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  Membrane electrode assemblies and method for manufactureUSPTO Application #: 20060172882Title: Membrane electrode assemblies and method for manufacture Abstract: Reel-to-Reel method for making membrane electrode assemblies. A first catalyst is deposited in a repeating cell pattern on a first side of a proton exchange membrane film. A second catalyst is deposited on the back side of the proton exchange membrane. An electron conductor material is deposited on a support film which is adhered by means of an adhesive film to the proton exchange membrane film. The various layers are aligned and laminated together to form the membrane electrode assembly. (end of abstract) Agent: Hewlett-packard Company Intellectual Property Administration - Fort Collins, CO, US Inventor: Marzio Leban USPTO Applicaton #: 20060172882 - Class: 502101000 (USPTO) Related Patent Categories: Catalyst, Solid Sorbent, Or Support Therefor: Product Or Process Of Making, Catalyst Or Precursor Therefor, Making Catalytic Electrode, Process Only The Patent Description & Claims data below is from USPTO Patent Application 20060172882. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] Membrane electrode assemblies (MEA) are the core of fuel cells such as proton exchange media fuel cells which are well known. See, for example, "Fuel Cell Systems Explained," Larminie & Dicks, John Wylie & Sons, Ltd. (2000), the contents of which are incorporated herein by reference. Membrane electrode assemblies contain the electron collectors, the catalyst, and the proton exchange medium. Current methods of production of MEAs focus on individual units in which the catalysts are chemically deposited or inked on an electron collector and proton exchange medium. The elements of the unit are then sandwiched together with the application of heat and pressure to produce a single MEA. This prior art method is both costly and not easily scaled up to high volume production. SUMMARY OF THE INVENTION [0002] In one aspect, the invention is a method for making a membrane electrode assembly including providing an elongate proton exchange membrane film having a front and a back side. A first catalyst material is deposited in a repeating cell pattern on the front side of the film to form cathode regions of a plurality of unit cells. A second catalyst material is deposited in the repeating pattern on the back side of the film to form anode regions of the unit cells. An elongate support film perforated in the repeating cell pattern is provided and electron conductor material is deposited onto the support film in the repeating cell pattern along with electrical contact nubs. An adhesive film precut in the repeating cell pattern is also provided and the support and adhesive films are assembled on the front and back sides of the proton exchange membrane film with the repeating patterns of the respective films aligned and with the unit cells connected electrically. The assembled films are passed through hot rollers to laminate the films to produce the assembly. BRIEF DESCRIPTION OF THE DRAWING [0003] FIG. 1 is a plan view of a proton exchange membrane film with a deposited catalyst in one embodiment of the invention. [0004] FIG. 2 is a plan view of a perforated Kapton support film in one embodiment of the invention. [0005] FIGS. 3 and 4 are plan views of Kapton support film with electron conductor material deposited thereon in one embodiment of the invention. [0006] FIG. 5 is a plan view of Kapton support film with an adhesive film aligned and laminated thereon in one embodiment of the invention. [0007] FIG. 6 is a plan view showing the alignment and lamination of proton exchange media over adhesive film in one embodiment of the invention. [0008] FIG. 7 is a plan view of a completed membrane electrode assembly of the invention in one embodiment of the invention. [0009] FIG. 8 is a schematic view illustrating the reel-to-reel process of the invention in one embodiment of the invention. [0010] FIG. 9 is a perspective schematic view of a Z-folded membrane electrode assembly in one embodiment of the invention. [0011] FIG. 10 is a perspective schematic view of a Z-folded membrane electrode assembly inserted into an endplate in one embodiment of the invention. [0012] FIG. 11 is a cross-sectional schematic view of a fuel cell using the membrane electrode assembly in one embodiment of the invention. [0013] FIG. 12 is a schematic illustration of a roll transfer lamination process in one embodiment of the invention. [0014] FIG. 13 is a planned view of a proton exchange membrane film with a deposited catalyst in one embodiment of the invention. [0015] FIG. 14 is a planned view of a cell for parallel connection in one embodiment of the invention. [0016] FIG. 15 is a planned view of a completed parallel connect PEM material cell in one embodiment of the invention. [0017] FIG. 16 is a planned view of parallel connected cells in one embodiment of the invention. [0018] FIG. 17 is a planned view of a conventional flooded anode stacked design in one embodiment of the invention. [0019] FIG. 18 is a schematic illustration of the flooded anode stacked design in one embodiment of the invention. [0020] FIG. 19 is a schematic illustration of a stacked design utilizing an anode wicking medium in one embodiment of the invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Continue reading... 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