Abstract: An electrochemical includes a membrane electrode assembly comprising a proton exchange membrane with a cathode catalyst between the proton exchange membrane and a gas diffusion layer, and with an anode catalyst between the proton exchange membrane and a porous transport layer. The cathode catalyst and the anode catalyst extend substantially to an outermost peripheral edge of the proton exchange membrane. A thermoplastic film is impregnated within outer peripheral edges of the gas diffusion layer and the porous transport layer to form an electrochemical assembly with a sealed outer edge. A method of forming an electrochemical device is also disclosed.

Abstract: A electrochemical device includes a membrane electrode assembly, a gas diffusion layer positioned on one side of the membrane electrode assembly, and a porous transport layer positioned on an opposite side of the membrane electrode assembly. A thermoplastic film is impregnated within outer peripheral edges of the gas diffusion layer and the porous transport layer to form an electrochemical assembly with a sealed outer edge. A method of forming a an electrochemical device is also disclosed.

Abstract: An illustrative example embodiment of method of making a fuel cell component includes placing a graphite substrate and a polytetrafluoroethylene (PTFE) layer in a heated press with a fluoroelastomer adhesive between the graphite substrate and the PTFE layer; pressing the PTFE layer, the fluoroelastomer adhesive and the graphite substrate together using the heated press; removing the graphite substrate, the fluoroelastomer adhesive and the PTFE layer from the heated press; and allowing the graphite substrate, the fluoroelastomer adhesive, and the PTFE layer to cool.