Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.

Abstract: Fuel-cell membrane-subgasket assemblies may include an electrolyte membrane and a coated subgasket overlying the electrolyte membrane around a perimeter of the electrolyte membrane so as to define an active area inside the perimeter. The coated subgasket may comprise a subgasket body formed from a subgasket material. At least one side of the coated subgasket includes a subgasket coating layer containing or formed from a coating material such as metals, ceramics, polymers, polymer composites, or other hard coatings. Fuel-cell assemblies may include gas diffusion media, a bipolar plate, and a fuel-cell membrane-subgasket assembly having a coated subgasket. Fuel-cell stacks may include clamping plates, unipolar endplates, and a plurality of individual fuel-cell assemblies, at least one of which includes a fuel-cell membrane-subgasket assembly having a coated subgasket.

Abstract: Fuel-cell membrane-subgasket assemblies may include an electrolyte membrane and a coated subgasket overlying the electrolyte membrane around a perimeter of the electrolyte membrane so as to define an active area inside the perimeter. The coated subgasket may comprise a subgasket body formed from a subgasket material. At least one side of the coated subgasket includes a subgasket coating layer containing or formed from a coating material such as metals, ceramics, polymers, polymer composites, or other hard coatings. Fuel-cell assemblies may include gas diffusion media, a bipolar plate, and a fuel-cell membrane-subgasket assembly having a coated subgasket. Fuel-cell stacks may include clamping plates, unipolar endplates, and a plurality of individual fuel-cell assemblies, at least one of which includes a fuel-cell membrane-subgasket assembly having a coated subgasket.

Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.

Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.

Abstract: A method of making an electrode is provided. The method includes providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon; providing a transfer substrate with an adjacent adhesive layer; adhering the nanostructured thin catalytic layer adjacent to the adhesive layer to form a composite structure; removing the carrying substrate from the composite structure; and removing the transfer substrate from the composite structure to form the stand-alone nanostructured thin catalytic film comprising the adhesive layer with the nanostructured thin catalytic layer adhered thereto. A stand alone nanostructured thin catalytic film and methods of constructing electrodes with the stand alone nanostructured thin catalytic films are also described.

Abstract: An integrated fuel cell assembly is described. The integrated fuel cell assembly includes a polymer membrane; an anode electrode and a cathode electrode on opposite sides of the polymer membrane; a pair of gas diffusion media on opposite sides of the polymer membrane, the gas diffusion media comprising a microporous layer and a gas diffusion layer, the anode electrode and the cathode electrode positioned between the polymer membrane and the pair of gas diffusion media; a subgasket positioned around a perimeter of one of the gas diffusion media, the subgasket defining an active area inside the perimeter, the subgasket having a layer of thermally activated adhesive thereon; and a bipolar plate sealed to the subgasket by the layer of thermally activated adhesive. Methods of making the integrated fuel cell assembly and assembling fuel cell stacks are also described.

Abstract: An integrated fuel cell assembly is described. The integrated fuel cell assembly includes a polymer membrane; an anode electrode and a cathode electrode on opposite sides of the polymer membrane; a pair of gas diffusion media on opposite sides of the polymer membrane, the gas diffusion media comprising a microporous layer and a gas diffusion layer, the anode electrode and the cathode electrode positioned between the polymer membrane and the pair of gas diffusion media; a subgasket positioned around a perimeter of one of the gas diffusion media, the subgasket defining an active area inside the perimeter, the subgasket having a layer of thermally activated adhesive thereon; and a bipolar plate sealed to the subgasket by the layer of thermally activated adhesive. Methods of making the integrated fuel cell assembly and assembling fuel cell stacks are also described.

Abstract: A method of making an electrode is provided. The method includes providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon; providing a transfer substrate with an adjacent adhesive layer; adhering the nanostructured thin catalytic layer adjacent to the adhesive layer to form a composite structure; removing the carrying substrate from the composite structure; and removing the transfer substrate from the composite structure to form the stand-alone nanostructured thin catalytic film comprising the adhesive layer with the nanostructured thin catalytic layer adhered thereto. A stand alone nanostructured thin catalytic film and methods of constructing electrodes with the stand alone nanostructured thin catalytic films are also described.

Abstract: A UEA-subgasket assembly for a fuel cell system and a method of production thereof is disclosed. The UEA-subgasket assembly includes a membrane electrolyte assembly, diffusion media, and a subgasket, wherein the subgasket permeates into one of the diffusion media to form a substantially fluid-tight seal.

Abstract: A method of making an electrode ink containing nanostructured catalyst elements is described. The method comprises providing an electrocatalyst decal comprising a carrying substrate having a nanostructured thin catalytic layer thereon, the nanostructure thin catalytic layer comprising nanostructured catalyst elements; providing a transfer substrate with an adhesive thereon; transferring the nanostructured thin catalytic layer from the carrying substrate to the transfer substrate; removing the nanostructured catalyst elements from the transfer substrate; providing an electrode ink solvent; and dispersing the nanostructured catalyst elements in the electrode ink solvent. Electrode inks, coated substrates, and membrane electrode assemblies made from the method are also described.