Improved structures and manufacturing processes for catalyst-coated membranes for fuel cells

Simplified method for manufacturing a catalyst-coated membrane (CCM) for solid polymer electrolyte fuel cells are disclosed. The CCM comprises two reinforcing, expanded polymeric sheets, and the methods involve the formation of the electrolyte membrane during the assembly of the CCM. Thus, the conventional need to get solid polymer sheets, manipulate and transfer by peeling, are omitted in the CCM production. Furthermore CCM structures having improved mechanical strength can be prepared by reacting the expanded polymer sheets are aligned so that the stronger Zugfestigkeitsrichtung of the one is orthogonal to that of the other. Such improved CCM structures can be prepared by the simplified method of the invention can be used.