Abstract: A fuel cell membrane electrode assembly (MEA) comprising first and second gas diffusion layers and an ion exchange membrane disposed between the diffusion layers. Each diffusion layer includes an inner surface facing the membrane, an outer surface opposite the inner surface, and a side surface defining a perimeter of the diffusion layers. An outboard region extends about the diffusion layers at the perimeter. The outboard region surrounds an inboard region. The outboard region has a low density region proximate to the side surface and a high density region between the low density region and the inboard portion. A seal is mounted at the low density region. The high density region prevents portions of the seal from entering the inboard region thereby damaging the MEA. The seal includes a first rim having a smaller radius than a second rim.

Abstract: A gasket is formed using a plurality of compression limiting inserts each having first and second surfaces, and at least one edge disposed between the first and second surfaces with an elastomeric sealing material bonded thereto. Opposite ends of each of the compression limiting inserts are aligned with, and spliced to, adjacent ones of the compression limiting inserts by the elastomeric sealing material. The plurality of compression limiting inserts are aligned to form a completed gasket.

Abstract: An integrated gasket and membrane electrode assembly (MEA) for a fuel cell includes a first gasket having a first perimeter surface and an MEA having a first surface. A portion of the first surface is bonded to the first perimeter surface. Alternatively, the integrated gasket and MEA includes a first gasket having a first perimeter surface and a second gasket having a second perimeter surface. Portions of the first and second perimeter surfaces are bonded together. An MEA is disposed between the first gasket and the second gasket. Bonding is achieved by heat staking, friction welding or vibration welding.

Abstract: Fuel cell gaskets are employed to seal around an individual cell of a fuel cell assembly. The gaskets are made of a flexible material, and each includes at least one alignment feature defined by a partially formed hole creating a flap, with the flap being integral with its gasket. The gasket may be a multi-piece gasket with a carrier material having an elastomeric seal portion secured to it. One or both pieces of the multi-piece gasket may include one or more alignment features.