A method for production of a fuel cell includes:

a) Preparing a plurality of catalyst pastes which differ from each other at least in regard to one parameter influencing the catalytic activity,

b) Filling of at least two of the plurality of catalyst pastes into a first application means having a number of chambers corresponding to the number of catalyst pastes being filled, where only one of the catalyst pastes is filled into each of the chambers,

c) Filling of at least two of the plurality of catalyst pastes into a second application means having a number of chambers corresponding to the number of catalyst pastes being filled, where only one of the catalyst pastes is filled into each of the chambers,

d) Coating of a first side of a foil web of an electrolyte membrane which is moved past the first application means and the second application means by means of the first application means,

e) Coating of a second side of the foil web by means of the second application means,

f) Cutting of the resulting coated electrolyte membrane from the foil web and rotating of the electrolyte membrane by 90° with respect to a delivery direction of the foil web,

g) Placing of the electrolyte membrane between two flow field plates with a gradient in regard to the parameter which is oriented perpendicular to the flow field, and

h) Pressing together the flow field plates.

The present invention provides a catalysed ion-conducting membrane comprising an ion-conducting membrane, an electrocatalyst layer having two opposing faces, and a layer A comprising an ion-conducting material and a carbon containing material. Also provided are methods for preparing the catalysed ion-conducting membrane.

A small diameter roll is provided on the upstream side of a heating and sucking roll, an electrode slurry is applied by using a slot nozzle on the small diameter roll or an OFF roll, and an electrode is formed by instantaneously evaporating a solvent by the heating and sucking roll.

A catalyst for a fuel cell anode comprises an alloy of Pd and at least two other transition metals, at least one of which which binds to hydrogen and/or carbon monoxide at least as strongly as Pd does. Suitable transition metals which bind more strongly are Co, W, Ti, V, Cr, Fe, Mo, Nb, Hf, Ta, Zr and Re. PdCoW is the most preferred alloy. The catalyst is used on the anode of a hydrogen oxidising fuel cell, such as a PEMFC to catalyse the hydrogen oxidation reaction.

Materials for electrochemical cells are provided. BaZr.sub.0.4Ce.sub.0.4M.sub.0.2O.sub.3 compounds, where M represents one or more rare earth elements, are provided for use as electrolytes. PrBa.sub.0.5Sr.sub.0.5Co.sub.2−xFe.sub.xO.sub.5+δ is provided for use as a cathode. Also provided are electrochemical cells, such as protonic ceramic fuel cells, incorporating the compounds as electrolytes and cathodes.

There is provided a method for manufacturing a catalyst ink for fuel cell electrodes that allows simultaneously performing fineness of a catalyst and adjustment of viscosity of the catalyst ink. The method for manufacturing a catalyst ink for fuel cell electrodes containing a catalyst, a solvent, and an ionomer includes stirring and mixing the catalyst, the solvent, and the ionomer by a high-shear thin-film spin mixer. The ionomer contains a gel-like ionomer. The high-shear thin-film spin mixer includes a cylindrical stirring tank, a rotary vane, and a shaft. The cylindrical stirring tank has unevennesses on an inner peripheral surface. The rotary vane is concentric with the stirring tank and has an outer diameter slightly smaller than an inner diameter of the stirring tank. The shaft includes the rotary vane on an end portion and is rotatable at high speed in forward and reverse directions.

In certain embodiments, an apparatus includes an electrolyte membrane layer (EML), and includes a first electrode catalyst layer (ECL) and a first metallic gas diffusion layer (MGDL) positioned to a first side of the EML such that the first ECL is positioned between the first MGDL and the EML. The first MGDL includes a metal-containing layer and a coating of porous material disposed on a surface of the metal-containing layer of the first MGDL that faces the first ECL. The apparatus further includes a second ECL and a second MGDL positioned to the second side of the EML such that the second ECL is positioned between the second MGDL and the EML. The second MGDL includes a metal-containing layer and a coating of porous material disposed on a surface of the metal-containing layer of the second MGDL that faces the second ECL.

The present invention provides a catalysed decal transfer substrate comprising a decal transfer substrate, an electrocatalyst later, and a layer D between the decal transfer substrate and the electrocatalyst layer which comprises an ion-conducting polymer and a carbon material. The layer D is configured such that, upon transfer of the electrocatalyst layer to a surface, at least a portion of the layer D remains attached to and is transferred with the electrocatalyst layer.

Electrocatalysts and methods of forming the same are provided. A hybrid electrocatalyst can be a combination of a platinum (Pt)-based catalyst and a carbon-based non-precious-metal catalyst using a single atom approach. A fuel cell electrocatalyst can include a nitrogen-doped carbon support and a plurality of atoms of both Pt and of a non-precious-metal catalyst dispersed in the support. The dispersed atoms can be isolated from each other within the support.

A supported platinum catalyst having a high ratio of a diffraction peak intensity of a Pt (220) plane and having excellent oxidation resistance, obtained by a simple production method without using a polymer. The supported platinum catalyst includes a carbon support and platinum fine particles supported on the carbon support, the platinum fine particles being such that a ratio of a diffraction peak intensity of a (220) plane with respect to a total of diffraction peak intensities of a (111) plane, a (200) plane, and the (220) plane by X-ray diffraction is not less than 0.128.