Abstract: A unitized electrode assembly for a fuel cell stack assembly, includes a membrane electrode assembly having a first side, a second side, a peripheral edge area and a plurality of perforations along the peripheral edge area; a cathode substrate adjacent to the first side; an anode substrate adjacent to the second side; and a seal material bonding the cathode substrate to the anode substrate and extending through the plurality of perforations.

Abstract: A sealant system 13 for a manifold 10 of a proton exchange membrane fuel cell includes low temperature cured or heat cured silicone rubber bridges 14, 14a, 14c between the end plates 9 to compensate for the uneven edges of various fuel cell component layers, and a layer 15 of silicone rubber foam or sponge, or a molded silicone rubber gasket 15a, extending across the bridges and along the end plates, around the entire contact perimeter surfaces of the manifold, to seal the manifold to the fuel cell. The cured silicone rubber may extend along the end plates between the bridges. A rubber strip 20 may be adhered to the silicone rubber bridges and end plates. The bridges may comprise a first layer 22 of low shrinkage self-leveling RTV liquid rubber with viscosity in the range of 10,000-20,000 cps and a second layer 14 of RTV liquid rubber.

Abstract: A unitized electrode assembly for a fuel cell stack assembly, includes a membrane electrode assembly having a first side, a second side, a peripheral edge area and a plurality of perforations along the peripheral edge area; a cathode substrate adjacent to the first side; an anode substrate adjacent to the second side; and a seal material bonding the cathode substrate to the anode substrate and extending through the plurality of perforations.

Abstract: A stack (200) of fuel cells (202) sealed together with a formed elastomer seal (206) is disclosed. Each of the individual cell components are bonded to one another with thermoplastic film (204). As a result, only one formed elastomer seal (206) is required for each fuel cell (202) within a stack (200) to provide a modular fuel cell stack assembly (200).

Abstract: A sub-stack assembly 100 of a number of cells 102 bonded together with thermoplastic film 104 is disclosed. Each of the individual cell components are bonded to one another with thermoplastic film 104. A number of sub-stack assemblies 100 are stacked and sealed relative to one another by a soft compliant gasket seal 106, such as a foam rubber or other suitable materials. As a result, only one soft foam rubber seal 106 would be required for each sub-stack assembly 100 rather than for every cell.

Abstract: A sealant system 13 for a manifold 10 of a proton exchange membrane fuel cell includes low temperature cured or heat cured silicone rubber bridges 14, 14a, 14c between the end plates 9 to compensate for the uneven edges of various fuel cell component layers, and a layer 15 of silicone rubber foam or sponge, or a molded silicone rubber gasket 15a, extending across the bridges and along the end plates, around the entire contact perimeter surfaces of the manifold, to seal the manifold to the fuel cell. The cured silicone rubber may extend along the end plates between the bridges. A rubber strip 20 may be adhered to the silicone rubber bridges and end plates. The bridges may comprise a first layer 22 of low shrinkage self-leveling RTV liquid rubber with viscosity in the range of 10,000-20,000 cps and a second layer 14 of RTV liquid rubber.

Abstract: A stack (200) of fuel cells (202) sealed together with a formed elastomer seal (206) is disclosed. Each of the individual cell components are bonded to one another with thermoplastic film (204). As a result, only one formed elastomer seal (206) is required for each fuel cell (202) within a stack (200) to provide a modular fuel cell stack assembly (200).

Abstract: A fuel cell stack includes a plurality of fuel cells, each of which includes a membrane electrode assembly and a water transport plate, or a fluid flow plate fabricated from graphite. This plate and optionally a separator plate are held in assembled relationship with one another and with the membrane electrode assemblies by a fluoroelastomeric adhesive/sealant that is also coated on the external edges of these components to provide a water-tight seal to better contain the coolant fluid in the form of water provided in the fuel cell stack.

Abstract: An improved membrane electrode assembly for PEM fuel cells is provided. Catalyst layers (40, 44) are disposed, respectively, on both sides of the proton exchange membrane (48). Gas diffusion layers (38, 50) are disposed, respectively, on sides of the catalyst layers (40, 44) not in contact with the proton exchange membrane (48). Porous substrates (32, 34) are disposed, respectively, on sides of the gas diffusion layers (38, 50) not in contact with the catalyst layers (40, 44). The porous substrates (32, 34) are impregnated at their periphery with a thermoplastic material. Thermoplastic film layers (42, 46, 68) are employed at the periphery of the assembly (10) between component parts to bond and seal water transport plates (12' and 16) to each other, as well as substrates (32, 32', 34) to the membrane electrode assembly (20). A foam tape 60, 62, 62' are employed to seal water transport plates (12, 12', 16) to respective substrates (32, 32', 34).

Abstract: An improved membrane electrode assembly for PEM fuel cells is provided. Catalyst layers (40, 44) are disposed, respectively, on both sides of the full planform proton exchange membrane (48). Gas diffusion layers (38, 50) are disposed, respectively, on sides of the catalyst layers (40, 44) not in communication with the full planform proton exchange membrane (48). Porous substrates (32, 34) are disposed, respectively, on sides of the gas diffusion layers (38, 50) not in communication with the catalyst layers (40, 44). The porous substrates (32, 34) are impregnated at their periphery with a sealant. The gas diffusion layers (38, 50) are coated with a sealant (60, 62) on respective sides thereof in regions which are in communication with sealant impregnated regions (36, 52) of the porous substrates (32, 34). The gas diffusion layers (38, 50), the porous substrates (32, 34), and the catalyst layers (40, 44) are co-extensive with the proton exchange membrane (48).

Abstract: A support plate for a proton exchange membrane fuel cell includes a porous support body that has a central portion and a peripheral portion integral with and circumferentially completely surrounding the central portion, and a sealing body of elastomeric sealing material that completely fills the pores of the peripheral portion to make it impermeable to fluids. The support plate may be assembled with another one and with a proton exchange membrane interposed between the two support plates to form an assembly, and the sealing body then peripherally joins and seals the assembly and fills any gaps that may be present between the peripheral portions due to the absence of the membrane from such regions and thus to peripherally encapsulate the membrane.

Abstract: A butyl rubber/ethylene propylene latex sealant for use in fuel cells is disclosed. The sealant is comprised of between about 50 wt % and about 99 wt % butyl rubber and about 10 wt % to about 50 wt % ethylene propylene latex. Conventional fillers can be added to the sealant to attain or enhance various properties such as: desired viscosity, specific gravity, stability, strength, oxidation resistance, and accelerated cure.

Abstract: A method of forming thin porous sheets of ceramic material for use as electrodes or other components in a molten carbonate fuel cell is disclosed. The method involves spray drying a slurry of fine ceramic particles in liquid carrier to produce generally spherical agglomerates of high porosity and a rough surface texture. The ceramic particles may include the electrode catalyst and the agglomerates can be calcined to improve mechanical strength. After slurrying with suitable volatile material and binder tape casting is used to form sheets that are sufficiently strong for further processing and handling in the assembly of a high temperature fuel cell.