Abstract: A method for manufacturing a fuel cell includes the steps of: (1) providing a first bipolar plate and a second bipolar plate; (2) applying a first microseal to the first bipolar plate at a first metal bead seal region; (3) applying a first contaminant seal to the first microseal and the first metal bead seal region of the first bipolar plate, the first contaminant seal being configured to protect the first metal bead seal region from a debris piece; (4) assembling a UEA having a subgasket onto the first bipolar plate with a debris piece engaging with the first contaminant seal; and (5) compressing the second bipolar plate onto the first bipolar plate with the subgasket in-between while urging the first contaminant seal and the debris piece away from the first metal bead seal region. Alternatively, the first and second contaminant seals may be applied to the subgasket.

Abstract: A method for manufacturing a fuel cell includes the steps of: (1) providing a first bipolar plate and a second bipolar plate; (2) applying a first microseal to the first bipolar plate at a first metal bead seal region; (3) applying a first contaminant seal to the first microseal and the first metal bead seal region of the first bipolar plate, the first contaminant seal being configured to protect the first metal bead seal region from a debris piece; (4) assembling a UEA having a subgasket onto the first bipolar plate with a debris piece engaging with the first contaminant seal; and (5) compressing the second bipolar plate onto the first bipolar plate with the subgasket in-between while urging the first contaminant seal and the debris piece away from the first metal bead seal region. Alternatively, the first and second contaminant seals may be applied to the subgasket.

Abstract: One embodiment of the invention includes a method including applying a first ink comprising carbon over a substrate and drying the first ink to form a first electrode layer, applying a second ink including a second catalyst over the first electrode layer and drying the second ink to form a second electrode layer, and applying a third ink comprising an ionomer solution over the second electrode layer and drying the third ink to form an ionomer overcoat.

Abstract: A method including providing an ion conductive membrane and deactivating a selected region of the membrane.

Abstract: One embodiment of the invention includes a method including applying a first ink comprising carbon over a substrate and drying the first ink to form a first electrode layer, applying a second ink including a second catalyst over the first electrode layer and drying the second ink to form a second electrode layer, and applying a third ink comprising an ionomer solution over the second electrode layer and drying the third ink to form an ionomer overcoat.

Abstract: One exemplary embodiment may include an electrode including a hydrophobic material.

Abstract: A method of manufacturing a fuel cell membrane electrode assembly comprising forming and compressing a stack having a plurality of layers in a desired orientation. The layers comprise a membrane, a cathode, an anode, and at least one edge protection layer. The method includes providing at least one mechanical reinforcing layer adjacent the anode or cathode layer, and allowing the electrodes to relax under high heat to remove stress prior to lamination.

Abstract: A fuel cell system is provided including a fuel cell stack having a fuel cell having an anode, an anode outlet, an anode inlet, and a cathode. The fuel cell system further includes a hydrogen pump in communication with the anode outlet and the anode inlet. The hydrogen pump features a proton exchange membrane disposed between a first electrode and a second electrode. The first electrode is configured to accept an anode outlet stream from the anode outlet, the anode outlet stream including a hydrogen gas and an inert gas, the first electrode being configured to exhaust the inert gas. In one embodiment, the hydrogen pump is in communication with a PROX unit and configured to provide the hydrogen gas to the fuel cell stack. Further provided are methods employing the hydrogen pump wherein a start-stop degradation of the fuel cell is militated against and a hydrogen feed stream is humidified.

Abstract: A method including providing an ion conductive membrane and deactivating a selected region of the membrane.