Membrane-Electrode Assembly Manufacturing via Laminated Structure

The patent combines the catalyst electrode layer formation and membrane bonding into a single integrated process. The catalyst slurry is directly coated onto the polymer electrolyte membrane layer, eliminating the need for separate decal preparation, transfer, and bonding steps. This merging of processes reduces the number of subsidiary materials needed (such as release films and bonding agents) and simplifies the overall manufacturing complexity while maintaining reliable bonding between the electrode layer and membrane.

The patent extracts and eliminates the unnecessary intermediary steps of the decal transfer method. By removing the release film, separate catalyst layer preparation, and thermal compression bonding steps, the invention directly applies the catalyst slurry to the membrane and allows it to be formed in situ. This extraction of redundant processes reduces manufacturing cost and complexity while achieving the same functional result of a bonded membrane-electrode assembly.

The patent extracts and eliminates the interface problems inherent in the decal transfer method. By removing the separate decal layer and its associated release film, the invention creates a direct interface between the catalyst electrode layer and polymer electrolyte membrane layer. This eliminates the additional interfaces that would otherwise form at the boundaries of transferred components, thereby reducing interfacial resistance and improving both performance and durability.

The patent merges the catalyst electrode layer formation directly onto the membrane surface, creating a unified structure without separate bonded components. This merging eliminates the need for thermal compression bonding interfaces and release film interfaces, resulting in fewer total interfaces and reduced interfacial resistance. The direct coating approach ensures intimate contact between the catalyst layer and membrane, improving manufacturing precision at the interface level.

The patent applies preliminary action by pre-treating the polymer electrolyte membrane layer with a drying process before coating the catalyst slurry. This preliminary drying removes excess moisture from the membrane surface, creating a more stable substrate that is less prone to rapid expansion when the slurry's solvents are applied. By preparing the membrane in advance, the invention prevents the deformation issues that would otherwise occur during the coating process.

The patent employs periodic action through a multi-stage drying process. After coating the catalyst slurry, the membrane-electrode assembly undergoes sequential drying steps at different conditions (initial drying, then final drying at higher temperature). This periodic drying approach allows controlled removal of solvents over time, preventing rapid expansion and deformation of the electrolyte layer while still achieving complete solvent removal for a structurally sound final product.

The patent replaces the mechanical thermal compression bonding system with a chemical bonding mechanism. Instead of relying on high pressure and temperature to bond thin membranes (which becomes difficult as thickness decreases), the invention uses the catalyst slurry's binding agents and the membrane's surface chemistry to create strong adhesion. This substitution allows thin membranes to be effectively bonded without requiring the high forces that would damage or deform ultra-thin structures.

The patent changes the bonding parameters from mechanical (high pressure, high temperature) to chemical (slurry composition, drying conditions). By optimizing the catalyst slurry formulation and drying process parameters, the invention achieves reliable bonding of thin electrolyte membrane layers. This parameter change allows the use of reduced membrane thickness while maintaining bonding quality, as the chemical bonding mechanism is more suitable for thin substrates than mechanical compression.