Catalyst coating film and manufacturing method

Abstract

A method of making a catalyst coated ion conducting membrane for an electrochemical cell is provided, the method including providing an ion conducting membrane, an electrocatalyst layer, and a masking layer between the ion conducting membrane and the electrocatalyst layer, the masking layer comprising one or more openings for providing one or more exposed areas and one or more unexposed areas of the electrocatalyst layer, and contacting the layers such that the one or more exposed areas of the electrocatalyst layer are transferred onto the ion conducting membrane and the masking layer prevents the one or more unexposed areas of the electrocatalyst layer from being transferred onto the ion conducting membrane.

Description

[Technical field]

[0001] The present disclosure relates to components for electrochemical cells and methods of manufacturing components for electrochemical cells. In particular, the present disclosure relates to masked electrocatalyst components and processes for their manufacture, processes for making catalyst coated ion conducting membranes for use in electrochemical cells such as fuel cells or electrolyzers, preferably proton exchange membrane fuel cells or electrolyzers, catalyst coated membranes manufactured by such processes, and membrane electrode assemblies including such catalyst coated ion conducting membranes. [Background technology]

[0002] A fuel cell is an electrochemical cell that includes two electrodes separated by an electrolyte. A fuel (e.g., hydrogen, alcohols such as methanol or ethanol, or formic acid) is supplied to the anode and an oxidant (e.g., oxygen or air) is supplied to the cathode. Electrochemical reactions occur at the electrodes, converting the chemical energy of the fuel and oxidant into electrical energy and heat. Electrocatalysts are used to facilitate the electrochemical oxidation of the fuel at the anode and the electrochemical reduction of oxygen at the cathode.

[0003] Fuel cells are usually classified according to the nature of the electrolyte used. In most cases, the electrolyte is a solid polymer membrane that is electronically insulating but ionically conductive. In proton exchange membrane fuel cells, the ionically conductive membrane is proton conductive, and protons generated at the anode are transported across the ionically conductive membrane to the cathode, where they combine with oxygen to form water.

[0004] The main component of a proton exchange membrane fuel cell is a membrane electrode assembly (MEA) made up of several layers. The central layer is a polymeric ion-conducting membrane. On either side of the ion-conducting membrane are electrocatalyst layers that contain electrocatalysts designed for specific electrolysis reactions. This sandwich of ion-conducting membrane and electrocatalyst layers provides the electrochemically active area. The electrocatalyst layers also generally contain a proton-conducting material, such as a proton-conducting polymer, to aid in the transfer of protons from the anode electrocatalyst to the ion-conducting membrane and / or from the ion-conducting membrane to the cathode electrocatalyst. Adjacent to each electrocatalyst layer is a gas diffusion layer. The gas diffusion layers must allow reactants to reach the electrocatalyst layers and must conduct the electrical current generated by the electrochemical reactions. Thus, the gas diffusion layers must be porous and electrically conductive.

[0005] MEAs are typically subgasketed for use in fuel cells. In subgasketed MEAs, there is a subgasket on one or both sides of the polymeric ion-conducting membrane. The subgasket contains openings that define the active area of ​​the MEA and is attached to the ion-conducting membrane or electrocatalyst layer using an adhesive. These subgaskets are present to prevent gas leakage and may further contain openings away from the active area that are aligned in the fuel cell stack to facilitate porting of gases and liquids within the stack. A fuel cell stack can contain, for example, many subgasketed MEAs with carefully aligned flow field plates to avoid gas leakage, hydrogen crossover, and performance degradation. The power of the entire stack is proportional to the number of such assemblies in the stack. The performance of the stack depends in part on the health, various contacts, and sealing interfaces within and between adjacent assemblies in the stack.

[0006] The conventional process of manufacturing an MEA requires first manufacturing a catalyst coated ion conducting membrane, which includes a polymeric ion conducting membrane disposed between two electrocatalyst layers. This can be manufactured, for example, by a roll-to-roll process in which the electrocatalyst layers are transferred to each side of the ion conducting membrane by a decal transfer process. A subgasket can be applied to the catalyst coated ion conducting membrane in a second roll-to-roll process. The gas diffusion layer is then bonded to the subgasketed catalyst coated ion conducting membrane on the active area using an adhesive to bond the gas diffusion layer to the subgasketed catalyst coated ion conducting membrane. The adhesive can be a hot melt adhesive, in which case the parts are bonded using a heated plate in either a heated press or a custom-made equivalent machine. This allows the adhesive to flow and bond the parts together. The adhesive can also be a pressure sensitive adhesive.

[0007] In the decal transfer process described above, the electrocatalyst layer is provided in roll-good form on a temporary carrier web that is peeled off after the electrocatalyst layer is laminated onto the polymeric ion conductive membrane. The electrocatalyst is typically deposited or coated onto the temporary carrier web in the form of an ink or paste that includes catalyst particles dispersed in an ionomeric binder and / or solvent.

[0008] As one skilled in the art will appreciate, the same principles discussed above in relation to the manufacture of MEAs for fuel cells, and in particular proton exchange membrane fuel cells, also apply to the manufacture of MEAs for electrolysers, and in particular proton exchange membrane electrolysers. Summary of the Invention

[0009] The present invention aims to provide an improved process for producing catalyst coated ion conducting membranes, for example by controlling the transfer of the electrocatalyst onto the ion conducting membrane and reducing the consumption of the electrocatalyst, and for producing an electrocatalyst layer that is typically in roll-good form.

[0010] Methods for producing catalyst coated membranes According to a first aspect of the present invention there is provided a method of producing a catalyst coated ion conducting membrane for an electrochemical cell such as a fuel cell or electrolyser, preferably a proton exchange membrane fuel cell or electrolyser, the method comprising: providing an ion conducting membrane, an electrocatalyst layer, and a masking layer between the ion conducting membrane and the electrocatalyst layer, the masking layer comprising one or more openings for providing one or more exposed areas and one or more unexposed areas of the electrocatalyst layer; and contacting the layers such that one or more exposed areas of the electrocatalyst layer are transferred onto the ion conducting membrane, and a masking layer prevents one or more unexposed areas of the electrocatalyst layer from being transferred onto the ion conducting membrane.

[0011] A first aspect of the present invention provides a kind of print masking process for transferring an electrocatalyst layer onto an ion-conducting membrane, such as a polymer electrolyte membrane, whereby the electrocatalyst layer is transferred onto the ion-conducting membrane only in the exposed areas corresponding to the openings of the masking layer, and the electrocatalyst layer in the non-exposed areas around the openings cannot be transferred onto the ion-conducting membrane because it is physically separated from the ion-conducting membrane by the masking layer during lamination.

[0012] In conventional decal transfer processes, electrocatalyst decals are generally produced by coating or depositing areas of electrocatalyst in the form of ink or paste on a carrier web. Such inks or pastes tend to flow to some extent, and therefore it is difficult to control the exact dimensions of the electrocatalyst decal transferred onto the membrane during the decal transfer process. As a result, the electrocatalyst decal may be slightly larger than necessary for the area of ​​the membrane to be covered, which may cause problems with sealing the catalyst coated ion conducting membrane. On the other hand, the print masking process of the present invention allows the dimensions of the electrocatalyst decal to be precisely controlled by the openings in the masking layer, for example, reducing such sealing problems.

[0013] In some embodiments, the method further comprises the initial step of providing a masking layer without openings and cutting openings into the masking layer prior to the step of providing a masking layer between the ion-conducting membrane and the electrocatalyst layer. This allows the size and shape of the openings, and therefore the size and shape of the electrocatalyst decal, to be controlled and customized as needed. As will be understood by those skilled in the art, the size and shape of the openings are determined by the intended use of the catalyst coated ion-conducting membrane. For example, the openings may be irregular or regular in shape, e.g., quadrilateral, e.g., substantially rectangular, or the openings may be substantially circular or elliptical. However, the size and shape of the openings are not limited. When there are two or more openings, the openings are preferably substantially the same shape and size.

[0014] In some embodiments, the step of contacting the layers includes pressing the layers together. In some embodiments, the layers are pressed together between a pair of rollers in a roll-to-roll lamination process. Alternatively, the layers may be pressed together by a flatbed press or similar device, which may be preferred in embodiments in which the layers are provided as separate patches rather than as a continuous web.

[0015] In some embodiments, the roller or flatbed press heats the layers to a temperature in the range and inclusive of, for example, 100-200° C. It will be appreciated that the exact lamination temperature will depend on the materials used for the electrocatalyst layer and the ion conductive membrane. The lamination temperature should be high enough to bond the electrocatalyst layer and the ion conductive membrane together, but preferably not so high as to anneal or damage the layers.

[0016] In some embodiments, the method further comprises removing the masking layer and the unexposed areas of the electrocatalyst layer from the ion conducting membrane after the step of contacting the layers. Removal of the masking layer and the unexposed areas of the electrocatalyst layer can be facilitated, for example, by the use of a vacuum. Alternatively, in a roll-to-roll process, removal can be accomplished by the use of a peel bar or idler roller.

[0017] In some embodiments, the unexposed areas of the electrocatalyst layer are recovered and recycled for further use, thereby reducing waste of electrocatalyst material. For example, the recovered electrocatalyst may be reformulated into an ink or paste and made into a new electrocatalyst layer for use in the method of the first aspect.

[0018] In some embodiments, an electrocatalyst layer is provided on both sides of the ion conducting membrane and a masking layer is provided between the ion conducting membrane and each respective electrocatalyst layer, In such embodiments, both sides of the ion conducting membrane are simultaneously coated with electrocatalyst, thereby improving the efficiency of the method.

[0019] In some embodiments, the ion-conducting membrane is sandwiched between two layers of non-ion-conducting sealing material to form a membrane seal assembly, the membrane seal assembly comprising one or more inner regions and one or more border regions, the inner regions being devoid of non-ion-conducting sealing material and being ion-conducting, and the border regions being comprised of non-ion-conducting sealing material and being non-ion-conducting. The inner regions are thus active areas. The membrane seal assembly aims to reduce waste of expensive membrane material by minimizing the amount of membrane material that extends beyond the active area of ​​the catalyst-coated ion-conducting membrane, as described, for example, in the applicant's previous application WO 2015 / 145129 A1. It will be appreciated that the exposed area of ​​the electrocatalyst layer is substantially aligned with the inner region, and the masking layer is substantially aligned with the border region, such that the electrocatalyst layer is transferred onto the ion-conducting membrane, and the masking layer prevents one or more exposed areas of the electrocatalyst layer from being transferred onto the non-ion-conducting sealing material. The exposed area of ​​the electrocatalyst layer is advantageously larger in area than the area of ​​the inner region of the membrane seal assembly to compensate for the step caused by the non-ion-conducting seal material and ensure that the ion-conducting membrane is completely covered and not left exposed during the transfer of the electrocatalyst layer. However, it is undesirable to transfer a substantial amount of the electrocatalyst layer onto the non-ion-conducting seal material, and therefore the area of ​​the exposed area is typically not large enough to facilitate the transfer of the electrocatalyst layer onto the non-ion-conducting seal material. Typically, the exposed area of ​​the electrocatalyst layer is larger in area than the area of ​​the inner region of the membrane seal assembly, so that the exposed area of ​​the electrocatalyst layer forms a frame around the inner region of the ion-conducting membrane with a width of up to 2 mm, typically 1 mm or more.

[0020] In some embodiments, the ion-conducting membrane comprises a polymer electrolyte membrane. Types of polymer electrolyte membranes suitable for use in electrochemical cells such as fuel cells or electrolyzers, preferably proton exchange membrane fuel cells or electrolyzers, are known to those skilled in the art and can include proton-conducting polymers or anion-conducting polymers such as hydroxyl anion-conducting polymers. Examples of suitable proton-conducting polymers include perfluorosulfonic acid ionomers (e.g., Nafion® (EI DuPont de Nemours and Co.), Aciplex® (Asahi Kasei), Aquivion™ (Solvay Speciality Polymers), Flemion® (Asahi Glass Co.), or ionomers based on sulfonated hydrocarbons such as those available as Fumapem® P, E or K series products from FuMA-Tech GmbH, JSR Corporation, Toyobo Corporation, etc. Examples of suitable anion-conducting polymers include A901 manufactured by Tokuyama Corporation and Fumasep FAA from FuMA-Tech GmbH.

[0021] Similarly, types of electrocatalysts suitable for use in electrochemical cells are known to those skilled in the art. For example, the electrocatalyst layer can be a cathode or anode electrocatalyst layer of a fuel cell or electrolyser, preferably a proton exchange membrane fuel cell or electrolyser. For example, the electrocatalyst can include a platinum group metal, i.e., ruthenium, rhodium, palladium, osmium, iridium or platinum, or an alloy of a platinum group metal.

[0022] The electrocatalyst layer preferably includes an ion-conducting polymer, such as a proton-conducting ionomer, to improve the ionic conductivity of the layer. Thus, the ion-conducting material may include ionomers such as perfluorosulfonic acid (e.g., perfluorosulfonic acid ionomer materials from Nafion® (Chemours Company), Aciplex® (Asahi Kasei), Aquivion® (Solvay Specialty Polymer), Flemion® (Asahi Glass Co.), and 3M®), or ionomers based on partially fluorinated or non-fluorinated hydrocarbons that are sulfonated or phosphonated polymers, such as those available as fumapem® P, E, or K series products from FuMA-Tech GmbH, JSR, Toyobo, and other companies. Preferably, the ionomer is a perfluorosulfonic acid, particularly the Nafion® series available from Chemours, especially Nafion® 1100EW, and the Aquivion® series available from Solvay, especially Solvay® 830EW.

[0023] In some embodiments, the masking layer comprises a polymer film. Preferably, the polymer film comprises a polymer that is thermally stable at the temperature used to laminate the layers to prevent contamination of the catalyst coated ion conducting membrane by the masking layer. Thus, in some embodiments, the polymer film comprises a polymer that is thermally stable at temperatures ranging from and including 100 to 200°C. In some embodiments, the polymer film is selected from the group consisting of polyetherimide, polyimide (PI), polyethersulphone (PES), fluorinated ethylene propylene (FEP), ethylene tetrafluoroethylene (ETFE), Viton®, polyethylene oxide (PEO), polyphenylene ether (PPE), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyacrylonitrile (PAN), poly(p-phenylene sulphide) (PPS), polyolefins and silicones, preferably polyethylene naphthalate (PEN), polyethyleneimine (PEI), polyether ether ketone (PEEK), polyphenylene sulfide ... The masking layer may include, for example, polysulfide (PPS), polytetrafluoroethylene (PTFE), or a mixture thereof. The masking layer may be printed onto the electrocatalyst layer using, for example, inkjet or gravure printing. Any printable polymer that is thermally stable at the temperatures used to laminate the layers may be used. Printing the masking layer allows for an even higher level of precision, including thickness profile, in addition to the masking layer.Suitably, polymers having precursors that do not require solvents in order to be formulated into a printable ink can be used, for example UV curable polymers.

[0024] In some embodiments, the ion conductive membrane, the electrocatalyst layer, and the masking layer are each provided separately, for example, separate webs of the ion conductive membrane, the electrocatalyst layer, and the masking layer can be fed simultaneously between a pair of laminating rollers in a roll-to-roll process.

[0025] In other embodiments, the electrocatalyst layer and the masking layer are provided together as a preformed masked electrocatalyst component. Preferably, the masking layer is bonded to the electrocatalyst layer. In some such embodiments, the masking layer is bonded to the electrocatalyst layer by an adhesive. Preferably, the adhesive is thermally stable at the temperatures used to laminate the layers to prevent contamination of the catalyst coated ion conducting membrane by the adhesive. Thus, in some embodiments, the adhesive is thermally stable at temperatures in the range and including 100-200°C. In some embodiments, the adhesive comprises a pressure sensitive adhesive, such as a silicone pressure sensitive adhesive.

[0026] The preformed masked electrocatalyst components can be provided as a continuous web for a roll-to-roll process or as separate patches for an individual assembly process.

[0027] In some embodiments, the method further includes applying a subgasket around the active area of ​​the catalyst coated ion conductive membrane. For example, the catalyst coated ion conductive membrane can be laminated between two half subgasket layers that are bonded to the catalyst coated ion conductive membrane by an adhesive. The subgasket can be applied to the catalyst coated ion conductive membrane in a roll-to-roll lamination process.

[0028] According to a second aspect of the present disclosure, there is provided a catalyst coated ion conducting membrane produced by the method of the first aspect.

[0029] According to a third aspect of the present invention there is provided a membrane electrode assembly comprising the catalyst coated ion conducting membrane of the second aspect, The membrane electrode assembly comprises a gas diffusion layer adjacent each electrocatalyst layer.

[0030] According to a fourth aspect of the present invention there is provided a fuel cell, preferably a proton exchange membrane fuel cell, comprising the catalyst coated ion conducting membrane of the second aspect or the membrane electrode assembly of the third aspect.

[0031] According to a fifth aspect of the present invention there is provided an electrolyser, preferably a proton exchange membrane electrolyser, comprising the catalyst coated ion conducting membrane of the second aspect or the membrane electrode assembly of the third aspect.

[0032] Method for producing masked electrocatalytic components According to a sixth aspect of the present invention, there is provided a method for producing a masked electrocatalyst component for use in the manufacture of a catalyst coated ion conducting membrane, the method comprising: Providing an electrocatalyst layer; providing a masking component comprising a masking layer, the masking layer comprising one or more openings; combining the masking layer with the electrocatalyst layer to form a masked electrocatalyst component.

[0033] Materials suitable for use in the electrocatalyst layer and masking layer are as described in relation to the first aspect. For example, in some embodiments the electrocatalyst layer comprises a platinum group metal or an alloy of a platinum group metal.

[0034] Preferably, combining the masking layer with the electrocatalyst layer to form a masked electrocatalyst component is bonding the masking layer to the electrocatalyst layer to form a masked electrocatalyst component, hi some embodiments, bonding the masking layer to the electrocatalyst layer is performed by a roll-to-roll lamination process, where the layers are pressed together between a pair of rollers.

[0035] In some embodiments, the electrocatalyst layer is supported on a temporary carrier layer. The carrier layer helps protect the electrocatalyst layer and allows the masked electrocatalyst component to be wound into a roll. The carrier layer can be removed before the masked electrocatalyst component is used in a process to manufacture a catalyst coated ion conducting membrane. The temporary carrier can be formed of any suitable material that can remove the electrocatalyst layer without damage and can retain mechanical strength / integrity at high temperatures, e.g., up to 200°C. Examples of suitable materials include fluoropolymers, e.g., polytetrafluoroethylene (PTFE), ethylene tetrafluoroethylene (ETFE), perfluoroalkoxy polymer (PFA), fluorinated ethylene propylene (FEP-copolymer of hexafluoropropylene and tetrafluoroethylene), polyolefins (e.g., biaxially oriented polypropylene (BOPP)), and polyethylene terephthalate (PET).

[0036] Preferably, the masking layer is bonded to the electrocatalyst layer by an adhesive. In such an embodiment, the layer may or may not require heating to bond the masking layer to the electrocatalyst layer. However, the masked electrocatalyst component may be subjected to heating during the manufacturing process of the catalyst coated ion conducting membrane, for example, in the method according to the first aspect, when the electrocatalyst layer is laminated to the ion conducting membrane. Thus, in some embodiments, the adhesive is thermally stable at temperatures in the range and including 100-200°C to ensure that the adhesive does not contaminate the active area during lamination of the catalyst coated ion conducting membrane. In some embodiments, the adhesive comprises a pressure sensitive adhesive, such as a silicone pressure sensitive adhesive.

[0037] In some embodiments, the masking component further comprises a reinforcing layer for stabilizing the masking layer during the step of bonding the masking layer to the electrocatalyst layer. The masking layer is typically about 10-30 μm, suitably 10-20 μm, preferably 10-15 μm thick, and thus the reinforcing layer provides structural stability to prevent deformation of the masking layer (especially the shape of the openings) while the masking layer is in contact with the electrocatalyst layer.

[0038] The reinforcing film can comprise any material capable of retaining mechanical strength / integrity during the process. In some embodiments, the reinforcing layer comprises a reinforced polymer film. Since the reinforcing material is typically removed prior to application of high temperatures, it is preferred that the material does not need to be stable at high temperatures. Thus, the material can be a low-cost, mechanically robust material. In some embodiments, the reinforcing polymer film comprises polyethyleneimine (PEI), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), polyimide (PI), polyethylene terephthalate (PET). PET has the advantage of being low-cost and mechanically robust. In some embodiments, the reinforcing layer is bonded to the masking material by an adhesive. In embodiments where an adhesive is used to bond the respective layers together, the adhesive used to bond the reinforcing layer to the masking layer should be weaker than the adhesive used to bond the masking layer to the electrocatalyst layer to ensure that the masking layer does not separate from the electrocatalyst layer when the reinforcing layer is removed. Stated another way, the adhesive used to bond the reinforcing layer to the masking layer must be less tacky than the adhesive used to bond the masking layer to the electrocatalyst layer.

[0039] In some embodiments, the method further comprises removing the reinforcing layer after combining the masking layer with the electrocatalyst layer, which minimizes the thickness of the masking component. The reinforcing layer may be removed by any suitable means, for example, by a peel bar or idle roller in a continuous roll-to-roll process, or by use of a vacuum.

[0040] In some embodiments, the electrocatalyst layer and the masking component are each provided in the form of a continuous web, with the masking layer comprising a plurality of openings along the length of the web. In some such embodiments, when the masked electrocatalyst component is produced in the form of a continuous web, the masked electrocatalyst component may be wound up into a roll or may be used directly in further processes to manufacture a catalyst coated ion conducting membrane.

[0041] Alternatively, in some embodiments, the method further comprises cutting the masked electrocatalytic components into separate patches. In some such embodiments, the masked electrocatalytic components are cut between the openings in the masking layer such that the masking layer in each patch comprises a single opening. The patches can then be used to form individual catalyst coated ion conducting membranes in a non-roll-to-roll process.

[0042] In some embodiments, the method further includes cutting alignment features into the masked electrocatalyst component to aid in aligning the masked electrocatalyst component during the process of fabricating the catalyst coated ion conducting membrane. During the process of fabricating the catalyst coated ion conducting membrane, the alignment features in the masked electrocatalyst component can be aligned with corresponding alignment features in the ion conducting layer or membrane, allowing the electrocatalyst layer to be precisely positioned on the membrane.

[0043] According to a seventh aspect of the present invention there is provided a masked electrocatalyst component produced by the method of the sixth aspect. The masked electrocatalyst component of the seventh aspect may be used in the method of the first aspect.

[0044] Masked electrocatalytic components According to an eighth aspect of the present invention there is provided a masked electrocatalytic component for use in the manufacture of an electrochemical cell such as a fuel cell or electrolyser, preferably a proton exchange membrane fuel cell or electrolyser. The masked electrocatalytic component comprises: an electrocatalyst layer having a first surface and an oppositely disposed second surface; a masking layer disposed on the first surface of the electrocatalyst layer; The masking layer includes one or more openings therein, thereby providing one or more exposed areas and one or more unexposed areas of the first surface of the electrocatalyst layer.

[0045] As described above in relation to the first embodiment, one or more exposed areas of the electrocatalyst layer correspond to one or more openings of the masking layer, while one or more non-exposed areas of the electrocatalyst layer remain covered under the masking layer around the openings. There are preferably two or more openings, thereby providing two or more exposed areas and two or more non-exposed areas. The size and shape of the openings are determined by the intended use of the electrochemical cell. For example, the openings may be irregular or regular in shape, e.g., quadrilateral, e.g., substantially rectangular, or the openings may be substantially circular or elliptical. However, the size and shape of the openings are not limited. When there are two or more openings, the openings are preferably substantially the same shape and size.

[0046] In some embodiments, the masked electrocatalyst component is in the form of a continuous web (also known as roll-good form), and the electrocatalyst layer and the masking layer are each continuous webs, with the masking layer comprising a plurality of openings along the length of the web, thereby providing a plurality of exposed and unexposed areas of the first surface of the electrocatalyst layer. The openings may be spaced at regular intervals along the web. The masked electrocatalyst component in roll-good form may be wound onto a roll, thereby forming a roll-good assembly.

[0047] In other embodiments, the masked electrocatalyst components are in the form of separate patches that can be used in the manufacture of individual catalyst coated ion conducting membranes. In some such embodiments, the masking layer comprises a single opening, thereby providing one exposed area and one unexposed area of ​​the first surface of the electrocatalyst layer. This facilitates the transfer of a single exposed area of ​​the electrocatalyst layer onto the membrane during the process for manufacturing the catalyst coated ion conducting membrane.

[0048] In some embodiments, the masked electrocatalytic component further comprises a carrier layer disposed on the second surface of the electrocatalytic layer. The carrier layer helps support and protect the electrocatalytic layer and allows a continuous web of the masked electrocatalytic component to be wound into a roll. Examples of suitable carrier materials include fluoropolymers such as polytetrafluoroethylene (PTFE), ethylene tetrafluoroethylene (ETFE), perfluoroalkoxy polymers (PFA), fluorinated ethylene propylene (FEP - a copolymer of hexafluoropropylene and tetrafluoroethylene), polyolefins (e.g., biaxially oriented polypropylene, (BOPP)), and polyethylene terephthalate (PET).

[0049] Materials suitable for use in the electrocatalyst layer and masking layer are as described in relation to the first aspect. For example, in some embodiments the electrocatalyst layer comprises a platinum group metal or an alloy of a platinum group metal.

[0050] In some embodiments, the masking layer is bonded to the electrocatalyst layer by an adhesive. Preferably, the adhesive is thermally stable at the lamination temperatures used in the process for producing the catalyst coated ion conductive membrane to prevent contamination of the catalyst coated ion conductive membrane by the adhesive. Thus, in some embodiments, the adhesive is thermally stable at temperatures ranging and including 100-200°C. In some embodiments, the adhesive comprises a pressure sensitive adhesive, such as a silicone pressure sensitive adhesive.

[0051] In some embodiments, the masked electrocatalytic component comprises alignment features to help align the masked electrocatalytic component, for example during the process of manufacturing the catalyst coated ion conducting membrane according to the first aspect of the present invention. During the process of manufacturing the catalyst coated ion conducting membrane, the alignment features in the masked electrocatalytic component can be aligned with corresponding alignment features in the ion conducting layer, allowing the electrocatalytic layer to be accurately positioned on the ion conducting membrane. The alignment features can be openings cut into the masking layer or the masking layer and the electrocatalytic layer, such as holes, notches, slots or grooves. Alternatively, the alignment features can be visible marks made on the masking layer or the masking layer and the electrocatalytic layer that can be detected by a vision system for alignment.

[0052] The masked electrocatalytic component of the eighth aspect may be used in the method of the first aspect.

[0053] It will be appreciated that any feature described in relation to the first, second, third, sixth, seventh or eighth aspect may be freely combined with any other aspect as appropriate. [Brief description of the drawings]

[0054] The embodiments of the invention will be explained in more detail with reference to the following drawings, which are illustrative and not limiting: [Figure 1] FIG. 2 is a perspective view of a masked electrocatalytic component according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view of the masked electrocatalytic component of FIG. 1. [Diagram 3] FIG. 2 is a perspective view of a masked electrocatalytic component according to an embodiment of the present invention. [Figure 4] FIG. 4 is a cross-sectional view of the masked electrocatalytic component of FIG. 3. [Diagram 5] FIG. 1 is a process flow diagram illustrating a method for making a catalyst coated ion conducting membrane according to an embodiment of the present invention. [Figure 6] FIG. 1 is a process flow diagram illustrating a method for making a catalyst coated ion conducting membrane according to an embodiment of the present invention. [Figure 7] 1 shows a catalyst coated ion conducting membrane being manufactured by a roll-to-roll process according to an embodiment of the present invention. [Figure 8] FIG. 2 is a process flow diagram illustrating a method for fabricating a masked electrocatalyst component according to one embodiment of the present invention. [Figure 9] FIG. 1 is a process flow diagram illustrating a method for making a masked electrocatalyst compound according to one embodiment of the present invention. [Figure 10A] 1 illustrates the subsystems of a roll-to-roll based system for manufacturing a masked electrocatalyst component according to the method of the present invention. [Figure 10B] 1 illustrates the subsystems of a roll-to-roll based system for manufacturing a masked electrocatalyst component according to the method of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0055] 1 and 2 show a masked electrocatalytic component 100 according to one embodiment of the present invention. In the embodiment shown, the masked electrocatalytic component 100 is in the form of a discrete patch for use in the manufacture of individual catalyst coated ion conducting membranes.

[0056] The masked electrocatalyst component 100 comprises an electrocatalyst layer 2 having a first surface 4 and an oppositely disposed second surface 6. The masked electrocatalyst component 100 further comprises a masking layer 8 disposed on the first surface 4 of the electrocatalyst layer 2. The masking layer 8 includes an opening 10 exposing a region of the electrocatalyst layer 2 disposed beneath the masking layer 8. The region of the electrocatalyst layer 2 corresponding to the opening 10 may be referred to as an exposed region 12, while the region of the electrocatalyst layer 2 remaining beneath the masking layer 8 around the opening 10 may be referred to as an unexposed region 14. In the illustrated embodiment, the masking layer 8 is bonded to the electrocatalyst layer 2 by an adhesive layer 16. This is preferred as it facilitates easier handling of the masked electrocatalyst component.

[0057] Figures 3 and 4 show a masked electrocatalyst component 200 according to another embodiment of the invention, which is in the form of a continuous web (which may be used in a roll-good) rather than separate patches. Components that are common between the embodiment shown in Figures 1 and 2 and the embodiment shown in Figures 3 and 4 have the same reference numbers.

[0058] In the illustrated embodiment, a carrier layer 18 is provided adjacent the second surface 6 of the electrocatalyst layer 2 to help support and protect the electrocatalyst layer 2. The masking layer 8 is provided as a continuous web with a plurality of openings 10 therein, thereby forming a plurality of exposed areas 12 of the electrocatalyst layer 2.

[0059] In the illustrated embodiment, alignment features 20 are provided to aid in aligning the masked electrocatalyst component 200 with the ion conducting membrane during fabrication of the catalyst coated ion conducting membrane. The alignment features 20 are notches cut into the masked electrocatalyst component 200. The alignment features 20 may also aid in alignment with a second masked electrocatalyst component when two such components are applied simultaneously to the ion conducting membrane.

[0060] 5 shows a flow diagram of a method for manufacturing a catalyst coated ion conducting membrane according to an embodiment of the present invention. In a first step, an ion conducting membrane, an electrocatalyst layer, and a masking layer between the ion conducting membrane and the electrocatalyst layer are provided (306). The masking layer comprises one or more openings to provide one or more exposed areas and one or more unexposed areas of the electrocatalyst layer. In a second step, the layers are brought into contact (308), such that one or more exposed areas of the electrocatalyst layer are transferred onto the ion conducting membrane, and the masking layer prevents one or more unexposed areas of the electrocatalyst layer from being transferred onto the ion conducting membrane.

[0061] Thus, an electrocatalyst decal corresponding to the opening in the masking layer is transferred onto the ion conducting membrane, which allows precise control of the exact size and shape of the electrocatalyst decal by modifying the size and shape of the opening in the masking layer. The result is a catalyst coated ion conducting membrane with a very precisely defined electrocatalyst layer that does not extend undesirable distances beyond the intended active area.

[0062] Preferably, contacting the layers step 308 includes pressing the layers together. The layers may be pressed together between a pair of rollers in a roll-to-roll lamination process or between two plates of a flatbed press. The rollers or flatbed press may heat the layers to a temperature in the range and inclusive of 100-200° C. to aid in adhering the electrocatalyst decal to the ion conductive membrane without the need for a separate adhesive.

[0063] 6 shows a flow diagram of a method for fabricating a catalyst coated ion conducting membrane according to another embodiment of the present invention. A masking layer is first provided (302) and openings are cut into the masking layer (304). The size and shape of the openings can be tailored to the requirements of the electrocatalyst layers in the catalyst coated ion conducting membrane.

[0064] Next, an ion conducting membrane, an electrocatalyst layer, and a masking layer are provided (306), the masking layer being provided between the ion conducting membrane and the electrocatalyst layer, and one or more openings in the masking layer providing one or more exposed areas and one or more unexposed areas of the electrocatalyst layer.

[0065] The layers are then contacted (308) such that one or more exposed regions of the electrocatalyst layer are transferred onto the ion conductive membrane and the masking layer prevents one or more unexposed regions of the electrocatalyst layer from being transferred onto the ion conductive membrane. As previously mentioned, contacting the layers 308 can include pressing the layers together. The layers can be pressed together between a pair of rollers in a roll-to-roll lamination process or between two plates of a flatbed press, and the rollers or flatbed press can heat the layers to a temperature ranging from and including 100-200°C.

[0066] In the next step, the masking layer and the unexposed areas of the electrocatalyst layer are removed from the ion conducting membrane (310), leaving only the electrocatalyst decal on the ion conducting layer. The unexposed areas of the electrocatalyst layer can then be recovered and recycled (312) for further use, for example in a new electrocatalyst layer that is provided at the start of the process (306).

[0067] As shown in FIG. 7 , which illustrates a roll-to-roll process for manufacturing a catalyst coated ion conducting membrane according to the present invention, an electrocatalyst layer 2 (shown disposed on a carrier layer or backing liner 18) may be provided on both sides of an ion conducting membrane 22, with a masking layer 8 disposed between the ion conducting membrane 22 and each respective electrocatalyst layer 2.

[0068] The layers are simultaneously provided between a pair of laminating rollers 24, which laminate the layers and transfer the exposed areas 12 of the electrocatalyst layer 2 (corresponding to the openings 10 in the masking layer 8) onto the ion-conducting membrane 22. The masking layer 8 and the non-exposed areas 14 of the electrocatalyst layer 2 (along with the backing liner 18) are then peeled off from the ion-conducting membrane 22, leaving the exposed areas 12 of the electrocatalyst layer on the ion-conducting membrane 22 as an electrocatalyst decal. In the roll-to-roll process shown, each of the respective layers is provided as a continuous web, so that the resulting catalyst coated ion-conducting membrane is also produced in the form of a continuous web, i.e., in roll-good form. The catalyst coated ion-conducting membrane can then either be used directly in a roll-to-roll process for manufacturing a membrane electrode assembly, or wound onto a roll for future use.

[0069] Thus, the process of the present invention can provide a highly efficient process for producing catalyst coated ion conducting membranes in roll-good form having precisely defined electrocatalyst decals.

[0070] Although the masking layer 8 and the electrocatalyst layer 2 are shown as separate layers provided between rollers 24, they may also be provided bonded together as a preformed masked electrocatalyst component.

[0071] FIG. 8 shows a flow diagram of a method for manufacturing a masked electrocatalyst component according to one embodiment of the present invention. First, an electrocatalyst layer is provided (402) and a masking component comprising a masking layer is provided (404). Next, the masking layer is bonded to the electrocatalyst layer to form the masked electrocatalyst component (406). Although bonding is not required, bonding is preferred as it facilitates easier handling of the masked electrocatalyst material. The masking layer and the electrocatalyst layer may be bonded, for example, by an adhesive. The adhesive should preferably be thermally stable at the lamination temperatures used in the process for manufacturing the catalyst coated ion conducting membrane. For example, the adhesive may be a silicone pressure sensitive adhesive.

[0072] 9 shows a flow diagram of a method for manufacturing a masked electrocatalyst component according to another embodiment of the invention. An electrocatalyst layer is provided (402), and a masking component is provided (403) comprising a masking layer and a reinforcing layer. The reinforcing layer helps stabilize the masking layer and maintain its shape while in contact with the electrocatalyst layer. The reinforcing layer can be removed (405) from the masking component before bonding the masking layer to the electrocatalyst layer (406). Alignment features can then be cut (410) into the masked electrocatalyst component.

[0073] Removing the reinforcing layer is not required, but helps to minimize the thickness of the masking components during the process for producing the catalyst coated ion conducting membrane. Removing the reinforcing layer also means that the reinforcing layer can be made from a polymer that does not need to be thermally stable at the lamination temperatures used during the process for producing the catalyst coated ion conducting membrane.

[0074] 10A and 10B show model subsystems of a roll-to-roll based system for manufacturing a masked electrocatalyst component according to an embodiment of the present invention.

[0075] The masking component 60, comprising the masking layer and the reinforcing layer, is fed to a rotary die cutter 62, which cuts an opening in the masking layer. The protective layer 64, covering the adhesive previously applied on the masking layer, is also removed at this point. The masking component, comprising the opening in the masking layer, is then gently placed onto the electrocatalyst layer 2. The masking component and the electrocatalyst layer are laminated together between rollers 66. The reinforcing layer 68 is then peeled away from the masking layer by a peel bar 70, leaving a masked electrocatalyst component 72, comprising the masking layer and the electrocatalyst layer.

[0076] Alignment features may be cut into the masked electrocatalyst component by a rotary die cutter 74. The masked electrocatalyst component may then be wound onto a roll 76 for later use if not directly provided to a process for manufacturing a catalyst coated ion conducting membrane.

[0077] It will be understood that the drawings used herein to illustrate embodiments of the invention are not drawn to scale and are provided purely to aid in the understanding of the invention.

Claims

**Claim 1** A method for manufacturing a catalyst-coated ion-conductive membrane for an electrochemical cell, the method comprising: providing an ion-conductive membrane, an electrocatalyst layer, and a masking layer between the ion-conductive membrane and the electrocatalyst layer, the masking layer comprising one or more openings for providing one or more exposed regions and one or more non-exposed regions of the electrocatalyst layer; contacting the layers such that the one or more exposed regions of the electrocatalyst layer are transferred onto the ion-conductive membrane and the masking layer prevents the one or more non-exposed regions of the electrocatalyst layer from being transferred onto the ion-conductive membrane. **Claim 2** The method of claim 1, further comprising an initial step of providing a masking layer without openings, and a step of cutting the openings in the masking layer, prior to the step of providing the masking layer between the ion-conductive membrane and the electrocatalyst layer. **Claim 3** The method of claim 1, wherein the step of contacting the layers comprises pressing the layers together. **Claim 4** The method of claim 3, wherein the layers are pressed together between a pair of rollers in a roll-to-roll lamination process. **Claim 5** The method of claim 3, wherein the layers are pressed together by a flatbed press. **Claim 6** The method of claim 4 or 5, wherein the roller or the flatbed press heats the layers to a temperature in the range of 100 to 200 °C, including 100 to 200 °C. **Claim 7** The method according to any one of claims 1 to 5, further comprising, after the step of contacting the layers, removing the masking layer and the non-exposed regions of the electrocatalyst layer from the ion-conductive membrane. **Claim 8** The method of claim 7, wherein the non-exposed regions of the electrocatalyst layer are recovered and recycled for further use. **Claim 9** The method according to any one of claims 1 to 5, wherein the electrocatalyst layer is provided on both sides of the ion-conductive membrane and the masking layer is provided between the ion-conductive membrane and each respective electrocatalyst layer. **Claim 10** The method according to any one of claims 1 to 5, wherein the ion conductive membrane is sandwiched between two layers of non-ion conductive seal material such that the membrane seal assembly has one or more inner regions and one or more boundary regions, the inner regions being free of non-ion conductive seal material and being ion conductive, and the boundary regions including the non-ion conductive seal material and being non-ion conductive.

11. The method according to any one of claims 1 to 5, wherein the ion conductive membrane includes a polymer electrolyte membrane.

12. The method according to any one of claims 1 to 5, wherein the electrocatalyst layer and the masking layer are provided together as a pre-formed masked electrocatalyst component, and the masking layer is joined to the electrocatalyst layer.

13. The method according to any one of claims 1 to 5, further comprising applying a sub-gasket around the active area of the catalyst-coated ion conductive membrane.

14. A catalyst-coated ion conductive membrane produced by the method according to any one of claims 1 to 5.

15. A membrane electrode assembly comprising the catalyst-coated ion conductive membrane according to claim 14.

16. A method of producing a masked electrocatalyst component for use in the manufacture of a catalyst-coated ion conductive membrane, the method comprising: providing an electrocatalyst layer; providing a masking component comprising a masking layer, the masking layer comprising one or more openings; combining the masking layer with the electrocatalyst layer to form a masked electrocatalyst component.

17. The method according to claim 16, wherein the step of combining the masking layer with the electrocatalyst layer to form a masked electrocatalyst component is a step of joining the masking layer to the electrocatalyst layer to form a masked electrocatalyst component.

18. The method according to claim 17, wherein the step of joining the masking layer to the electrocatalyst layer is carried out by a roll-to-roll lamination process in which the layers are pressed together between a pair of rollers.

19. The method according to claim 17 or 18, wherein the masking layer is joined to the electrocatalyst layer by an adhesive.

20. The method according to any one of claims 16 to 18, wherein the masking component further comprises a reinforcing layer for stabilizing the masking layer during the step of combining the masking layer with the electrocatalyst layer.

21. The method according to claim 20, wherein the reinforcing layer comprises a reinforcing polymer film.

22. The method according to claim 20, wherein the reinforcing layer is joined to the masking material by an adhesive.

23. The method according to claim 20, further comprising a step of removing the reinforcing layer after the step of joining the masking layer to the electrocatalyst layer.

24. The method according to any one of claims 16 to 18, wherein the electrocatalyst layer and the masking component are each provided in the form of a continuous web, and the masking layer comprises a plurality of openings along the length of the web.

25. The method according to claim 24, wherein the masked electrocatalyst component is produced in the form of a continuous web, and further comprising a step of cutting the masked electrocatalyst component into separate patches.

26. The method according to claim 25, wherein the masked electrocatalyst component is cut between the openings of the masking layer such that the masking layer within each patch comprises a single opening.

27. The method according to any one of claims 16 to 18, further comprising a step of cutting alignment features into the masked electrocatalyst component to assist in aligning the masked electrocatalyst component during the process of manufacturing a catalyst-coated ion-conductive membrane.

28. A pre-formed electrocatalyst component produced by the method according to any one of claims 16 to 18.

29. A masked electrocatalyst component for use in the manufacture of an electrochemical cell, wherein the masked electrocatalyst component comprises an electrocatalyst layer having a first surface and a second surface disposed on the opposite side; a masking layer disposed on the first surface of the electrocatalyst layer, the masking layer comprising one or more openings, thereby providing one or more exposed regions and one or more non-exposed regions of the first surface of the electrocatalyst layer.

30. The masked electrocatalyst component is in the form of a roll good, the electrocatalyst layer and the masking layer are each a continuous web, and the masking layer comprises a plurality of openings along the length of the web. The masked electrocatalyst component according to claim 29.

31. The masked electrocatalyst component according to claim 29, wherein the masked electrocatalyst component is in the form of separate patches.

32. The masked electrocatalyst component according to claim 31, wherein the masking layer comprises a single opening.

33. The masked electrocatalyst component according to any one of claims 29 to 32, further comprising a carrier layer disposed on the second surface of the electrocatalyst layer.

34. The masked electrocatalyst component according to any one of claims 29 to 32, wherein the electrocatalyst layer comprises a platinum group metal or an alloy of a platinum group metal.

35. The masked electrocatalyst component according to any one of claims 29 to 32, wherein the masking layer comprises a polymer film.

36. The masked electrocatalyst component according to claim 35, wherein the polymer film comprises a polymer that is thermally stable in the range of 100 to 200 °C and at temperatures including 100 to 200 °C.

37. The masked electrocatalyst component according to claim 35, wherein the polymer film comprises polyethylene naphthalate (PEN), polyethyleneimine (PEI), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), polyimide (PI), polytetrafluoroethylene (PTFE), or a mixture thereof.

38. The masked electrocatalyst component according to any one of claims 29 to 32, wherein the masking layer is joined to the electrocatalyst layer by an adhesive.

39. The masked electrocatalyst component according to claim 38, wherein the adhesive is thermally stable in the range of 100 to 200 °C and at temperatures including 100 to 200 °C.

40. The masked electrocatalyst component according to claim 38, wherein the adhesive comprises a silicone pressure-sensitive adhesive.

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