Patent ID: 8512908

Claim:
A method of making a catalyst coated diffusion media comprising: providing an electrode decal comprising a carrying substrate with a nanostructured thin catalytic layer thereon, the nanostructured thin catalytic layer having a first surface and a second surface, the first surface of the nanostructured thin catalytic layer adjacent the carrying substrate; providing a porous transfer substrate with an adjacent adhesive layer; adhering the second surface of the nanostructured thin catalytic layer adjacent to the adhesive layer to form a composite structure; removing the carrying substrate from the composite structure such that a residual layer formed on the first surface of the nanostructured thin catalytic layer of the electrocatalyst decal becomes exposed; and removing the adhesive layer from the composite structure and further removing the residual layer from the composite structure to form a reconstructed electrode decal comprising the porous transfer substrate and the nanostructured thin catalytic layer, wherein the second surface of the nanostructured thin catalytic layer is adjacent to the porous transfer substrate; providing a gas diffusion media layer comprising a conductive porous substrate and a microporous layer such that the microporous layer is adjacent to the first surface of the nanostructured thin catalytic layer; applying a bonding layer adjacent to the microporous layer, the first surface of the nanostructured thin catalytic layer, or both such that the first surface of the nanostructured thin catalytic layer is adjacently adhered to the microporous layer with the bonding layer; removing the porous transfer substrate; and removing at least a portion of the bonding layer; to form the catalyst coated diffusion media comprising the conductive porous substrate, the microporous layer, and the nanostructured thin catalytic layer adjacent to the microporous layer on a side opposite the conductive porous substrate.