Abstract: The present invention relates to a process for making single or multiple planar array five layer membrane electrode assemblies utilizing array assemblies, as well as the array assemblies themselves, comprising proton exchange membrane (PEM), catalyst coated membranes (CCM) and gas diffusion layers (GDL), as well as gas diffusion electrodes (GDE) for use in fuel cells, wherein the process is practical, efficient and scalable.

Abstract: Multipurpose sealing adhesive materials for sealing different components of an electrochemical cell are provided. The sealing materials are acid, acid anhydride, acid ester or metallocene modified polyolefins that are capable of providing multiple sealing functionalities in a heat activated sealing process. These sealing polymers are capable of adhering to plain and textured metal, graphite and graphite-filled polymer composite separator plates.

Abstract: Disclosed is a unitized electrochemical cell sub-assembly having a first separator plate and a second separator plate that each has a first surface. A recess is located in at least one of the first surfaces to define a chamber adjacent the periphery of the plates when the plates face each other. A membrane electrode assembly (MEA) comprising an ion exchange membrane and a pair of gas diffusion layers is disposed on and between each of the first surfaces between the two plates when the plates face each other so that the peripheral edge of the ion exchange membrane is located within the chamber. Also located in the chamber is a non-conductive sealant polymer that seals and joins the first and second plates to each other, and that seals and joins the first and second plates to the edge of the ion exchange membrane. Also disclosed is a fabrication method for making the unitized electrochemical cell sub-assembly.

Abstract: The invention provides a unitized membrane electrode assembly having improved edge sealing by a one-step compression molding process.