Fabrication of catalyst coated diffusion media layers containing nanostructured thin catalytic layers

Abstract

A method of transferring nanostructured thin catalytic layers to a gas diffusion layer and thus making a catalyst coated diffusion media is described. The method includes treating the gas diffusion layer with a temporary adhesive to temporarily increase the adhesion strength within the microporous layer and to carbon fiber paper substrate, transferring the nanostructured thin catalytic layer to the microporous side of a gas diffusion media layer. The nanostructured thin catalytic layer can then be further processed, including adding additional components or layers to the nanostructured thin catalytic layer on the gas diffusion media layer. Preparation of catalyst coated diffusion media and a catalyst coated diffusion media based membrane electrode assembly (MEA) are also described.