The present invention provides a continuous process for producing
catalyst-coated polymeric electrolyte membranes and membrane electrode
assemblies for fuel cells. The process of the invention uses an ionomer
membrane having a polymeric backing film on the back side. After the
first coating step, the membrane is dried, during which the residual
solvent may be almost completely removed. After this, the polymeric
backing film is removed and the back side of the membrane is coated in a
second step. The front and back sides of the membrane can be coated by
various methods, such as screen printing or stencil printing. Two gas
distribution layers are applied to the two sides of the catalyst-coated
membrane to produce a 5-layer membrane electrode assembly. The membrane
electrode assemblies are used in polymeric electrolyte membrane fuel
cells and in direct methanol fuel cells.