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.

A method of manufacturing a membrane electrode assembly for hydrogen fuel cells includes mixing an electrode binder with a catalyst, followed by dispersing and thermal treatment, to prepare an electrode slurry, coating release paper with the electrode slurry to produce an electrode, and bonding the release paper-coated electrode to an electrolyte membrane, followed by thermal treatment, to perform electrode-membrane bonding.

A method for manufacturing a fuel cell electrode includes forming a first mixture by mixing a first cation exchange resin, a metal catalyst, and a first solvent, powderizing the first mixture to produce a first catalyst powder comprising the metal catalyst coated with the first cation exchange resin, forming a second mixture by mixing the first catalyst powder, a second cation exchange resin, and a second solvent, powderizing the second mixture to produce a catalyst powder having a core and two or more layers of shells and being coated with the second cation exchange resin, mixing the catalyst powder having the core and two or more layers of shells with a third solvent to produce a catalyst slurry, and coating, using the catalyst slurry, to produce an electrode.

Improved catalyst layers for use in fuel cell membrane electrode assemblies, and methods for making such catalyst layers, are provided. Catalyst layers can comprise structured units of catalyst, catalyst support, and ionomer. The structured units can provide for more efficient electrical energy production and/or increased lifespan of fuel cells utilizing such membrane electrode assemblies. Catalyst layers can be directly deposited on exchange membranes, such as proton exchange membranes.

Improved catalyst layers for use in fuel cell membrane electrode assemblies, and methods for making such catalyst layers, are provided. Catalyst layers can comprise structured units of catalyst, catalyst support, and ionomer. The structured units can provide for more efficient electrical energy production and/or increased lifespan of fuel cells utilizing such membrane electrode assemblies. Catalyst layers can be directly deposited on exchange membranes, such as proton exchange membranes.

A composite including an electrolyte layer containing solid oxide, and at least one electrode selected from a cathode disposed on one side of the electrolyte layer in a first direction and an anode disposed on the other side of the electrolyte layer in the first direction. Either one of two surfaces of the composite located on opposite sides in the first direction satisfies a first requirement that, as viewed in the first direction, a curvature determined on the basis of any three points juxtaposed at intervals of 5 mm is less than 0.0013 (l/mm) and that, as viewed in a second direction perpendicular to the first direction, the curvature is the reciprocal of the radius of an imaginary circle passing through the any three points.

A method of fabricating a SSZ/SDC bi-layer electrolyte solid oxide fuel cell, comprising the steps of: fabricating an NiO-YSZ anode substrate from a mixed NiO and yttria-stabilized zirconia by tape casting; sequentially depositing a NiO-SSZ buffer layer, a thin SSZ electrolyte layer and a SDC electrolyte on the NiO-YSZ anode substrate by a particle suspension coating or spraying process, wherein the layers are co-fired at high temperature to densify the electrolyte layers to at least about 96% of their theoretical densities; and painting/spraying a SSC-SDC slurry on the SDC electrolyte to form a porous SSC-SDC cathode. A SSZ/SDC bi-layer electrolyte cell device and a method of using such device are also discussed.

The present disclosure provides a method for manufacturing a membrane electrode assembly for a fuel cell in which a transfer failure is suppressed. The present disclosure relates to a method for manufacturing a membrane electrode assembly for a fuel cell, which comprises intermittently applying a catalyst ink on a substrate sheet and drying the catalyst ink to form a catalyst layer on the substrate sheet, and transferring the catalyst layer from the substrate sheet onto an electrolyte membrane. The catalyst ink contains catalyst particles, an ionomer, an alcohol, and water, and a water content in the catalyst ink is 57% to 61% by weight of a total weight of the catalyst ink.

A polymer electrolyte fuel cell (PEFC), comprises a first electrode and a second electrode, wherein the first electrode includes a coaxial nanowire electrode. In some embodiments, the coaxial nanowire electrode comprises a plurality of ionomer nanowires, and a catalyst coating that coats at least part of the ionomer nanowires. Moreover, in some embodiments, a nanowire of the plurality of ionomer nanowires and a section of the catalyst coating that coats the nanowire form two coaxial cylinders.

A device for manufacturing a membrane-electrode assembly for a fuel cell may include top and bottom side bonding rolls respectively disposed above and below a transfer path through which an electrolyte membrane and top and bottom electrode films transferred with a predetermined line speed, one of the top side and bottom side bonding rolls provided reciprocally movable in a vertical direction through a first driving source, and transfer anode and cathode catalyst electrode layers of the top and bottom electrode films to top and bottom sides of the electrolyte membrane while compressing the top and bottom electrode films; film rewinders provided above and below the transfer path to rewind the top and bottom electrode films; and a compulsive driving roll provided in a rewinding path of an electrode film rewound by one of the film rewinders and selectively compulsively feeding the electrode film with a predetermined driving speed.