed by curing a polymer precursor from a liquid state and a multiplicity of nanoparticles having a median diameter of one micrometer or less substantially uniformly dispersed throughout the polymer composite matrix, and optionally, a corrosion resistant sheath surrounding the substantially continuous filament. In some embodiments, the multiplicity of particles includes surface-modified particles having a core and a surface modifying agent associated with the core and reacted with the polymer cured from a liquid state. Stranded cables including one or more such thermoset polymer composite wires, and methods of making and using such thermoset polymer composite wires and stranded cables are also described.

Abstract: The present invention provides a method of making a fuel cell gas diffusion layer comprising the steps of a) providing a carbon fiber construction; b) coating at least the upper surface of the carbon fiber construction with composition which comprises a fluoropolymer; and c) exposing the upper surface to at least one plasma, such as a silane plasma, so as to generate a hydrophilic surface layer having a thickness of no more than 1 micron. The present invention also provides a method additionally comprising the step of partially covering the upper surface with a mask having windows according to a pattern, such that the hydrophilic surface layer is applied according to the pattern. The present invention also provides a method wherein the carbon fiber construction is provided as a roll good and the step of exposing said upper surface to at least one plasma is performed in continuous roll-to-roll fashion.

Abstract: A method of making a five-layer membrane electrode assembly is provided which includes the steps of: providing a catalyst coated membrane web; providing a laminating station wherein the catalyst coated membrane web is drawn between a pair of laminating rollers which form a laminating nip; die-cutting first and second webs of gas diffusion layer material to make first and second gas diffusion layers; feeding first and second gas diffusion layers into the laminating nip adjacent to the catalyst coated membrane web; and laminating the first gas diffusion layer, catalyst coated membrane web and second gas diffusion layer to form a laminate.

Abstract: The present invention provides a method of making 3-layer membrane electrode assemblies (MEAs) involving a direct transfer of the catalyst to the polymer electrolyte membrane as a decal in protonated form (acid form) at low temperature, particularly by use of a microstructured transfer medium or a flame-treated silicone-containing transfer medium.