Method for fabricating gas diffusion electrode assembly for fuel cells

A method for fabricating an electrode assembly for solid polymer electrolyte fuel cells comprising a cation exchange membrane provided with an electrode catalyst layer and a carbon cloth or paper layer in this order on each of the surfaces of the membrane, the method comprising the steps of:

• (a) providing a cation exchange membrane comprising a perfluorosulfonic acid group-containing copolymer comprising tetrafluoroethylene units and perfluorovinyl ether units having sulfonic acid groups on their side chains and represented by the following formula (1) or (2);
• ##STR3## wherein X represents H, Na or K, k is about 2.1 to about 7.6, m is about 3.8 to about 9.3 and l and n represent a positive integer, where the membrane has a thickness of from 50 to 100 .mu.m in dry state at room temperature and an ion exchange capacity of 1.12 to 1.43 meq/g (dry resin),
• (b) bonding the electrode catalyst layers and the carbon cloth or paper layers on both surfaces of the cation exchange membrane by;
• (i) preparing a uniform mixture of electrode catalyst loaded on fine carbon particles and a polytetrafluoroethylene dispersion,
• (ii) applying the mixture on a surface of a sheet of electroconductive and gas permeable carbon cloth or paper and subjecting the sheet having the applied mixture layer to hot pressing to obtain a carbon cloth or paper sheet for anode having an electrode catalyst layer formed from the applied mixture layer,
• (iii) repeating the procedure of the above step (ii) to obtain a carbon cloth or paper sheet having an electrode catalyst layer, applying a mixture containing fine carbon particles and a polytetrafluoroethylene dispersion to a surface of the sheet opposite to the one provided with the electrode catalyst layer and subjecting the sheet to hot pressing to obtain a carbon cloth or paper sheet for cathode having the electrode catalyst layer and a water-repellent layer formed from the applied mixture layer of fine carbon particles and a polytetrafluoroethylene dispersion,
• (iv) preparing a solution or dispersion of perfluorosulfonic acid copolymer represented by the above formula (1) or (2) where X represents the same element as the element X of the copolymer of the cation exchange membrane,
• (v) applying the solution or the dispersion to either or both of the surfaces of the electrode catalyst layers formed on the carbon cloth or paper sheets for anode and cathode and the surfaces of the cation exchange membrane,
• (vi) stacking the cation exchange membrane and the carbon cloth or paper sheets so that each of the surfaces of the electrode catalyst layers formed on the carbon cloth or paper sheets are in contact with each of the both surfaces of the cation exchange membrane,
• (vii) subjecting the stacked cation exchange membrane and carbon cloth or paper sheets to hot pressing at a temperature lower than the softening temperature of the perfluorosulfonic acid copolymer of the cation exchange membrane by 10.degree. C. or more to give the electrode assembly.