W. L. Gore & Associates, Inc.

F Colin Busby

Mark D Edmundson

Donald T Freese

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.

Membrane electrode assembly manufacturing process

A method of making a component of a membrane electrode assembly comprising the steps of forming an electrode on an air-permeable backer comprising ePTFE, depositing a mixture comprising ionomer and a water-insoluble alcohol onto said electrode, drying said mixture to form a protective ionomer layer, and depositing an ePTFE-reinforced ionomer layer onto said protective ionomer layer.

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Newark, DE, United States of America

F Colin Busby