In polymer electrolyte membrane (PEM) fuel cells and electrolyzes, attaining and maintaining high membrane conductivity and durability is crucial for performance and efficiency. The use of low equivalent weight (EW) perfluorinated ionomers is one of the few options available to improve membrane conductivity. However, excessive dimensional changes of low EW ionomers upon application of wet/dry or freeze/thaw cycles yield catastrophic losses in membrane integrity. Incorporation of ionomers within porous, dimensionally-stable perforated polymer electrolyte membrane substrates provides improved PEM performance and longevity. The present invention provides novel methods using micromolds to fabricate the perforated polymer electrolyte membrane substrates. These novel methods using micromolds create uniform and well-defined pore structures. In addition, these novel methods using micromolds described herein may be used in batch or continuous processing.

In polymer electrolyte membrane (PEM) fuel cells and electrolyzes, attaining and maintaining high membrane conductivity and durability is crucial for performance and efficiency. The use of low equivalent weight (EW) perfluorinated ionomers is one of the few options available to improve membrane conductivity. However, excessive dimensional changes of low EW ionomers upon application of wet/dry or freeze/thaw cycles yield catastrophic losses in membrane integrity. Incorporation of ionomers within porous, dimensionally-stable perforated polymer electrolyte membrane substrates provides improved PEM performance and longevity. The present invention provides novel methods using micromolds to fabricate the perforated polymer electrolyte membrane substrates. These novel methods using micromolds create uniform and well-defined pore structures. In addition, these novel methods using micromolds described herein may be used in batch or continuous processing.

The present invention relates to a laminate comprising (i) an ion exchange membrane comprising an ion exchange polymer, and (ii) a monolayered release film removably adhered to at least one side of the ion exchange membrane, wherein the monolayered release film comprises at least 95% by weight of syndiotactic polystyrene (sPS). The invention also relates to a method for producing the laminate, use of the monolayered release film in producing an electrolyte membrane or a membrane electrode assembly, and a method for producing an electrolyte membrane or a membrane electrode assembly.

The present invention relates to a laminate comprising (i) an ion exchange membrane comprising an ion exchange polymer, and (ii) a monolayered release film removably adhered to at least one side of the ion exchange membrane, wherein the monolayered release film comprises at least 95% by weight of syndiotactic polystyrene (sPS). The invention also relates to a method for producing the laminate, use of the monolayered release film in producing an electrolyte membrane or a membrane electrode assembly, and a method for producing an electrolyte membrane or a membrane electrode assembly.

A process for the recovery of a perfluorosulphonic acid ionomer from a component comprising a perfluorosulphonic acid ionomer is disclosed, the process comprising immersing the component comprising the perfluorosulphonic acid ionomer in a solvent comprising an aliphatic diol and heating. Also disclosed is the use of the recovered perfluorosulphonic acid ionomer, for example in to prepared a proton conducting membrane or a catalyst ink.

A process for the recovery of a perfluorosulphonic acid ionomer from a component comprising a perfluorosulphonic acid ionomer is disclosed, the process comprising immersing the component comprising the perfluorosulphonic acid ionomer in a solvent comprising an aliphatic diol and heating. Also disclosed is the use of the recovered perfluorosulphonic acid ionomer, for example in to prepared a proton conducting membrane or a catalyst ink.

A fuel cell, a reinforced membrane electrode assembly and a method of fabricating a reinforced membrane electrode assembly. The method comprises depositing an electrode ink onto a first substrate to form a first electrode layer, applying a first porous reinforcement layer on a surface of the first electrode layer to form a first catalyst coated substrate, depositing a first ionomer solution onto the first catalyst coated substrate to form a first ionomer layer, and applying a membrane porous reinforcement layer on a surface of the first ionomer layer to form a reinforced membrane layer.

A fuel cell, a reinforced membrane electrode assembly and a method of fabricating a reinforced membrane electrode assembly. The method comprises depositing an electrode ink onto a first substrate to form a first electrode layer, applying a first porous reinforcement layer on a surface of the first electrode layer to form a first catalyst coated substrate, depositing a first ionomer solution onto the first catalyst coated substrate to form a first ionomer layer, and applying a membrane porous reinforcement layer on a surface of the first ionomer layer to form a reinforced membrane layer.

A membrane obtainable by A) mixing: (vii) aromatic tetraamino compounds and (viii) aromatic carboxylic acids or esters thereof which contain at least two acid groups per carboxylic acid monomer, or (ix) aromatic and/or heteroaromatic diaminocarboxylic acids, in polyphosphoric acid to form a solution and/or dispersion B) heating the mixture from step A), and polymerizing until an intrinsic viscosity of at least 0.8 dl/g, is obtained for the polymer being formed, C) adding polyazole polymers, D) heating the mixture from step C), E) applying a membrane layer using the mixture according to step D) on a carrier or an electrode, F) treating the membrane formed in the presence of water and/or moisture, G) removing the membrane from the carrier;
wherein the content of all polyazole polymers in the membrane is between 5% to 25% by weight and wherein the membrane has a Young Modulus is at least 2.0 MPa.

A membrane obtainable by A) mixing: (vii) aromatic tetraamino compounds and (viii) aromatic carboxylic acids or esters thereof which contain at least two acid groups per carboxylic acid monomer, or (ix) aromatic and/or heteroaromatic diaminocarboxylic acids, in polyphosphoric acid to form a solution and/or dispersion B) heating the mixture from step A), and polymerizing until an intrinsic viscosity of at least 0.8 dl/g, is obtained for the polymer being formed, C) adding polyazole polymers, D) heating the mixture from step C), E) applying a membrane layer using the mixture according to step D) on a carrier or an electrode, F) treating the membrane formed in the presence of water and/or moisture, G) removing the membrane from the carrier;
wherein the content of all polyazole polymers in the membrane is between 5% to 25% by weight and wherein the membrane has a Young Modulus is at least 2.0 MPa.