W. L. Gore & Associates, Inc.

Mark D Edmundson

Paul D Gassler

F Colin Busby

Takeyuki Suzuki

Alexander Agapov

Justin John Skaife

Justin J Skaife

Scott J Zero

Donald T Freese

Colin Busby

Paul Gassler

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

Embodiments are directed to composite membranes having: increased volume of the microporous polymer structure relative to the total volume of the PEM; decreased permeance and thus increased selectivity; and lower ionomer content. An increased amount of polymers of the microporous polymer structure is mixed with a low equivalent weight ionomer (e.g., <460 cc/mole eq) to obtain a composite material having at least two distinct materials. Various embodiments provide a composite membrane comprising a microporous polymer structure that occupies from 13 vol % to 65 vol % of a total volume of the composite membrane, and an ionomer impregnated in the microporous polymer structure. The acid content of the composite membrane is 1.2 meq/cc to 3.5 meq/cc, and/or the thickness of the composite membrane is less than 17 microns. The selectivity of the composite membrane is greater than 0.05 MPa/mV, based on proton conductance and hydrogen permeance.

Highly reinforced ionomer membranes for high selectivity and high strength

The present disclosure is flexible and stretchable conductive articles that include a printed circuit and a stretchable substrate. The printed circuit contains an electrically conductive trace. The electrically conductive trace may be positioned on the surface of or be imbibed into the pores through the thickness of a synthetic polymer membrane. The synthetic polymer membrane is compressed in the x-y direction such that buckling of the membrane occurs in the z-direction. Additionally, the synthetic polymer membrane may be porous or non-porous. In some embodiments, the synthetic polymer membrane is microporous. The printed circuit may be discontinuously bonded to the stretchable substrate. Advantageously, the flexible, conductive articles retain conductive performance over a range of stretch. In some embodiments, the conductive articles have negligible resistance change when stretched up to 50% strain. The printed circuits may be integrated into garments, such as smart apparel or other wearable technology.

Flexible and stretchable printed circuits on stretchable substrates

Embodiments are directed to composite membranes having: increased volume of the microporous polymer structure relative to the total volume of the PEM; decreased permeance and thus increased selectivity; and lower ionomer content. An increased amount of polymers of the microporous polymer structure is mixed with a low equivalent weight ionomer (e.g., &#x3c;460 cc/mole eq) to obtain a composite material having at least two distinct materials. Various embodiments provide a composite membrane comprising a microporous polymer structure that occupies from 13 vol % to 65 vol % of a total volume of the composite membrane, and an ionomer impregnated in the microporous polymer structure. The acid content of the composite membrane is 1.2 meq/cc to 3.5 meq/cc, and/or the thickness of the composite membrane is less than 17 microns. The selectivity of the composite membrane is greater than 0.05 MPa/mV, based on proton conductance and hydrogen permeance.

The present invention is directed to flexible conductive articles () that include a printed circuit () and a stretchable or non-stretchable substrate (). In some embodiments, the substrate has a printed circuit on both sides. The printed circuit contains N therein a porous synthetic polymer membrane () and an electrically conductive trace () as well as a non-conducive region (). The electrically conductive trace is imbibed or otherwise incorporated into the porous synthetic polymer membrane. In some embodiments, the synthetic polymer membrane is microporous. The printed circuit may be discontinuously bonded to the stretchable or non-stretchable substrate by adhesive dots (). The printed circuits may be integrated into garments, such as smart apparel or other wearable technology.

Flexible and durable printed circuits on stretchable and non-stretchable substrates

The present invention is directed to flexible printed circuits for dermal applications that include a synthetic polymer membraneand at least one electrically conductive trace. In an alternative embodiment, the electrically conductive trace is located on both sides of the microporous synthetic polymer membrane. The electrically conductive trace may be located on the surface of or be imbibed into the pores and through the thickness of a microporous synthetic polymer membrane. The flexible printed circuits may be electrically coupled to an electronic component to form a flexible printed circuit board and adhered to the skinby a dermally acceptable adhesive. The flexible printed circuit or the flexible printed circuit board may be coupled to an electronic moduleto form a hybrid flexible printed circuit board. The flexible printed circuit, flexible printed circuit board, and hybrid flexible printed circuit board achieve a balance of comfort, flexibility, and durability for on-skin use.

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Philadelphia, PA, United States of America

Mark D Edmundson