This Small Business Innovation Research Phase I project will address the manufacturing process used for proton exchange membrane (PEM) fuel cell membrane electrode assemblies (MEA). Current manufacturing techniques for production MEAs use large quantities of platinum (up to 4 mg/cm2) and require intensive labor to assemble. The various processes yield consistent performance among different manufacturers, but all are extremely costly due to high material and labor costs. This effort will explore the methodology and develop techniques to deposit low platinum loadings directly on the polymer membrane surface using a process similar to that used in laser printers. Objectives include demonstrating the feasibility of electrostatic deposition of catalyst on a polymer membrane; identifying the optimum conditions (size of particles, particle carrier, electrical charge, and pressure/temperature relations) for electrostatic deposition; and developing a continuing R&D plan for Phase II. The Phase I program will use a modified laser printer to evaluate platinum deposition techniques. Various platinum particle sizes and platinum/carrier particle mixes will be tested for transfer rates, coverage, electrical conductivity, and chemical reactivity. Light and transmission electron microscopes will be used to evaluate membrane coverage and conditions following platinum deposition.
