Provided is a membrane electrode assembly capable of keeping contact resistance between a catalyst layer and a gas diffusion layer (GDL) low. The membrane electrode assembly includes an electrolyte membrane and a pair of electrode layers disposed to sandwich the electrolyte membrane. The pair of electrode layers includes a pair of catalyst layers disposed to sandwich the electrolyte membrane, and a pair of GDLs disposed on opposite sides of the electrolyte membrane on the respective pair of catalyst layers. Each of the pair of GDLs includes a plurality of GDL protrusions that protrude on a catalyst layer side from the GDL and enter in the catalyst layer, and a gas flow path formed on an opposite side of the catalyst layer. Each of the pair of catalyst layers has a plurality of catalyst layer recesses in contact with the respective plurality of GDL protrusions.

A method of making a thin film is provided. The method includes ball milling a suspension including a nanopowder, an additive component, and a solvent to generate a suspension of milled nanopowder, disposing a layer of the suspension of milled nanopowder onto a substrate, drying the layer by removing at least a portion of the solvent to form a green film, compressing the green film to form a compressed green film, debindering the compressed green film to form a debindered film, and sintering the debindered film to generate the thin film. The additive component includes a component selected from the group consisting of a dispersant, a binder, a plasticizer, and combinations thereof.

The invention concerns a bioreactor obtained by compressing a mixture of an enzyme, a conductor and chitosan. The conductor can consist of carbon nanotubes. This bioreactor can be produced according to the following steps: preparing a mixture of powders in which the proportion of enzyme powder relative to a carbon nanotube powder is of the order of 50/50 by weight; preparing a viscous solution of chitosan in a ratio of 5 to 15 (in mg) of chitosan to 0.75 to 1.25 (in ml) of acetic acid diluted to 0.4 to 0.6% by volume in water; adding the viscous chitosan to the mixture of powders in a proportion be weight of 3 to 5 of powder to 5 to 10 of chitosan; carrying out a first compression followed by light grinding; carrying out a second compression to produce a pellet; and drying at ambient temperature.

Provided herein are energy storage device electrode films comprising a hybrid electrode film, and methods of forming such multilayer hybrid electrode films and energy storage devices comprising multilayer hybrid electrode films. Each hybrid electrode film may comprise a self-supporting dry coated active layer and a wet cast active layer, wherein each active layer comprises a binder and an active material. The binder and/or active material may be the same or different as any other active layer. The hybrid multilayer electrode film may further comprise at least one additional layer, and the hybrid multilayer electrode film may be laminated with a current collector to form an electrode.

The invention relates to a method for manufacturing a membrane electrode assembly for a fuel cell, which membrane electrode assembly comprises a membrane (2) with a catalyst layer (3) and a frame (6) arranged on the same side of the membrane (2) and a gap (5) between the catalyst layer (3) and the frame (6). To allow an easy and cost-effective way for manufacturing such a membrane assembly, the manufacturing method comprises the following steps: *- Positioning a first decal layer (10, 13), which is made of the same material as the first catalyst layer (3), on the first side of the membrane (2) in a way that the first decal layer (10, 13) overlaps the frame (6), *- positioning a second decal layer (10, 14), which is made of the same material as the second catalyst layer (4), on the second side of the membrane (2), *- pressing the first decal layer (10, 13) and the second decal layer (10, 14) against each other with the membrane (2) and the frame (6) positioned in-between.

Systems and methods are provided for an electrode assembly. In one example, a method for fabricating the electrode assembly includes co-extruding a first layer, comprising a conductive thermoplastic, with a second layer, comprising a nonconductive thermoplastic, to form a stack. The stack may be pressed between a set of rollers and cooled to provide a bipolar plate with an integrated negative electrode spacer bonded to a surface of the bipolar plate.

There is provided a process for the manufacture of a membrane electrode assembly, a membrane electrode assembly obtainable by such a process, and a fuel cell comprising such a membrane electrode assembly. The electrode is provided by applying a layer of a first electrode first composition on an electrolyte membrane and a layer of a first electrode second composition to the same side of the electrolyte membrane as the first electrode first composition and then heating. The weight ratio of ion exchange material to catalyst in the first electrode first composition is greater than the weight ratio of ion exchange material to first catalyst in the first electrode second composition.

An object of the present invention is to provide, in the manufacture of a membrane-catalyst assembly including a polymer electrolyte membrane and a catalyst layer bonded to the polymer electrolyte membrane, a method that achieves both the relaxation of thermocompression bonding conditions and the improvement of adhesion between the catalyst layer and the electrolyte membrane with high productivity. A main object of the present invention is to provide a method of manufacturing a membrane-catalyst assembly including an electrolyte membrane and a catalyst layer bonded to the electrolyte membrane, the method including a liquid application step of applying a liquid to a surface of the catalyst layer before bonding, and a thermocompression bonding step of bonding, to the electrolyte membrane, the catalyst layer to which the liquid is applied by thermocompression bonding.

For manufacturing a Zn-air battery, a semi-liquid hydrogel including a polymer component comprising an irradiation activatable crosslinking initiator, and including an electrolyte component is deposited on a zinc anode. At least parts of the semi-liquid hydrogel are irradiated to activate the irradiation activatable crosslinking initiator for crosslinking the polymer component such as to transform the semi-liquid hydrogel into a drop-free yet sticky hydrogel. An air cathode is stuck to the drop-free yet sticky hydrogel.

A multi-faceted zinc-air electrochemical cell design holistically leverages interactions between components, especially with respect to conductive carbons from differing sources, lamination and the resulting impact it has on the air electrode's surface and other additives that impact the relative hydrophilicity of the membrane and/or performance of the anode, to improve the overall reliability and performance of the resulting battery.