Membrane-electrode assembly, method for manufacturing same, and fuel cell comprising same

A method for manufacturing a membrane-electrode assembly, the method comprising:

• applying a catalyst dispersion to a first release film having a first recessed pattern;
• covering the applied catalyst dispersion with a second release film having a second recessed pattern or a plurality of holes;
• drying at least a surface of the catalyst dispersion to form an electrode, the electrode having a first patterned structure formed on a first surface thereof by means of the second release film and a second patterned structure formed on a second surface thereof by means of the first release film;
• removing the second release film;
• transferring the electrode to a polymer electrolyte membrane in such a way that the first surface of the electrode faces the polymer electrolyte membrane;
• and
• removing the first release film,
• wherein the first patterned structure has a plurality of projected parts respectively having a circumscribed circle diameter of 10 to 1000 μm at a base plane thereof such that both the electrode and the polymer electrolyte membrane have increased active areas, whereas the second patterned structure has at least one projected pattern extending in a direction parallel to the second surface and having a width of 10 to 1000 μm and a recessed pattern adjoining the projected pattern such that a non-channel part of a separator to be disposed on the second patterned structure corresponds only to the recessed pattern of the second patterned structure.

A fuel cell comprising:

• a membrane-electrode assembly comprising:
• a first electrode;
• a second electrode;
• and a polymer electrolyte membrane between the first and second electrodes, wherein the first electrode has a first surface that faces the polymer electrolyte membrane and a second surface opposite the first surface, the first surface has a first patterned structure, and the second surface has a second patterned structure;
• and
• a separator disposed on the second patterned structure of the first electrode, wherein
• the second patterned structure comprises:
• at least one projected pattern extending in a direction parallel to the first and second surfaces and having a width of 10 to 1000 μm;
• and a recessed pattern adjoining the projected pattern,
• the separator has a third surface that faces the membrane-electrode assembly and a fourth surface opposite the third surface,
• the third surface comprises:
• a groove-shaped channel part functioning as a fluid path;
• and a non-channel part,
• the first patterned structure has a plurality of projected parts respectively having a circumscribed circle diameter of 10 to 1000 μm at a base plane thereof such that both the first electrode and the polymer electrolyte membrane can have increased active areas, and
• the membrane-electrode assembly and the separator are aligned such that the non-channel part of the separator corresponds only to the recessed pattern of the second patterned structure.