Methods and compositions for making fuel cell components are described. In one embodiment, the method comprises providing a substrate, and forming or adhering an electrode on the substrate, wherein the forming includes depositing an aqueous mixture comprising water, a water-insoluble component, a catalyst, and an ionomer. The water-insoluble component comprises a water-insoluble alcohol, a water-insoluble carboxylic acid, or a combination thereof. The use of such water-insoluble components results in a stable liquid medium with reduced reticulation upon drying, reduced dissolution of the substrate, and reduced penetration of the pores of the substrate.

An object is to provide an electrode catalyst layer, a membrane electrode assembly, and a polymer electrolyte fuel cell that can suppress decrease in durability of the membrane electrode assembly and decrease in power generation performance of the polymer electrolyte fuel cell by suppressing crack generation in the electrode catalyst layer. An electrode catalyst layer according to one aspect of the present invention is an electrode catalyst layer including at least: a catalytic substance; aggregates of polymer electrolytes; and polymer electrolyte fibers. In the electrode catalyst layer, an amount of phosphorus and an amount of platinum defined via elemental analysis by energy dispersive X-ray spectroscopy (EDX) satisfy a following equation (1). 0 < P/Pt≤ 3.0 ... Equation (1)

A fuel cell electrode with catalysts grown in situ on an ordered structure microporous layer and a method for preparing a membrane electrode assembly (MEA) are disclosed. The fuel cell electrode includes an electrode substrate layer, a hydrophobic layer, an ordered structure hydrophilic layer and catalysts. The hydrophobic layer is prepared on the electrode substrate layer. The ordered structure hydrophilic layer is prepared on the hydrophobic layer. The catalysts are uniformly distributed on the ordered structure hydrophilic layer.

This method for producing an electrode catalyst includes: a dispersion liquid preparation step wherein a dispersion liquid is prepared by mixing (i) at least one solvent selected from the group consisting of sulfoxide compounds and amide compounds, (ii) a catalyst carrier powder composed of a metal oxide, (iii) a platinum compound, (iv) a transition metal compound and (v) an aromatic compound that contains a carboxyl group; a loading step wherein the dispersion liquid is heated so that a platinum alloy of platinum and a transition metal is loaded on the surface of the catalyst carrier powder; a solid-liquid separation step wherein a dispersoid is separated from the dispersion liquid after the loading step, thereby obtaining a catalyst powder wherein the catalyst carrier powder is loaded with the platinum alloy; and a heat treatment step wherein the catalyst powder is heated under vacuum or in a reducing gas atmosphere.

A membrane electrode assembly for a polymer electrolyte membrane fuel cell includes an anodic catalyst layer, a cathodic catalyst layer, and a polymer electrolyte membrane mediating protic communication between the anodic and cathodic catalyst layers. The cathodic catalyst layer includes an ionic liquid, 1-methyl-2,3,4,6,7,8-hexahydro-1H-pyrimido[1,2-a]pyrimidin-9-ium 1,1,2,2,3,3,4,4,4-nonafluorobutane-1-sulfonate, in admixture with carbon-supported particles of platinum or a platinum alloy. The ionic liquid improves performance in both high moisture and low moisture operating conditions.

A composition comprised of a tin (Sn) or lead (Pb) film, wherein the film is coated by a shell, wherein the shell: (a) is comprised of an active metal, and (b) is characterized by a thickness of less than 50 nm, is discloses herein. Further disclosed herein is the use of the composition for the oxidation of e.g., methanol, ethanol, formic acid, formaldehyde, dimethyl ether, methyl formate, and glucose.

Disclosed are an electrode including a polymer matrix and a catalyst including metal nanoparticles and a conductive polymer shell and, a method of preparing the same. According to various exemplary embodiments of the present invention, various hybrid nano-composites may be formed by a combination of other conductive polymers than P3HT with metal nanoparticles. For example, the method may include selectively disposing metal nanoparticles to a surface modified conductive polymer including a block copolymer of two or more types of conductive polymers.

An electrode catalyst for a fuel battery includes a mesoporous material and catalyst metal particles supported at least in the mesoporous material. In the electrode catalyst for a fuel battery, before supporting the catalyst metal particles, the mesoporous material has mesopores having a mode radius of greater than or equal to 1 nm and less than or equal to 25 nm and has a value of greater than 0.90, the value being determined by dividing a specific surface area S.sub.1-25 (m.sup.2/g) of the mesopores obtained by analyzing a nitrogen adsorption-desorption isotherm according to a BJH method, the mesopores having a radius of greater than or equal to 1 nm and less than or equal to 25 nm, by a BET specific surface area (m.sup.2/g) evaluated according to a BET method.

Some aspects of the invention may be directed to a catalyst layer for anodes of Alkaline Exchange Membrane Fuel Cells (AEMFC). Such catalyst layer may include catalyst nanoparticles and an ionomer. Each catalyst nanoparticle may include one or more nanoparticles of catalytically active metal supported on at least one nanoparticle of crystalline RuO.sub.2. The diameter of the at least one nanoparticle of the crystalline RuO.sub.2 may be about order of magnitude larger than the diameter of the one or more nanoparticles of catalytically active metal.

An electrode catalyst is configured such that non-noble metal particles, noble metal particles or nitride-doped noble metal particles are supported on a carbon support, wherein the carbon support has a 2D planar crystal structure or a 3D polyhedral crystal structure and is doped with nitrogen, thereby exhibiting increased catalytic activity.