Microporous layer assembly and method of making the same
One embodiment includes a process including coating a first microporous layer onto a first decal and curing the first microporous layer and the first decal.
1. A process comprising;
coating a first microporous layer onto a first transfer decal, the first microporous layer comprising a polymeric binder and at least one of carbon black or graphitized carbon; and
curing the first microporous layer onto the first decal, and thereafter peeling the first transfer decal away from the cured first microporous layer.
2. A process as set forth in claim 1 wherein the decal comprises a polymer.
3. A process as set forth in claim 1 wherein the decal comprises expanded polytetrafluoroethylene film.
4. A process as set forth in claim 1 wherein the decal comprises a polytetrafluoroethylene film.
5. A process as set forth in claim 1 wherein the decal comprises a polyimide film.
6. A process comprising:
coating a first microporous layer onto a first transfer decal, the first microporous layer comprising a polymeric binder and at least one of carbon black or graphitized carbon;
curing the first microporous layer onto the first decal; and
coating a first catalyst layer over the first microporous layer so that the first catalyst layer is adhered to the first microporous layer.
7. A process as set forth in claim 6 further comprising;
providing a membrane comprising is first face and a second face; and
hot pressing the first microporous layer and the first catalyst layer to the first face of the membrane.
8. A process as set forth in claim 7 further comprising:
coating a second microporous layer onto a second transfer decal;
curing the second microporous layer and the second decal;
coating a second catalyst layer over the second microporous layer; and
hot pressing the second microporous layer and the second catalyst layer to the second face of the membrane.
9. A process as set forth in claim 7 wherein the membrane comprises a polymer electrolyte membrane.
10. A process as set forth in claim 6 further comprising:
coating a second microporous layer onto a second decal;
curing the second microporous layer and the second decal;
coating a second catalyst layer over the second microporous layer;
providing a membrane comprising a first face and a second face; and
simultaneously hot pressing the first microporous layer and the first catalyst layer to the first face of the membrane, and the second microporous layer and the second catalyst layer to the second face of the membrane.
11. A process as set forth in claim 10 wherein the first decal and the second decal comprise one of expanded polytetrafluoroethylene (ePTFE), polytetrafluoroethylene (PTFE), or poly(4,4′-oxydiphenylene-pyromellitimide).
12. A process as set forth in claim 10 wherein the second microporous layer and the second decal are cured at the glass transition temperature of a polymeric binder in the second microporous layer.
13. A process as set forth in claim 10 wherein the first and second catalyst layers comprise catalyst particles and an ion conductive material.
14. A process as set forth in claim 10 wherein the second microporous layer comprises at least one of carbon black or graphitized carbon.
15. A process as set forth in claim 10 further comprising:
removing the first decal and providing a first gas diffusion media layer over the first microporous layer;
providing a first bipolar plate over the first as diffusion media layer, wherein the first bipolar plate includes a plurality of lands and channels;
removing the second decal and providing a second gas diffusion media layer over the second microporous layer; and
providing a second bipolar plate over the second gas diffusion media layer, wherein the second bipolar plate includes a plurality of lands and channels.
16. A process as set forth in claim 15 wherein the first microporous layer is free of an ionomer.
17. A process as set forth in claim 6 wherein the first microporous layer further comprises a hydrophobic agent.
18. A process as set forth in claim 17 wherein the hydrophobic agent comprises a fluorocarbon.
19. A process as set forth in claim 6 wherein the first microporous layer is free of a metal catalyst.
20. A process as set forth in claim 6 wherein the curing comprises heating the first microporous layer and first decal in an oven.
21. A process comprising:
coating a first microporous layer onto a first transfer decal, the first microporous layer comprising a polymeric binder and at least one of carbon black or graphitized carbon; and
curing the first microporous layer onto the first decal, wherein the first microporous layer and the first decal are cured at the glass transition temperature of the binder in the first microporous layer.
22. A process comprising:
coating a first microporous layer onto a first peelable transfer decal film, the first microporous layer comprising a polymeric binder and at least one of carbon black or graphitized carbon; and
curing the first microporous layer onto the first decal, and thereafter peeling the first transfer decal away from the cured first microporous layer.
23. A process as set forth in claim 22 wherein the decal comprises a polymer.
24. A process as set forth in claim 22 wherein the decal comprises expanded polytetrafluoroethylene film.
25. A process as set forth in claim 22 wherein the decal comprises a polytetrafluoroethylene film.
26. A process as set forth in claim 22 wherein the decal Comprises a polyimide film.