Catalyst layer assembly

A process for preparing a reinforced catalyst layer assembly suitable for use in a fuel cell, said reinforced catalyst layer assembly comprising:

• (a) a planar reinforcing component consisting of a porous material having pores extending through the thickness of the material in the z-direction, the planar reinforcing component having a first surface and a second surface;
• (b) a first catalyst layer having a first surface and a second surface, the first catalyst layer comprising a first ion-conducting material and a first primary metal;
• (c) a second catalyst layer having a first surface and a second surface, the second catalyst layer comprising a second ion-conducting material and a second primary metal;
• (d) an ion-conducting layer having a first surface and a second surface, wherein the first surface of the ion-conducting layer is in contact with the first surface of the first catalyst layer, and the second surface of the ion-conducting layer is in contact with the first surface of the second catalyst layer;
• wherein the planar reinforcing component extends across the ion-conducting layer into the first catalyst layer, such that the first surface of the planar reinforcing component is within the first catalyst layer;
• wherein said process comprises the steps:
• (i) applying a coating of a first ink comprising the first catalyst component onto a substrate;
• (ii) applying the planar reinforcing component onto the coating of the first ink, such that the first ink partially impregnates and becomes embedded within the planar reinforcing component to form the first catalyst layer, wherein the first catalyst layer is partially embedded within the planar reinforcing component such that the first surface of the planar reinforcing component is within the first catalyst layer and the second surface of the planar reinforcing component extends beyond the first surface of the first catalyst layer in a through-plane direction;
• (iii) applying a dispersion comprising a third ion-conducting material to the first surface of the first catalyst layer, such that the third ion-conducting material at least partially impregnates and becomes embedded within the planar reinforcing component extending beyond the first surface of the first catalyst layer to form the ion-conducting layer, wherein the ion-conducting layer is at least partially embedded within the planar reinforcing component;
• (iv) applying a coating of a second ink comprising the second catalyst component to the second surface of the ion-conducting layer;
• (v) drying to form the reinforced catalyst layer assembly.