Abstract: A fuel cell includes a proton exchange membrane having a first major side and a second major side. The membrane electrode assembly includes a first anisotropic reinforced layer having a first plurality of fiber preferentially oriented along a first direction, a second anisotropic reinforced layer having a second plurality of fiber preferentially oriented along a second direction, and a polymeric layer including a plurality of sulfonic acid groups. A cathode catalyst layer is disposed over the first major side of the proton exchange membrane while an anode catalyst layer is disposed over the second major side of the proton exchange membrane. An anode flow field plate is disposed over the anode catalyst layer and a cathode flow field plate is disposed over the cathode catalyst layer.

Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.

Abstract: Disclosed are methods for fabricating a reinforced membrane electrode assembly having one or more freestanding external reinforcement layers. The method comprises providing a freestanding external reinforcement layer, and depositing a catalyst solution and membrane solution onto at least a portion of the freestanding external reinforcement layer.

Abstract: Methods of making reinforced membrane electrode assemblies are described. Catalyst coated free standing microporous layers and reinforced membrane electrode assemblies are also described.

Abstract: A method of coating carbon based electrodes and thick electrodes without mud-cracking is described. The electrode ink is deposited on a decal substrate, and transferred to a hot press before the electrode ink is completely dried. The partially dried electrode ink is hot pressed to the membrane to form a membrane electrode assembly. A membrane electrode assembly including a polymer membrane; and a pair of crack-free electrode layers on opposite sides of the polymer membrane, each of the pair of electrode layers having a thickness of at least about 50 ?m is also described.

Abstract: A method of transferring a nanostructured thin catalytic layer from its carrying substrate to a porous transfer substrate and further processing and restructuring the nanostructured thin catalytic layer on the porous transfer substrate is provided. The method includes transferring the nanostructured catalytic layer from its carrying substrate to a transfer substrate. The nanostructured catalytic layer then is processed and reconstructed, including removing the residual materials and adding additional components or layers to the nanostructured catalytic layer, on the transfer substrate. Methods of fabricating catalyst coated membranes with the reconstructed electrode including the nanostructured thin catalytic layer, reconstructed electrode decals, and catalyst coated proton exchange membranes are also described.

Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.

Abstract: A fuel cell includes a proton exchange membrane having a first major side and a second major side. The membrane electrode assembly includes a first anisotropic reinforced layer having a first plurality of fiber preferentially oriented along a first direction, a second anisotropic reinforced layer having a second plurality of fiber preferentially oriented along a second direction, and a polymeric layer including a plurality of sulfonic acid groups. A cathode catalyst layer is disposed over the first major side of the proton exchange membrane while an anode catalyst layer is disposed over the second major side of the proton exchange membrane. An anode flow field plate is disposed over the anode catalyst layer and a cathode flow field plate is disposed over the cathode catalyst layer.

Abstract: A method of transferring nanostructured thin catalytic layers to a gas diffusion layer and thus making a catalyst coated diffusion media is described. The method includes treating the gas diffusion layer with a temporary adhesive to temporarily increase the adhesion strength within the microporous layer and to carbon fiber paper substrate, transferring the nanostructured thin catalytic layer to the microporous side of a gas diffusion media layer. The nanostructured thin catalytic layer can then be further processed, including adding additional components or layers to the nanostructured thin catalytic layer on the gas diffusion media layer. Preparation of catalyst coated diffusion media and a catalyst coated diffusion media based membrane electrode assembly (MEA) are also described.

Abstract: A method of making a reconstructed electrode having a plurality of nanostructured thin catalytic layers is provided. The method includes combining a donor decal comprising at least one nanostructured thin catalytic layer on a substrate with an acceptor decal comprising a porous substrate and at least one nanostructured thin catalytic layer. The donor decal and acceptor decal are bonded together using a temporary adhesive, and the donor substrate is removed. The temporary adhesive is then removed with appropriate solvents. Catalyst coated proton exchange membranes and catalyst coated diffusion media made from the reconstructed electrode decals having a plurality of nanostructured thin catalytic layers are also described.

Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.

Abstract: A method of making an electrode is provided. The method includes providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon; providing a transfer substrate with an adjacent adhesive layer; adhering the nanostructured thin catalytic layer adjacent to the adhesive layer to form a composite structure; removing the carrying substrate from the composite structure; and removing the transfer substrate from the composite structure to form the stand-alone nanostructured thin catalytic film comprising the adhesive layer with the nanostructured thin catalytic layer adhered thereto. A stand alone nanostructured thin catalytic film and methods of constructing electrodes with the stand alone nanostructured thin catalytic films are also described.

Abstract: Methods of making reinforced membrane electrode assemblies are described. Catalyst coated free standing microporous layers and reinforced membrane electrode assemblies are also described.

Abstract: A method of making an electrode is provided. The method includes providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon; providing a transfer substrate with an adjacent adhesive layer; adhering the nanostructured thin catalytic layer adjacent to the adhesive layer to form a composite structure; removing the carrying substrate from the composite structure; and removing the transfer substrate from the composite structure to form the stand-alone nanostructured thin catalytic film comprising the adhesive layer with the nanostructured thin catalytic layer adhered thereto. A stand alone nanostructured thin catalytic film and methods of constructing electrodes with the stand alone nanostructured thin catalytic films are also described.

Abstract: A method of coating carbon based electrodes and thick electrodes without mud-cracking is described. The electrode ink is deposited on a decal substrate, and transferred to a hot press before the electrode ink is completely dried. The partially dried electrode ink is hot pressed to the membrane to form a membrane electrode assembly. A membrane electrode assembly including a polymer membrane; and a pair of crack-free electrode layers on opposite sides of the polymer membrane, each of the pair of electrode layers having a thickness of at least about 50 ?m is also described.

Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.

Abstract: A method of transferring nanostructured thin catalytic layers to a gas diffusion layer and thus making a catalyst coated diffusion media is described. The method includes treating the gas diffusion layer with a temporary adhesive to temporarily increase the adhesion strength within the microporous layer and to carbon fiber paper substrate, transferring the nanostructured thin catalytic layer to the microporous side of a gas diffusion media layer. The nanostructured thin catalytic layer can then be further processed, including adding additional components or layers to the nanostructured thin catalytic layer on the gas diffusion media layer. Preparation of catalyst coated diffusion media and a catalyst coated diffusion media based membrane electrode assembly (MEA) are also described.

Abstract: A method of transferring a nanostructured thin catalytic layer from its carrying substrate to a porous transfer substrate and further processing and restructuring the nanostructured thin catalytic layer on the porous transfer substrate is provided. The method includes transferring the nanostructured catalytic layer from its carrying substrate to a transfer substrate. The nanostructured catalytic layer then is processed and reconstructed, including removing the residual materials and adding additional components or layers to the nanostructured catalytic layer, on the transfer substrate. Methods of fabricating catalyst coated membranes with the reconstructed electrode including the nanostructured thin catalytic layer, reconstructed electrode decals, and catalyst coated proton exchange membranes are also described.

Abstract: A method of making a reconstructed electrode having a plurality of nanostructured thin catalytic layers is provided. The method includes combining a donor decal comprising at least one nanostructured thin catalytic layer on a substrate with an acceptor decal comprising a porous substrate and at least one nanostructured thin catalytic layer. The donor decal and acceptor decal are bonded together using a temporary adhesive, and the donor substrate is removed. The temporary adhesive is then removed with appropriate solvents. Catalyst coated proton exchange membranes and catalyst coated diffusion media made from the reconstructed electrode decals having a plurality of nanostructured thin catalytic layers are also described.