Abstract: A method is provided for making a gasketed fuel cell membrane electrode assembly (MEA) comprising the steps of: i) selecting a fluid transport layer sheet material; ii) selecting a target level of compression Ct % for use of said fluid transport layer sheet material in a fuel cell membrane electrode assembly; iii) measuring the pressure Pt for which the fluid transport layer sheet material achieves compression of Ct %; iv) positioning between the platens of a press a membrane electrode assembly comprising: a) a polymer electrolyte membrane; b) an anode catalyst material; c) a cathode catalyst material; d) an anode-side fluid transport layer comprising the selected fluid transport layer sheet material; and e) a cathode-side fluid transport layer comprising the selected fluid transport layer sheet material; v) depositing a gasket material in the outer edge portions of the anode and cathode faces of the polymer electrolyte membrane; vi) compressing the membrane electrode assembly to a pressing pressure Pp which

Abstract: The present invention is a system for molding a gasket to a membrane electrode assembly. The system comprises a cavity defined at least in part by closable mold blocks, at least one injection gate for injecting gasket material into the cavity, a mount for retaining the membrane electrode assembly adjacent to the cavity, and a mold insert independently movable relative to the closable mold blocks for applying pressure to the membrane electrode assembly retained on the mount.

Abstract: The present invention relates to a curable precursor of a fire-retardant, low-density and essentially halogen-free epoxy composition comprising (i) 10 to 70 weight percent of at least one organic epoxide compound with an epoxide functionality of at least one, (ii) 1 to 55 weight percent of at least one epoxide hardener, (iii) 5 to 50 weight percent of an essentially halogen-free fire-retardant system that includes a mixture of: (1) at least one compound selected from the group comprising alkaline earth metal hydroxides and aluminium group hydroxides, and (2) at least one phosphorous-containing material, (iv) 10 to 60 weight percent of a filler system capable of reducing the density of the precursor that includes a mixture of (1) at least one low-density inorganic filler having a density of between 0.1 to 0.5 g cm?3?, (2) at least one low-density organic filler having a density of between 0.01 to 0.30 g/cm?3? and being compressible.

Abstract: A fuel cell membrane electrode assembly is provided comprising a polymer electrolyte membrane comprising a first polymer electrolyte and at least one manganese compound; and one or more electrode layers comprising a catalyst and at least one cerium compound. The membrane electrode assembly demonstrates an unexpected combination of durability and performance.

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 of making a durable fuel cell polymer electrolyte membrane is provided comprising the steps of: a) providing a polymer electrolyte membrane; b) providing a solution of a salt selected from the group consisting of manganese salts and cerium salts or a suspension of particles of a compound selected from the group consisting of manganese oxides and cerium oxides; and c) applying the solution or suspension to the polymer electrolyte membrane by a method selected from the group consisting of brushing, spraying and use of a slot die. Some embodiments comprise metered application of the solution to the polymer electrolyte membrane.

Abstract: Fuel cell membrane electrode assemblies and fuel cell polymer electrolyte membranes are provided comprising manganese oxides which demonstrate increased durability. Methods of making same are provided.

Abstract: The present disclosure provides a tape comprising: a) a single layer comprising a crosslinked polymer, selected from the group consisting of crosslinked polyurethane, crosslinked polyurea, and crosslinked mixed polyurethane/polyurea polymer, and b) an adhesive layer. In another embodiment, the disclosure provides an erosion resistant construction comprising, first, an element of an aircraft comprising: an aircraft skin segment having an external surface, and a deicing mechanism associated with said aircraft skin segment capable of heating said external surface to temperatures in excess of 65° C.; and, second, a tape comprising: at least one layer comprising a crosslinked elastomeric polymer, which may be a crosslinked polymer selected from the group consisting of crosslinked polyurethane, crosslinked polyurea, and crosslinked mixed polyurethane/polyurea polymer, and an adhesive layer; wherein the tape is bonded to the external surface of the aircraft skin segment by the adhesive layer.

Abstract: Fuel cell membrane electrode assemblies and fuel cell polymer electrolyte membranes are provided comprising manganese oxides which demonstrate increased durability. Methods of making same are provided.

Abstract: The present disclosure provides a compound according to the formula: Rf1[CH(—O—CH(3-m)Rf2m)(—O—CF2—CFH—Rf3)]n ??[I] wherein n is 1 or 2, wherein m is 1, 2 or 3, wherein, when n is 1, Rf1 is selected from the group consisting of highly fluorinated alkyl groups which are linear, branched, cyclic, or a combination thereof, which may optionally be substituted, and which may optionally contain one or more catenated heteroatoms; wherein, when n is 2, Rf1 is selected from the group consisting of highly fluorinated alkylene groups which are linear, branched, cyclic, or a combination thereof, which may optionally be substituted, and which may optionally contain one or more catenated heteroatoms; wherein each Rf2 is independently selected from the group consisting of alkyl groups which are linear, branched, cyclic, or a combination thereof, which may optionally be substituted, and which may optionally contain one or more catenated heteroatoms; wherein at least one Rf2 is highly fluorinated; wherein each Rf3 is indepe

Abstract: The present disclosure provides a method of making a thin film semiconductor device such as a transistor comprising the steps of: a) providing a substrate bearing first and second conductive zones which define a channel therebetween, where the channel does not border more than 75% of the perimeter of either conductive zone; and b) depositing a discrete aliquot of a solution comprising an organic semiconductor adjacent to or on the channel, where a majority of the solution is deposited to one side of the channel and not on the channel. In some embodiments of the present disclosure, the solution is deposited entirely to one side of the channel, not on the channel, and furthermore the solution is deposited in a band having a length that is less than the channel length. The present disclosure additionally provides thin film semiconductor devices such as a transistors.

Abstract: An ion-conductive membrane that includes a first layer comprising a first ionomer, and a porous polymer substrate, where at least a portion of the first ionomer is interpenetrated within the porous polymer substrate by ionomer-induced phase separation.

Abstract: An oxygen-reducing catalyst layer, and a method of making the oxygen-reducing catalyst layer, where the oxygen-reducing catalyst layer includes a catalytic material film disposed on a substrate with the use of physical vapor deposition and thermal treatment. The catalytic material film includes a transition metal that is substantially free of platinum. At least one of the physical vapor deposition and the thermal treatment is performed in a processing environment comprising a nitrogen-containing gas.

Abstract: A method is provided for making a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles, where the method comprises step a) of vacuum deposition of material from at least a first carbon target in the presence of nitrogen and step b) of vacuum deposition of material from a second target comprising at least one transition metal, the second target comprising no precious metals. In one embodiment, step a) is carried out prior to step b). In another embodiment, steps a) and b) are carried out simultaneously. Typically the deposition steps are carried out in the absence of oxygen. Typically, the transition metal is iron or cobalt, and most typically iron. The present disclosure also provides a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles made according to the present method.

Abstract: A flexible flow field separator includes a substrate layer formed of a flexible material and having first and second surfaces. A structured flow field pattern is defined on the first surface of the substrate layer. The structured flow field pattern defines one or more fluid channels. The separator includes a first layer formed of one or more metals and disposed on the first surface of the substrate layer. The first layer is formed of an electrically conductive material. The separator further includes a second layer disposed on the second surface of the substrate layer. The second layer is formed of a flexible electrically conductive material. The first layer contacts the second layer at one or more locations to define an electrical connection between the first and second layers.

Abstract: A catalyst ink is provided, comprising: 25-95% by weight water; 1-50% by weight of at least one solid catalyst, typically a highly dispersed platinum catalyst; 1-50% by weight of at least one polymer electrolyte in acid (H+) form; and 1-50% by weight of at least one polar aprotic organic solvent. The catalyst ink typically has a viscosity at 1 sec?1 of 10 Pa·sec or less. The catalyst ink typically does not ignite spontaneously when dried to completion in air at a temperature of 80° C. or greater. The catalyst ink may be used in the fabrication of membrane electrode assemblies for use in fuel cells.

Abstract: A method is provided for obtaining crosslinked polymers having pendent sulfonic acid groups by crosslinking through the sulfonic acid groups or their precursors with aromatic crosslinkers or aromatic pendent crosslinking groups to form aromatic sulfones. Such crosslinked polymers may be used to make polymer electrolyte membranes (PEM's) that may be used in electrolytic cells such as fuel cells.

Abstract: Fuel cell membrane electrode assemblies and fuel cell polymer electrolyte membranes are provided comprising bound anionic functional groups and polyvalent cations, such as Mn or Ru cations, which demonstrate increased durability. Methods of making same are also provided.

Abstract: A simple and inexpensive method of making a flow field plate that exhibits increased durability under conditions of use is provided. In some embodiments, the method includes the steps of applying a dry carbon powder to a flow field surface of the flow field plate and buffing the carbon powder onto the flow field surface. In some embodiments, the method includes the steps of rubbing a flow field surface of the flow field plate with a dry carbon solid and optionally buffing the carbon onto the flow field surface.

Abstract: A method of making a five-layer membrane electrode assembly is provided which includes the steps of: providing a catalyst coated membrane web; providing a laminating station wherein the catalyst coated membrane web is drawn between a pair of laminating rollers which form a laminating nip; die-cutting first and second webs of gas diffusion layer material to make first and second gas diffusion layers; feeding first and second gas diffusion layers into the laminating nip adjacent to the catalyst coated membrane web; and laminating the first gas diffusion layer, catalyst coated membrane web and second gas diffusion layer to form a laminate.