Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) coating a hydrophobic microporous layer across the substrate; (3) coating a catalyst layer onto the hydrophobic microporous layer in the AA region; (4) coating a first fuel cell membrane ionomer layer onto the catalyst layer in the AA region and onto the hydrophobic microporous layer in the WVT region; (5) optionally applying a membrane support layer to the first fuel cell membrane ionomer layer in the AA region and the WVT region; (6) optionally applying a coating of second fuel cell membrane ionomer layer thereby forming a coated substrate; and (7) assembling the coated substrate to a companion coated substrate.

Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) simultaneously coating a microporous layer, a catalyst layer, and a first membrane ionomer layer onto the substrate; (3) applying an optional membrane support layer to the first membrane ionomer layer in the AA region and the WVT region; (4) applying an optional second membrane ionomer layer; (5) heating treating a coated substrate; and (6) assembling the coated substrate to a companion coated substrate.

Abstract: Disclosed are fuel cell systems, reinforced membrane electrode assemblies, and methods for fabricating a reinforced membrane electrode assembly. In an example, a disclosed method includes depositing an electrode ink onto a first substrate to form a first electrode layer, and applying a first porous reinforcement layer onto a surface of the first electrode layer to form a first catalyst coated substrate. The method also includes depositing a first ionomer solution onto the first catalyst coated substrate to form a first ionomer layer. A membrane porous reinforcement layer is applied onto a surface of the first ionomer layer to form a reinforced membrane layer.

Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) simultaneously coating a microporous layer, a catalyst layer, and a first membrane ionomer layer onto the substrate; (3) applying an optional membrane support layer to the first membrane ionomer layer in the AA region and the WVT region; (4) applying an optional second membrane ionomer layer; (5) heating treating a coated substrate; and (6) assembling the coated substrate to a companion coated substrate.

Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) coating a hydrophobic microporous layer across the substrate; (3) coating a catalyst layer onto the hydrophobic microporous layer in the AA region; (4) coating a first fuel cell membrane ionomer layer onto the catalyst layer in the AA region and onto the hydrophobic microporous layer in the WVT region; (5) optionally applying a membrane support layer to the first fuel cell membrane ionomer layer in the AA region and the WVT region; (6) optionally applying a coating of second fuel cell membrane ionomer layer thereby forming a coated substrate; and (7) assembling the coated substrate to a companion coated substrate.

Abstract: An electrode assembly and a method of making an electrode assembly. One embodiment of the method includes coating an ionomer solution onto a catalyst coated diffusion media to form a wet ionomer layer, and applying a porous reinforcement layer to the wet ionomer layer such that the wet ionomer layer at least partially impregnates the reinforcement layer. Drying the wet ionomer layer with the impregnated reinforcement layer and joining it to the catalyst coated diffusion media forms an assembly that includes an integrally-reinforced proton exchange membrane layer. This layer may be additionally joined to other ionomer layers and other catalyst coated diffusion media such that a membrane electrode assembly is formed.

Abstract: Disclosed are fuel cell systems, reinforced membrane electrode assemblies, and methods for fabricating a reinforced membrane electrode assembly. In an example, a disclosed method includes depositing an electrode ink onto a first substrate to form a first electrode layer, and applying a first porous reinforcement layer onto a surface of the first electrode layer to form a first catalyst coated substrate. The method also includes depositing a first ionomer solution onto the first catalyst coated substrate to form a first ionomer layer. A membrane porous reinforcement layer is applied onto a surface of the first ionomer layer to form a reinforced membrane layer.

Abstract: A fuel cell, a reinforced membrane electrode assembly and a method of fabricating a reinforced membrane electrode assembly. The method comprises depositing an electrode ink onto a first substrate to form a first electrode layer, applying a first porous reinforcement layer on a surface of the first electrode layer to form a first catalyst coated substrate, depositing a first ionomer solution onto the first catalyst coated substrate to form a first ionomer layer, and applying a membrane porous reinforcement layer on a surface of the first ionomer layer to form a reinforced membrane layer.

Abstract: Disclosed are methods for simultaneous application of multiple fuel cell component coatings onto a substrate. The method comprises providing a substrate, and simultaneously coating two or more solutions onto the substrate under laminar flow.

Abstract: Methods of making a substantially crack-free electrode layer are described. The methods include depositing an electrode ink on a substrate; placing a layer of porous reinforcement layer on a surface of the wet electrode ink; and drying the electrode ink to form the substantially crack-free electrode layer on the substrate. Substantially crack-free electrode layers and fuel cells incorporating substantially crack-free electrode layers 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: A multilayer polyelectrolyte membrane for fuel cell applications includes a first perfluorocyclobutyl-containing layer that includes a polymer having perfluorocyclobutyl moieties. The first layer is characteristically planar having a first major side and a second major side over which additional layers are disposed. The membrane also includes a first PFSA layer disposed over the first major side of the first layer and a second PFSA layer disposed over the second major side of the first layer.

Abstract: Methods of making a substantially crack-free electrode layer are described. The methods include depositing an electrode ink on a substrate; placing a solid polymer film on a surface of the wet electrode ink; drying the electrode ink; and removing the solid polymer film from the surface of the dry electrode ink to form the substantially crack-free electrode layer on the substrate.

Abstract: Disclosed are methods for simultaneous application of multiple fuel cell component coatings onto a substrate. The method comprises providing a substrate, and simultaneously coating two or more solutions onto the substrate under laminar flow.

Abstract: A graded electrode is described. The graded electrode includes a substrate; and at least two electrode layers on the substrate forming a combined electrode layer, a composition of the at least two electrode layers being different, the combined electrode layer having an average level of the property that changes across the substrate. Fuel cells using graded electrodes and methods of making graded electrodes are also described.

Abstract: A multilayer polyelectrolyte membrane for fuel cell applications includes a first perfluorocyclobutyl-containing layer that includes a polymer having perfluorocyclobutyl moieties. The first layer is characteristically planar having a first major side and a second major side over which additional layers are disposed. The membrane also includes a first PFSA layer disposed over the first major side of the first layer and a second PFSA layer disposed over the second major side of the first layer.

Abstract: An electrode assembly and a method of making an electrode assembly. One embodiment of the method includes coating an ionomer solution onto a catalyst coated diffusion media to form a wet ionomer layer, and applying a porous reinforcement layer to the wet ionomer layer such that the wet ionomer layer at least partially impregnates the reinforcement layer. Drying the wet ionomer layer with the impregnated reinforcement layer and joining it to the catalyst coated diffusion media forms an assembly that includes an integrally-reinforced proton exchange membrane layer. This layer may be additionally joined to other ionomer layers and other catalyst coated diffusion media such that a membrane electrode assembly is formed.

Abstract: Methods of making a substantially crack-free electrode layer are described. The methods include depositing an electrode ink on a substrate; placing a layer of porous reinforcement layer on a surface of the wet electrode ink; and drying the electrode ink to form the substantially crack-free electrode layer on the substrate. Substantially crack-free electrode layers and fuel cells incorporating substantially crack-free electrode layers are also described.

Abstract: Methods of making a substantially crack-free electrode layer are described. The methods include depositing an electrode ink on a substrate; placing a solid polymer film on a surface of the wet electrode ink; drying the electrode ink; and removing the solid polymer film from the surface of the dry electrode ink to form the substantially crack-free electrode layer on the substrate.

Abstract: A graded electrode is described. The graded electrode includes a substrate; and at least two electrode layers on the substrate forming a combined electrode layer, a composition of the at least two electrode layers being different, the combined electrode layer having an average level of the property that changes across the substrate. Fuel cells using graded electrodes and methods of making graded electrodes are also described.