초록

A method of manufacturing fuel cell membrane electrode assemblies using solution cast films, and the resulting electrode assemblies. The assemblies are prepared by applying a catalyst slurry onto a decal, subsequently applying ionomer solution and at least partially curing the ionomer.

대표청구항 ▼

1. A method of manufacturing a membrane electrode assembly component comprising: a. applying a catalyst slurry onto a removable decal; b. drying the catalyst slurry to form a dried catalyst layer; c. applying at least one ionomer solution layer on the resulting dried catalyst layer; and d. at

1. A method of manufacturing a membrane electrode assembly component comprising: a. applying a catalyst slurry onto a removable decal; b. drying the catalyst slurry to form a dried catalyst layer; c. applying at least one ionomer solution layer on the resulting dried catalyst layer; and d. at least partially curing the at least one ionomer solution layer to form a membrane electrode assembly component. 2. A method of claim 1 wherein the catalyst slurry is at least partially cured before applying the at least one ionomer solution. 3. A method of manufacturing a membrane electrode assembly comprising: a. applying a catalyst slurry onto a removable decal; b. drying the catalyst slurry to form a dried catalyst layer; c. applying at least one ionomer solution layer on the resulting dried catalyst layer; d. at least partially curing the at least one ionomer solution layer to form a membrane electrode assembly component; and repeating steps (a) to (d) to prepare a second membrane electrode assembly component and joining the two components together with the ionomer layers in contact with each other and removing the decals to form a membrane electrode assembly. 4. A method of claim 3 further comprising placing a perimeter sealing material partly between the two ionomer layers. 5. A method of claim 4 wherein the two decal assemblies are hot pressed together. 6. A method of claim 3 wherein the two components are hot pressed together. 7. A method of claim 6 further comprising applying a layer of diffusion medium to the outside surface of each catalyst layer. 8. A method of claim 3 further comprising placing perimeter sealing material on the outer edges of both catalyst layers. 9. A method of claim 7 further comprising partially infusing the diffusion media with a perimeter sealing material. 10. A method of manufacturing a membrane electrode assembly component comprising: a. applying a catalyst slurry onto a first decal; b. drying the catalyst slurry to form a catalyst layer; c. applying at least one ionomer solution layer to a second decal; d. drying and at least partly curing the resulting applied ionomer solution layer; e. joining the two decal assemblies with the ionomer and catalyst layers in contact with each other; and f. removing the decal from the ionomer layer to form a membrane electrode assembly component. 11. A method of claim 10 wherein each of the decals is a polymeric film. 12. A method of claim 11 wherein the decal onto which the catalyst slurry is applied consists essentially of poly (tetrafluoroethylene) film. 13. A method of claim 11 wherein the decal onto which the ionomer solution is applied consists essentially of polyester film. 14. A method of manufacturing a membrane electrode assembly comprising: a. applying a catalyst slurry onto a first decal; b. drying the catalyst slurry to form a catalyst layer; c. applying at least one ionomer solution layer to a second decal; d. drying and at least partly curing the resulting applied ionomer solution layer; e. joining the two decal assemblies with the ionomer and catalyst layers in contact with each other; f. removing the decal from the ionomer layer to form a membrane electrode assembly component; and and repeating steps (a) to (f) to prepare a second membrane electrode assembly component, and combining the resulting two membrane electrode assembly components by bringing the ionomer layers of each component into contact to join the ionomer layers; and removing the decals from the resulting membrane electrode assembly. 15. A method of claim 14 further comprising placing a perimeter sealing material partly between the two ionomer layers. 16. A method of claim 14 wherein a diffusion medium layer is placed on the outside surface of each catalyst layer. 17. A method of claim 14 further comprising placing perimeter sealing material on outer edges of both catalyst layers.