Gm Global Technolgoy Operations, Inc.

John C Doyle

Susan Yan

Bhaskar Sompalli

A technique for fabricating an MEA. The technique includes providing a polymer electrolyte proton conducting membrane, and then spraying a catalyst ink directly on the membrane to form a catalyst layer. In one embodiment, the catalyst ink includes the proper ionomer to carbon ratio, such as 0.8/1, for the desired fuel cell performance. In another embodiment, the catalyst ink includes too little ionomer for the proper ionomer to carbon ratio for the desired fuel cell performance. An ionomer layer is sprayed on the membrane before the catalyst layer to provide the proper final ionomer to carbon ratio.

Membrane electrode assembly prepared by direct spray of catalyst to membrane

A technique for fabricating an MEA for a fuel cell that is prepared as a catalyst-coated diffusion media (CCDM). The MEA includes a diffusion media layer having a microporous layer. A catalyst layer is deposited on the microporous layer so that it covers its entire surface. An ionomer layer is sprayed on the catalyst layer. A perfluorinated membrane is sandwiched between one CCDM at the anode side of the MEA and another CCDM at the cathode side of the MEA where the ionomer spray layers face the membrane.

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Bergen, NY, United States of America

John C Doyle