Abstract: A method is provided for making an edge-sealed fuel cell membrane electrode assembly comprising the steps of: i) providing a suitable membrane electrode assembly lay-up; ii) positioning a suitable annular layer of a thermoplastic; and iii) applying pressure and heat sufficient to melt impregnate the thermoplastic into the fluid transport layer or layers of the membrane electrode assembly lay-up and simultaneously bond the fluid transport layer or layers to the polymer electrolyte membrane of the membrane electrode assembly lay-up. The polymer electrolyte membrane of the membrane electrode assembly lay-up may be perforated in its outer sealing area. Membrane electrode assemblies made according to the method of the present invention are also provided.

Abstract: A method is provided for making an edge-sealed fuel cell membrane electrode assembly comprising the steps of: i) providing a suitable membrane electrode assembly lay-up; ii) positioning a suitable annular layer of a thermoplastic; and iii) applying pressure and heat sufficient to melt impregnate the thermoplastic into the fluid transport layer or layers of the membrane electrode assembly lay-up and simultaneously bond the fluid transport layer or layers to the polymer electrolyte membrane of the membrane electrode assembly lay-up. The polymer electrolyte membrane of the membrane electrode assembly lay-up may be perforated in its outer sealing area. Membrane electrode assemblies made according to the method of the present invention are also provided.

Abstract: A method is provided for making an edge-sealed fuel cell membrane electrode assembly comprising the steps of: i) providing a suitable membrane electrode assembly lay-up; ii) positioning a suitable annular layer of a thermoplastic; and iii) applying pressure and heat sufficient to melt impregnate the thermoplastic into the fluid transport layer or layers of the membrane electrode assembly lay-up and simultaneously bond the fluid transport layer or layers to the polymer electrolyte membrane of the membrane electrode assembly lay-up. The polymer electrolyte membrane of the membrane electrode assembly lay-up may be perforated in its outer sealing area. Membrane electrode assemblies made according to the method of the present invention are also provided.

Abstract: A method is provided for making an edge-sealed fuel cell membrane electrode assembly comprising the steps of: i) providing a suitable membrane electrode assembly lay-up; ii) positioning a suitable annular layer of a thermoplastic; and iii) applying pressure and heat sufficient to melt impregnate the thermoplastic into the fluid transport layer or layers of the membrane electrode assembly lay-up and simultaneously bond the fluid transport layer or layers to the polymer electrolyte membrane of the membrane electrode assembly lay-up. The polymer electrolyte membrane of the membrane electrode assembly lay-up may be perforated in its outer sealing area. Membrane electrode assemblies made according to the method of the present invention are also provided.

Abstract: A flow field for an electrochemical cell such as a fuel cell is provided, having micro-flow channels having a width or depth of less than 800 &mgr;m, a pitch of less than 800 &mgr;m, or a proportion of inter-channel land area of less than 25%. The channels may further comprise micro-features within the channels. A flow field plate comprising the subject flow field is provided.

Abstract: A polymer electrolyte membrane is provided comprising an intimate mixture of an ionomeric polymer and a structural film-forming polymer. A method of making the polymer electrolyte membrane is also provided, comprising the step of coalescing at least one of an ionomeric polymer and a structural film-forming polymer in a mixture of the two resulting from a mixed dispersion and optionally crosslinking one or both.