The present disclosure relates to a gas diffusion layer structure for a unit cell of a fuel cell, the gas diffusion layer structure includes a gas diffusion layer disposed between a catalyst layer and a separator of the unit cell of the fuel cell, in which the gas diffusion layer includes a microporous layer positioned adjacent to the catalyst layer, and a base layer positioned between the microporous layer and the separator, in which the base layer includes: a microporous layer adjacent region disposed adjacent to the microporous layer, and a gas channel adjacent region disposed adjacent to the separator, and in which the gas diffusion layer is pressed so that a solid volume fraction of the gas channel adjacent region and the microporous layer adjacent region increases to a target solid volume fraction.

The present disclosure relates to a gas diffusion layer structure for a unit cell of a fuel cell, the gas diffusion layer structure includes a gas diffusion layer disposed between a catalyst layer and a separator of the unit cell of the fuel cell, in which the gas diffusion layer includes a microporous layer positioned adjacent to the catalyst layer, and a base layer positioned between the microporous layer and the separator, in which the base layer includes: a microporous layer adjacent region disposed adjacent to the microporous layer, and a gas channel adjacent region disposed adjacent to the separator, and in which the gas diffusion layer is pressed so that a solid volume fraction of the gas channel adjacent region and the microporous layer adjacent region increases to a target solid volume fraction.

Disclosed is a porous support including fine porous structures formed between nanofibers, wherein the fine porous structures have a porosity of 50% to 90%, a pore size of 0.01 μm to 10 μm and an air permeability of 0.01 to 7 sec/100 cc.Math.air, and the porous support has a thickness of 5 μm to 50 μm, a method of manufacturing the same and a reinforced membrane including the same.

A solid polymer electrolyte membrane having a first surface and a second surface opposite the first surface, where the solid polymer electrolyte membrane has a failure force greater than about 115 grams and comprises a composite membrane consisting essentially of (a) at least one expanded PTFE membrane having a porous microstructure of polymeric fibrils, and (b) at least one ion exchange material impregnated throughout the porous microstructure of the expanded PTFE membrane so as to render an interior volume of the expanded PTFE membrane substantially occlusive; (c) at least one substantially occlusive, electronically insulating first composite layer interposed between the expanded PTFE membrane and the first surface, the first composite layer comprising a plurality of first carbon particles supporting a catalyst comprising platinum and an ion exchange material, wherein a plurality of the first carbon particles has a particle size less than about 75 nm, or less than about 50 nm, or less than about 25 nm.

A solid polymer electrolyte membrane having a first surface and a second surface opposite the first surface, where the solid polymer electrolyte membrane has a failure force greater than about 115 grams and comprises a composite membrane consisting essentially of (a) at least one expanded PTFE membrane having a porous microstructure of polymeric fibrils, and (b) at least one ion exchange material impregnated throughout the porous microstructure of the expanded PTFE membrane so as to render an interior volume of the expanded PTFE membrane substantially occlusive; (c) at least one substantially occlusive, electronically insulating first composite layer interposed between the expanded PTFE membrane and the first surface, the first composite layer comprising a plurality of first carbon particles supporting a catalyst comprising platinum and an ion exchange material, wherein a plurality of the first carbon particles has a particle size less than about 75 nm, or less than about 50 nm, or less than about 25 nm.

The invention includes a reinforced membrane-seal assembly that comprises a reinforcing component, ion-conducting material, and seal material. The reinforcing component comprises a central region comprising a plurality of apertures extending from a first surface to a second surface of the reinforcing component, the central region having a first aperture area density; an inner peripheral border region surrounding the central region, where the inner peripheral border region is devoid of apertures; and an outer peripheral border region comprising a plurality of apertures extending from the first surface to the second surface of the reinforcing component, the outer peripheral border region having a second aperture area density. The outer peripheral border region surrounds the inner peripheral border region. The ion-conducting material at least partially fills each aperture in the central region of the reinforcing component and seal material fills each aperture in the outer peripheral border region of the reinforcing component.

The invention includes a reinforced membrane-seal assembly that comprises a reinforcing component, ion-conducting material, and seal material. The reinforcing component comprises a central region comprising a plurality of apertures extending from a first surface to a second surface of the reinforcing component, the central region having a first aperture area density; an inner peripheral border region surrounding the central region, where the inner peripheral border region is devoid of apertures; and an outer peripheral border region comprising a plurality of apertures extending from the first surface to the second surface of the reinforcing component, the outer peripheral border region having a second aperture area density. The outer peripheral border region surrounds the inner peripheral border region. The ion-conducting material at least partially fills each aperture in the central region of the reinforcing component and seal material fills each aperture in the outer peripheral border region of the reinforcing component.

Provided are membranes useful for electrochemical or fuel cells. A membrane may be formed of or include a sulfonated polymer whereby the sulfonated polymer is covalently or ionically associated with a multi-nitrogen containing heterocyclic molecule. The resulting membranes possess excellent ion conductivity and selectivity.

Provided are membranes useful for electrochemical or fuel cells. A membrane may be formed of or include a sulfonated polymer whereby the sulfonated polymer is covalently or ionically associated with a multi-nitrogen containing heterocyclic molecule. The resulting membranes possess excellent ion conductivity and selectivity.

Disclosed herein are ceramic selective membranes and methods of forming the ceramic selective membranes by forming a selective silica ceramic on a porous membrane substrate.