Abstract: A frame equipped membrane electrode assembly includes a membrane electrode assembly and a frame member having a first frame shaped sheet provided on an outer peripheral portion of the membrane electrode assembly over the entire periphery. An outer peripheral portion of an electrolyte membrane is provided between a cathode and the first frame shaped sheet, stacked on an outer peripheral portion of the cathode, and joined to an inner peripheral portion of the first frame shaped sheet through an adhesive layer. The adhesive layer is filled in an area surrounded by an inner peripheral end of the first frame shaped sheet, an anode, and the electrolyte membrane.

Abstract: A frame equipped membrane electrode assembly includes a membrane electrode assembly and a frame member having a first frame shaped sheet provided on an outer peripheral portion of the membrane electrode assembly. An outer peripheral portion of an electrolyte membrane is provided between a cathode and the first frame shaped sheet, stacked on an outer peripheral portion of the cathode, and joined to an inner peripheral portion of the first frame shaped sheet through an adhesive layer. The elastic modulus of the first frame shaped sheet is larger than the elastic modulus of the electrolyte membrane. The elastic modulus of the adhesive layer is smaller than the elastic modulus of the first frame shaped sheet and the elastic modulus of the electrolyte membrane.

Abstract: A frame equipped membrane electrode assembly includes a membrane electrode assembly and a frame member having a first frame shaped sheet provided on an outer peripheral portion of the membrane electrode assembly. An outer peripheral portion of an electrolyte membrane is provided between a cathode and the first frame shaped sheet, stacked on an outer peripheral portion of the cathode, and joined to an inner peripheral portion of the first frame shaped sheet through an adhesive layer. The elastic modulus of the first frame shaped sheet is larger than the elastic modulus of the electrolyte membrane. The elastic modulus of the adhesive layer is smaller than the elastic modulus of the first frame shaped sheet and the elastic modulus of the electrolyte membrane.

Abstract: A frame equipped membrane electrode assembly includes a membrane electrode assembly and a frame member having a first frame shaped sheet provided on an outer peripheral portion of the membrane electrode assembly over the entire periphery. An outer peripheral portion of an electrolyte membrane is provided between a cathode and the first frame shaped sheet, stacked on an outer peripheral portion of the cathode, and joined to an inner peripheral portion of the first frame shaped sheet through an adhesive layer. The adhesive layer is filled in an area surrounded by an inner peripheral end of the first frame shaped sheet, an anode, and the electrolyte membrane.

Abstract: A fuel cell stack assembly is provided which includes a first bipolar plate, a second bipolar plate, a sub-gasket, and a gas diffusion layer. The second bipolar plate may define a bypass channel with the first bipolar plate. The bypass channel includes at least one embossment formed therein. The gas diffusion layer may be disposed between the first bipolar plate and the second bipolar plate while the sub-gasket is sandwiched between metal bead seals formed in each of the first bipolar plate and the second bi-polar plate.

Abstract: A fuel cell component includes a sub-gasket including a structural component and a thermally conductive layer. The sub-gasket defines a central opening while the structural component includes a first side and a second side. The sub-gasket also has an inner portion proximate to the central opening and an outer portion. The inner portion is positioned between the cathode layer outer edge and the ion-conducting membrane outer edge or between the anode layer outer edge and the ion-conducting membrane outer edge. Finally, the thermally conductive layer contacts the second side of the structural component. Advantageously, the thermally conductive layer dissipates locally generated heat caused by unintended particles falling on the sub-gasket.

Abstract: One embodiment includes a method comprising the steps of providing a first dry catalyst coated gas diffusion media layer, depositing a wet first proton exchange membrane layer over the first catalyst coated gas diffusion media layer to form a first proton exchange membrane layer; providing a second dry catalyst coated gas diffusion media layer; contacting the second dry catalyst coated gas diffusion media layer with the first proton exchange membrane layer; and hot pressing together the first and second dry catalyst coated gas diffusion media layers with the wet proton exchange membrane layer therebetween.

Abstract: A fuel cell stack assembly is provided which includes a first bipolar plate, a second bipolar plate, a sub-gasket, and a gas diffusion layer. The second bipolar plate may define a bypass channel with the first bipolar plate. The bypass channel includes at least one embossment formed therein. The gas diffusion layer may be disposed between the first bipolar plate and the second bipolar plate while the sub-gasket is sandwiched between metal bead seals formed in each of the first bipolar plate and the second bi-polar plate.

Abstract: Bipolar plates for a fuel cell stack that include opposing stamped metal plate halves having specialized embossed features so that when the stack is assembled, the embossed features of opposing plate halves are positioned relative to each other so that a centerline of opposing seal paths are offset to create offsets between more rigid sections and less rigid sections in the bipolar plate that allows for more uniform sealing along bead seals between the plate halves under the compressive assembly force.

Abstract: One embodiment includes a method comprising the steps of providing a first dry catalyst coated gas diffusion media layer, depositing a wet first proton exchange membrane layer over the first catalyst coated gas diffusion media layer to form a first proton exchange membrane layer; providing a second dry catalyst coated gas diffusion media layer; contacting the second dry catalyst coated gas diffusion media layer with the first proton exchange membrane layer; and hot pressing together the first and second dry catalyst coated gas diffusion media layers with the wet proton exchange membrane layer therebetween.

Abstract: One embodiment includes a method comprising providing a first catalyst coated gas diffusion media layer, depositing a wet first proton exchange membrane layer over the first catalyst coated gas diffusion media layer to form a first proton exchange membrane layer; providing a second catalyst coated gas diffusion media layer; contacting the second catalyst coated gas diffusion media layer, or second proton exchange membrane layer, with the first proton exchange membrane layer; and hot pressing together the catalyst coated diffusion layers and proton exchange membrane layer(s).

Abstract: A fuel cell system comprises a main body including a first partial header and a fastening point. The main body is adapted to be coupled to a plurality of plates forming a fuel cell stack, allowing a single plate design to be used for multiple fuel cell stack lengths having a large differential of energy requirements, affording a durable alignment mechanism for the fuel cell stack, and providing integration flexibility for components and configurations of the fuel cell system.

Abstract: A bipolar plate for a fuel cell has a first end, a second end, a first side, and a second side. The bipolar plate also has an active region, a feed region, a perimeter region, a sealing region, and a hinge region. The sealing region is disposed between the perimeter region and each of the active region and the feed region. A plurality of outwardly extending tabs are disposed adjacent the perimeter region at each of the first end and the second end of the bipolar plate. The hinge region is disposed between the perimeter region and the outwardly extending tabs. The hinge region extends from the first side of the plate to the second side of the bipolar plate. The hinge region permits a flexing of the outwardly extending tabs to connect with peripheral electrical device without undesirably flexing the sealing region.

Abstract: A method for forming variable section thicknesses from a uniformly thick resinous sheet in a PEM fuel cell. A method for forming a seal in a fuel cell includes a step of providing a sheet including a layer of resinous material. A first fold is formed in the sheet. The first fold extends from a substantially planar section of the sheet having a first side section and a second side section opposing the first side section and connected by a top section. A gasket is formed by folding the first fold over towards the planar section to form a compound fold. The compound fold is placed between a first fuel cell component and a second fuel cell component to form the seal therein. A fuel cell incorporating the gasket is also provided.

Abstract: A fuel cell stack of at least two fuel cells, each fuel cell having a unitized electrode assembly (UEA) including a membrane electrode assembly (MEA), a sub-gasket and gas diffusion media (DM), and positioned between modified stamped field-flow plates. The sub-gasket frames the MEA resulting in an overlap area between the MEA and the inner perimeter of the sub-gasket. The UEA is disposed between a pair of stamped flow-field plates which align in adjacent fuel cells to form a bipolar plate. The bipolar plate has an active region, an overlap region and a seal region. The active region is configured with channel and land features which provide reactant flow channels and coolant passages for the fuel cell. The configuration of features in the overlap region, however, is modified from the configuration in the active region so that the overlap region may sustain sufficient mechanical sealing pressure, and to prevent coolant and reactant bypass without impeding coolant and reactant flow in the active area.

Abstract: A method for forming variable section thicknesses from a uniformly thick resinous sheet in a PEM fuel cell. A method for forming a seal in a fuel cell includes a step of providing a sheet including a layer of resinous material. A first fold is formed in the sheet. The first fold extends from a substantially planar section of the sheet having a first side section and a second side section opposing the first side section and connected by a top section. A gasket is formed by folding the first fold over towards the planar section to form a compound fold. The compound fold is placed between a first fuel cell component and a second fuel cell component to form the seal therein. A fuel cell incorporating the gasket is also provided.

Abstract: A fuel cell system comprises a main body including a first partial header and a fastening point. The main body is adapted to be coupled to a plurality of plates forming a fuel cell stack, allowing a single plate design to be used for multiple fuel cell stack lengths having a large differential of energy requirements, affording a durable alignment mechanism for the fuel cell stack, and providing integration flexibility for components and configurations of the fuel cell system.

Abstract: A fuel cell system comprises a main body including a first partial header and a fastening point. The main body is adapted to be coupled to a plurality of plates forming a fuel cell stack, allowing a single plate design to be used for multiple fuel cell stack lengths having a large differential of energy requirements, affording a durable alignment mechanism for the fuel cell stack, and providing integration flexibility for components and configurations of the fuel cell system.

Abstract: A UEA for a fuel cell having an active region and a feed region is provided. The UEA includes an electrolyte membrane disposed between a pair of electrodes. The electrolyte membrane and the pair of electrodes is further disposed between a pair of DM. The electrolyte membrane, the pair of electrodes, and the DM are configured to be disposed at the active region of the fuel cell. A barrier film coupled to the electrolyte membrane is configured to be disposed at the feed region of the fuel cell. The dimensions of the electrolyte membrane are thereby optimized. A fuel cell having the UEA, and a fuel cell stack formed from a plurality of the fuel cells, is also provided.

Abstract: A fuel cell stack of at least two fuel cells, each fuel cell having a unitized electrode assembly (UEA) including a membrane electrode assembly (MEA), a sub-gasket and gas diffusion media (DM), and positioned between modified stamped field-flow plates. The sub-gasket frames the MEA resulting in an overlap area between the MEA and the inner perimeter of the sub-gasket. The UEA is disposed between a pair of stamped flow-field plates which align in adjacent fuel cells to form a bipolar plate. The bipolar plate has an active region, an overlap region and a seal region. The active region is configured with channel and land features which provide reactant flow channels and coolant passages for the fuel cell. The configuration of features in the overlap region, however, is modified from the configuration in the active region so that the overlap region may sustain sufficient mechanical sealing pressure, and to prevent coolant and reactant bypass without impeding coolant and reactant flow in the active area.