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 provides a method of making a gasketed fuel cell membrane electrode assembly by simultaneously binding together the parts of the MEA, impregnating uncured elastomeric gasket material into the outer edge portions of each fluid transport layer, and substantially curing the uncured elastomeric gasket material so as to form anode-side and cathode-side gaskets. In order to form a raised-ridge microstructured contact pattern on the contact face of each gasket, patterning plates bearing a negative relief of a raised-ridge microstructured contact pattern may be positioned between the press platens and the uncured elastomeric gasket material.

Abstract: A method is provided for making a gasketed fuel cell MEA comprising the steps of: selecting an FTL sheet material; selecting a target level of compression C % for use of said FTL sheet material in a fuel cell MEA; measuring die pressure Pt for which the FTL sheet material achieves compression of Ct %; positioning between the platens of a press an MEA comprising: a PEM; an anode catalyst material; a cathode catalyst material; an anode-side FTL comprising the selected FTL sheet material; and a cathode-side FTL comprising the selected FTL sheet material; depositing a gasket material in the outer edge portions of the anode and cathode faces of the PEM; compressing the MEA to a pressing pressure Pp which is between 90% and 110% of Pt; and substantially fixing the gasket material so as to form a gasketed fuel cell MEA.

Abstract: The present invention provides a gasketed fuel cell membrane electrode assembly comprising: a polymer electrolyte membrane; layers of anode and cathode catalyst; anode-side and cathode-side fluid transport layer; and anode-side and cathode-side gaskets; where the gaskets comprise an elastomeric gasket material which is impregnated into the outer edge portions of the respective fluid transport layer; and where at least a portion of the contact face of each gasket bears a raised-ridge microstructured contact pattern. The gasketed fuel cell membrane electrode assembly according to the present invention may additionally comprise a rigid, non-elastomeric anode-side and cathode-side shims positioned between at least a portion of the gasket and the polymer electrolyte membrane. The raised-ridge microstructured contact pattern preferably comprises ridges which meet at joining points, wherein no more than three ridges meet at any one joining point.

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 provides a gasketed fuel cell membrane electrode assembly comprising: a polymer electrolyte membrane; layers of anode and cathode catalyst; anode-side and cathode-side fluid transport layer; and anode-side and cathode-side gaskets; where the gaskets comprise an elastomeric gasket material which is impregnated into the outer edge portions of the respective fluid transport layer; and where at least a portion of the contact face of each gasket bears a raised-ridge microstructured contact pattern. The gasketed fuel cell membrane electrode assembly according to the present invention may additionally comprise a rigid, non-elastomeric anode-side and cathode-side shims positioned between at least a portion of the gasket and the polymer electrolyte membrane. The raised-ridge microstructured contact pattern preferably comprises ridges which meet at joining points, wherein no more than three ridges meet at any one joining point.