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.

1 - 14 . (canceled)  
   
   
       15 . A membrane electrode assembly, comprising: 
 an elongate proton exchange membrane (“PEM”) film having first and second sides;    a plurality of spaced cathodes on the first side of the PEM film;    a plurality of spaced anodes on the second side of the PEM film respectively substantially aligned with the plurality of spaced cathodes such that the substantially aligned anodes and cathodes and portions of the PEM film therebetween define a plurality of spaced unit cells; and    conductive material electrically connecting adjacent unit cells.    
   
   
       16 . A membrane electrode assembly as claimed in  claim 15 , wherein the spaced unit cells are connected in series.  
   
   
       17 . A membrane electrode assembly as claimed in  claim 15 , wherein the spaced unit cells are connected in parallel.  
   
   
       18 . A membrane electrode assembly as claimed in  claim 15 , wherein the conductive material comprises a plurality of contact nubs.  
   
   
       19 . A membrane electrode assembly as claimed in  claim 18 , wherein 
 wherein each unit cell has at least one of the contact nubs connected thereto;    the PEM film includes a plurality of contact nub apertures; and    the contact nubs of adjacent unit cells are connected to one another by way of the PEM film contact nub apertures.    
   
   
       20 . A membrane electrode assembly as claimed in  claim 15 , wherein the PEM film comprises sulphonated polytetravluoroethylene film.  
   
   
       21 . A membrane electrode assembly as claimed in  claim 15 , wherein 
 the plurality of spaced cathodes comprise a plurality of spaced cathode catalyst material regions on the PEM film and a plurality of cathode conductor regions associated with the cathode catalyst material regions; and    the plurality of spaced anodes comprise a plurality of spaced anode catalyst material regions on the PEM film and a plurality of anode conductor regions associated with the anode catalyst material regions.    
   
   
       22 . A membrane electrode assembly as claimed in  claim 21 , wherein the cathode catalyst material comprises platinum.  
   
   
       23 . A membrane electrode assembly as claimed in  claim 21 , wherein the anode catalyst material comprises platinum-ruthenium.  
   
   
       24 . A membrane electrode assembly as claimed in  claim 21 , wherein the anode and cathode conductor regions comprise thin film carbon regions.  
   
   
       25 . A membrane electrode assembly as claimed in  claim 21 , wherein the anode and cathode conductor regions comprise thin film metal regions.  
   
   
       26 . A membrane electrode assembly as claimed in  claim 21 , wherein 
 the plurality of spaced cathode conductor regions are carried on a support film having a plurality of spaced perforation regions associated with the spaced cathode conductor regions; and    the plurality of spaced anode conductor regions are carried on a support film having a plurality of spaced perforation regions associated with the spaced anode conductor regions.    
   
   
       27 . A membrane electrode assembly as claimed in  claim 26 , wherein the support film comprises polyimide film.  
   
   
       28 . A membrane electrode assembly as claimed in  claim 15 , wherein the PEM film includes a plurality of folds shaped and positioned such that anodes face one another across respective gaps that define fuel chambers and cathodes face one another across respective gaps that define oxidant chambers.  
   
   
       29 . A membrane electrode assembly as claimed in  claim 28 , wherein the spaced unit cells are connected in series.  
   
   
       30 . A membrane electrode assembly as claimed in  claim 28 , further comprising wicking material located within the fuel chambers.