Fabrication process for making electrochemical multilayer membrane matertals

A method for fabricating an electrochemical sensor material, comprising:

• providing a proton exchange membrane having a first surface and an opposing second surface, the proton exchange membrane composed of a polymeric material having a glass transition temperature and having a total membrane thickness;
• positioning a first layer of molded graphene nanoplatelets adjacent the first surface of the proton exchange membrane and a second layer of molded graphene nanoplatelets adjacent the second surface of the proton exchange membrane to provide a multilayer stack;
• applying heat to the proton exchange membrane in an amount sufficient to bring a first region of the proton exchange membrane adjacent the first surface and a second region of the proton exchange membrane adjacent the second surface to the glass transition temperature, thereby providing a softened first region adjacent the first surface and a softened second region adjacent the second surface;
• applying compressive pressure to the multilayer stack in an amount sufficient to press a first portion of the first layer of graphene nanoplatelets into the softened first region, thereby producing a first integrated layer that includes the first portion of the first layer of graphene nanoplatelets integrated with the polymeric material of the softened first region and to press a first portion of the second layer of graphene nanoplatelets into the softened second region, thereby producing a second integrated layer that includes the first portion of the second layer of graphene nanoplatelets integrated with the polymeric material of the softened second region;
• permitting the polymeric material of the first integrated layer and the polymeric material of the second integrated layer to cool to a temperature below the glass transition temperature;
• exfoliating a second portion of the first layer of molded graphene nanoplatelets from the first integrated layer, thereby uncovering the first integrated layer;
• and
• exfoliating a second portion of the second layer of molded graphene nanoplatelets from the second integrated layer thereby uncovering the second integrated layer.

A method for fabricating an electrochemical sensor component, comprising:

• providing a multilayer proton exchange membrane comprising a plurality of layers, the plurality of layers including a first integrated layer at a first surface of the multilayer proton exchange membrane and a second integrated layer at a second surface of the multilayer proton exchange membrane, wherein a portion of the proton exchange membrane positioned between the first and second integrated layers comprises a nonconductive ion-permeable layer, the multilayer proton exchange membrane having a total membrane thickness, the first integrated layer having a first thickness, the second integrated layer having a second thickness and the nonconductive ion-permeable layer having a third thickness, the nonconductive ion-permeable layer comprising a polymeric material and each of the first and second integrated layers comprising graphene nanoplatelets embedded in the polymeric material wherein the multilayer proton exchange membrane comprises a metal layer deposited over the first integrated layer to provide a metal-coated membrane;
• and;
• cutting the metal-coated membrane to provide a sized metal-coated membrane having a first length and a first width;
• wherein said cutting comprises orienting a cutting edge of a cutting tool across the full thickness of the metal-coated membrane, wherein the cutting edge contacts and cuts through the layers of the metal-coated membrane simultaneously, and wherein the relative movement between the cutting edge and the metal-coated membrane causes the cutting edge to pass through the metal-coated membrane in a direction substantially parallel to a plane in which the metal-coated membrane lies.

An electrochemical sensor component, comprising:

• a multilayer proton exchange membrane comprising a first integrated layer at a first surface of the multilayer proton exchange membrane and a second integrated layer at a second surface of the multilayer proton exchange membrane, wherein a portion of the proton exchange membrane positioned between the first and second integrated layers comprises a nonconductive ion-permeable layer, the multilayer proton exchange membrane having a total membrane thickness, the first integrated layer having a first thickness, the second integrated layer having a second thickness and the nonconductive ion-permeable layer having a third thickness, the nonconductive ion-permeable layer comprising a polymeric material and each of the first and second integrated layers comprising graphene nanoplatelets embedded in the polymeric material;
• a metal layer positioned over the first integrated layer;
• a first electrical contact affixed to the metal layer in electrical communication with the metal layer;
• and
• a second electrical contact affixed to the second integrated layer in electrical communication with the second integrated layer.