Patent ID: 7285307

Claim:
A process for producing a 3-layer catalyst coated membrane suitable for use with a fuel cell, the process comprising the steps of: (a) coating a polymer electrolyte membrane, having a front side and a back side, on the front side with a first catalyst ink suitable for use with a fuel cell, wherein the back side of the polymer electrolyte membrane has a backing film; (b) drying the polymer electrolyte membrane resulting from step (a) to a residual solvent content of less than 5% by weight based on the total weight of the polymer electrolyte membrane, including the first catalyst coating and the backing film; (c) removing the backing film from the polymer electrolyte membrane; and (d) coating the back side of the polymer electrolyte membrane with a second catalyst ink suitable for use with a fuel cell so as to produce a 3-layer catalyst coated membrane, wherein the coating of the back side of the polymer electrolyte membrane is conducted without the backing film being present and without the presence of gas distribution layers on the membrane.