Membrane and electrode structure for methanol fuel cell

A membrane comprising:

• (a) a sheet of electronically insulating ion exchange material having top and bottom surfaces;
• (b) a passage extending through the sheet, the passage having an inner wall and a first end;
• (c) an electrocatalyst disposed along the inner wall of the passage;
• and
• (d) a metal current collector incorporated into a portion of the sheet, wherein the metal current collector is in electronic communication with the electrocatalyst in the passage.

A method for reducing the amount of reactant or product crossover in an electrolytic cell comprising an anode, a cathode and a solid polymer electrolyte membrane disposed between the anode and cathode, wherein the membrane has a passage extending therethrough, the method comprising:

• (a) allowing the reactant or product to enter the passage;
• (b) passing a fluid through the passage;
• (c) receiving the reactant or product in the fluid;
• and
• (d) removing the reactant or product from the cell along with the fluid.

A method for making a membrane comprising,

• coating at least a portion of a removable element with a catalyst;
• forming a polymeric material around the catalyst and the removable element to form a membrane, wherein the catalyst adheres to the membrane;
• and
• removing the removable element from the membrane to leave a passage extending through the membrane, the passage having at least a portion of an inside surface coated with the catalyst.

A method for making a membrane, the method comprising

• applying a catalyst layer to a portion of a surface of a first membrane sheet;
• positioning a removable element between the first membrane sheet and a second membrane sheet, wherein the surface of the first membrane sheet having the catalyst layer faces the removable element;
• bonding the two membrane sheets around the removable element to form a single membrane;
• and
• removing the removable element from the single membrane to form a passage extending through the membrane, the passage providing fluid communication with a portion of the catalyst.

A method of forming a metal layer on an inside surface of a passage formed in an ion exchange material, the method comprising:

• (a) contacting the inside surface of the passage formed in the ion exchange material with a solution containing an ion of a metal;
• (b) allowing the ions of the metal to exchange into the inside surface of the passage formed in the ion exchange material;
• and
• (c) chemically reducing the exchanged metal ions in the ion exchange material to form the metal layer.

A method for making a membrane, the method comprising:

• applying a catalyst layer to a portion of a surface of a first membrane sheet;
• positioning the first membrane sheet and a second membrane sheet, wherein the surface of the first membrane sheet having the catalyst layer faces the second membrane sheet;
• and
• bonding the two membrane sheets to form a single membrane.