Abstract: Simplified methods are disclosed for preparing a catalyst coated membrane that is reinforced with a porous polymer sheet (e.g. an expanded polymer sheet) for use in solid polymer electrolyte fuel cells. The methods involve forming a solid polymer electrolyte membrane by coating membrane ionomer solution onto a first catalyst layer and then applying the porous polymer sheet to the membrane ionomer solution coating, while it is still wet, such that the membrane ionomer solution only partially fills the pores of the porous polymer sheet. A second catalyst ink is then applied which fills the remaining pores of the porous polymer sheet. Not only are such methods simpler than many conventional methods, but surprisingly this can result in a marked improvement in fuel cell performance characteristics.

Abstract: Simplified methods are disclosed for preparing a catalyst coated membrane that is reinforced with a porous polymer sheet (e.g. an expanded polymer sheet) for use in solid polymer electrolyte fuel cells. The methods involve forming a solid polymer electrolyte membrane by coating membrane ionomer solution onto a first catalyst layer and then applying the porous polymer sheet to the membrane ionomer solution coating, while it is still wet, such that the membrane ionomer solution only partially fills the pores of the porous polymer sheet. A second catalyst ink is then applied which fills the remaining pores of the porous polymer sheet. Not only are such methods simpler than many conventional methods, but surprisingly this can result in a marked improvement in fuel cell performance characteristics.

Abstract: In solid polymer electrolyte fuel cells, an oxygen evolution reaction (OER) catalyst may be incorporated at the anode along with the primary hydrogen oxidation catalyst for purposes of tolerance to voltage reversal. Incorporating this OER catalyst in a layer at the interface between the anode's primary hydrogen oxidation anode catalyst and its gas diffusion layer can provide greatly improved tolerance to voltage reversal for a given amount of OER catalyst. Further, this improvement can be gained without sacrificing cell performance.

Abstract: A method of forming a membrane electrode assembly (MEA) includes first bonding a first electrode layer to a first side of an ion-exchange membrane. The method may further include protecting a second side of the membrane with a release sheet. The method may further include removing the release sheet and bonding the second side of the membrane to a first side of a second electrode layer. The method may further include positioning venting members on a second side of the second electrode layer to remove at least one of a liquid and a vapor that may be generated during the bonding process. In another embodiment an electrocatalyst can first bond to at least one side of the membrane, and subsequently, to a gas diffusion layer. An opposing side of the membrane can bond to an electrode layer in aqueous state.

Abstract: In solid polymer electrolyte fuel cells, an oxygen evolution reaction (OER) catalyst may be incorporated at the anode along with the primary hydrogen oxidation catalyst for purposes of tolerance to voltage reversal. Incorporating this OER catalyst in a layer at the interface between the anode's primary hydrogen oxidation anode catalyst and its gas diffusion layer can provide greatly improved tolerance to voltage reversal for a given amount of OER catalyst. Further, this improvement can be gained without sacrificing cell performance.

Abstract: A method of forming a membrane electrode assembly (MEA) includes first bonding a first electrode layer to a first side of an ion-exchange membrane. The method may further include protecting a second side of the membrane with a release sheet. The method may further include removing the release sheet and bonding the second side of the membrane to a first side of a second electrode layer. The method may further include positioning venting members on a second side of the second electrode layer to remove at least one of a liquid and a vapor that may be generated during the bonding process. In another embodiment an electrocatalyst can first bond to at least one side of the membrane, and subsequently, to a gas diffusion layer. An opposing side of the membrane can bond to an electrode layer in aqueous state.