Abstract: Methods of manufacturing a fuel cell array that include selectively removing portions of a coating layer from a composite layer. The composite layer includes a first surface and a second surface and a first coating is disposed over at least a portion of the first surface. A laser or mechanical tool is used to selectively remove portions of the first coating to form discontinuity regions at predetermined positions in the first coating.

Abstract: Methods of manufacturing electrochemical cells having a current collector which, at least in part, underlies a catalyst layer are discussed. A method comprises patterning a current collector to have at least one electrolyte opening, disposing an electrolyte into or through the at least one opening, and disposing a catalyst, at least in part, over the disposed electrolyte. Optionally, the method comprises pattering a substrate and attaching a patterned current collector to each side thereof. Patterning of the current collector can include patterning a continuous sheet, which comprises at least a first and a second separable current collector. In one such example, a continuous carbon-fiber sheet impregnated or laminated with a non-porous material is patterned. In another such example, a continuous plastic material sheet impregnated with one or more electrical conductive particles is patterned. Among other things, the pattern of the current collector can include an extruded slot or adjacently-disposable strips.

Abstract: Methods of manufacturing a fuel cell array that include selectively removing portions of a coating layer from a composite layer. The composite layer includes a first surface and a second surface and a first coating is disposed over at least a portion of the first surface. A laser or mechanical tool is used to selectively remove portions of the first coating to form discontinuity regions at predetermined positions in the first coating.

Abstract: MEAs are formed in regions corresponding to openings provided in a substrate. Each MEA includes an electrolyte membrane, an anode catalyst layer, and a cathode catalyst layer. The substrate has a first gas-impermeable region and a second gas-impermeable region between adjacent MEAs. A third gas-impermeable region is provided between the first gas-impermeable region and the second gas-impermeable region. The third gas-impermeable region having conductive property constitutes a part of interconnector.

Abstract: MEAs are formed in regions corresponding to openings provided in a substrate. Each MEA includes an electrolyte membrane, an anode catalyst layer, and a cathode catalyst layer. The substrate has a first gas-impermeable region and a second gas-impermeable region between adjacent MEAs. A third gas-impermeable region is provided between the first gas-impermeable region and the second gas-impermeable region. The third gas-impermeable region having conductive property constitutes a part of interconnector.

Abstract: Methods of manufacturing electrochemical cells having a current collector which, at least in part, underlies a catalyst layer are discussed. A method comprises patterning a current collector to have at least one electrolyte opening, disposing an electrolyte into or through the at least one opening, and disposing a catalyst, at least in part, over the disposed electrolyte. Optionally, the method comprises pattering a substrate and attaching a patterned current collector to each side thereof. Patterning of the current collector can include patterning a continuous sheet, which comprises at least a first and a second separable current collector. In one such example, a continuous carbon-fiber sheet impregnated or laminated with a non-porous material is patterned. In another such example, a continuous plastic material sheet impregnated with one or more electrical conductive particles is patterned. Among other things, the pattern of the current collector can include an extruded slot or adjacently-disposable strips.