decal transfer step. However, investigations on the application
of a roll-press-based decal process exploring its characteristic
features with experimental results are hardly found in
the literature reports. Recently, we reported the preliminary
stage results on the feasibility of such a technique to fabricate
MEAs for DMFCs [21]. The use of roll-press delivered reasonably
better catalyst transfer rate and MEA performance
compared with a conventional low-temperature decal method
using a flat-press.
In the present study, we have precisely examined the
various technical aspects of the novel decal method. In-depth
analysis has been conducted in terms of applied conditions
and MEA characterization to get insight into the crucial features
and advantages of the current method over existing
techniques. The parameters of pressure, temperature and
time are varied, and their effects on the degree of catalyst
transfer and MEA performance are analyzed. Ionomer content
in the cathode catalyst layer is also optimized. Several electrochemical
and physicochemical tools are employed to
analyze and compare the MEAs fabricated under different
conditions. Advantages and future prospects for the roll-press
decal method are also discussed.