Methods for forming membrane electrode assemblies

1. A method of forming a membrane electrode assembly, the method comprising:

pressing a stack comprising

a cathode comprising a gas diffusion layer, the gas diffusion layer comprising an electrically conductive material, and a microporous layer adjacent to the gas diffusion layer,

an anode,

a proton exchange membrane between the cathode and the anode,

a porous catalyst layer in contact with the proton exchange membrane and in contact with the cathode, the porous catalyst layer comprising an ionomer, the ionomer coating internal surfaces of pores of the porous catalyst layer, thereby providing internal ionomer-gas interfaces within the porous catalyst layer, and

a porous metal plate in contact with the cathode, the porous metal plate comprising pores in fluid communication with pores of the porous catalyst layer;

for a time, a pressure, and a temperature to bind the ionomer to the proton exchange membrane, whereby steam is generated within the porous catalyst layer;

removing the steam via pores of the porous catalyst layer to increase the hydrophobicity of the internal ionomer-gas interfaces within the porous catalyst layer;

further removing steam from the stack via pores of the porous metal plate while pressing the stack; and

further comprising flowing a gas through the pores of the porous catalyst layer during the pressing step, wherein the stack further comprises a gasket on a portion of the proton exchange membrane, wherein the gasket is configured to provide a pathway for the gas to flow out of the stack during pressing, and further wherein the pathway is through a side of the gasket such that the flow of the gas out of the stack is in a direction parallel to a plane defined by the proton exchange membrane.

2. The method of claim 1 , wherein the ionomer is a sulfonated tetrafluoroethylene based fluoropolymer-copolymer comprising sulfonate ionic groups.

3. The method of claim 2 , wherein the internal ionomer-gas interfaces are characterized by a sulfur-to-fluorine atomic percent ratio of no greater than 0.9.

4. The method of claim 2 , wherein the internal ionomer-gas interfaces are characterized by a sulfur-to-fluorine atomic percent ratio of no greater than 0.8.

5. The method of claim 1 , wherein the gas is dry, inert and heated.

6. The method of claim 1 , wherein the gas is flowed after a predetermined delay period.

7. The method of claim 6 , wherein the predetermined delay period is at least 65% of the pressing time.

8. The method of claim 6 , wherein the predetermined delay period is at least 75% of the pressing time.

9. A method of forming a membrane electrode assembly, the method comprising:

pressing a stack comprising

a cathode comprising a gas diffusion layer, the gas diffusion layer comprising an electrically conductive material, and a microporous layer adjacent to the gas diffusion layer,

an anode,

a proton exchange membrane between the cathode and the anode,

a porous catalyst layer in contact with the proton exchange membrane and in contact with the cathode, the porous catalyst layer comprising an ionomer, the ionomer coating internal surfaces of pores of the porous catalyst layer, thereby providing internal ionomer-gas interfaces within the porous catalyst layer, and

a porous metal plate in contact with the cathode, the porous metal plate comprising pores in fluid communication with pores of the porous catalyst layer;

for a time, a pressure, and a temperature to bind the ionomer to the proton exchange membrane, whereby steam is generated within the porous catalyst layer;

removing the steam via pores of the porous catalyst layer to increase the hydrophobicity of the internal ionomer-gas interfaces within the porous catalyst layer;

further removing steam from the stack via pores of the porous metal plate while pressing the stack; and

further comprising flowing a gas through the pores of the porous catalyst layer during the pressing step, wherein the gas is delivered via a flow field plate in fluid communication with the pores of the porous catalyst layer.

10. The method of claim 9 , wherein the flow field plate is configured as a dead-ended flow field to force the gas to flow downwardly into the pores of the porous catalyst layer.

11. The method of claim 1 , wherein the membrane electrode assembly, in a polymer electrolyte membrane fuel cell comprising the membrane electrode assembly, a first flow field in fluid communication with the cathode configured to deliver oxygen to the cathode, and a second flow field in fluid communication with the anode configured to deliver hydrogen to the anode, provides a peak power density that is at least 130% greater than that of a comparative polymer electrolyte membrane fuel cell, the peak power density measured at 25° C. using humidified hydrogen, humidified air and interdigitated flow fields.

12. A method of forming a membrane electrode assembly, the method comprising:

pressing a stack comprising

a cathode comprising a gas diffusion layer, the gas diffusion layer comprising an electrically conductive material, and a microporous layer adjacent to the gas diffusion layer,

an anode,

a proton exchange membrane between the cathode and the anode,

a porous catalyst layer in contact with the proton exchange membrane and in contact with the cathode, the porous catalyst layer comprising an ionomer, the ionomer coating internal surfaces of pores of the porous catalyst layer, thereby providing internal ionomer-gas interfaces within the porous catalyst layer, and

a porous metal plate in contact with the cathode, the porous metal plate comprising pores in fluid communication with pores of the porous catalyst layer;

for a time, a pressure, and a temperature to bind the ionomer to the proton exchange membrane, whereby steam is generated within the porous catalyst layer;

removing the steam via pores of the porous catalyst layer to increase the hydrophobicity of the internal ionomer-gas interfaces within the porous catalyst layer;

further removing steam from the stack via pores of the porous metal plate while pressing the stack, wherein the porous catalyst layer is between the cathode and the proton exchange membrane and the stack further comprises an additional porous catalyst layer in contact with the proton exchange membrane and between the anode and the proton exchange membrane, the additional porous catalyst layer comprising an ionomer, the ionomer coating internal surfaces of pores of the additional porous catalyst layer, thereby providing internal ionomer-gas interfaces within the additional porous catalyst layer;

further comprising removing additional steam via pores of the additional porous catalyst layer to increase the hydrophobicity of the internal ionomer-gas interfaces within the additional porous catalyst layer; and

further comprising flowing a dry, inert and heated gas through the pores of the additional porous catalyst layer during the pressing step.

13. The method of claim 12 , wherein the method provides the porous catalyst layer with a degree of hydrophobicity which is greater than that of the additional porous catalyst layer.