Abstract: An electrode assembly and a method of making an electrode assembly. One embodiment of the method includes coating an ionomer solution onto a catalyst coated diffusion media to form a wet ionomer layer, and applying a porous reinforcement layer to the wet ionomer layer such that the wet ionomer layer at least partially impregnates the reinforcement layer. Drying the wet ionomer layer with the impregnated reinforcement layer and joining it to the catalyst coated diffusion media forms an assembly that includes an integrally-reinforced proton exchange membrane layer. This layer may be additionally joined to other ionomer layers and other catalyst coated diffusion media such that a membrane electrode assembly is formed.

Abstract: A process including coating a fuel cell component with an aqueous solution including a polyelectrolyte polymer.

Abstract: Methods of making a substantially crack-free electrode layer are described. The methods include depositing an electrode ink on a substrate; placing a layer of porous reinforcement layer on a surface of the wet electrode ink; and drying the electrode ink to form the substantially crack-free electrode layer on the substrate. Substantially crack-free electrode layers and fuel cells incorporating substantially crack-free electrode layers are also described.

Abstract: A process comprising: submerging a fuel cell bipolar plate in a bath comprising nanoparticles and a liquid phase comprising a nanoparticles dispersion agent and wherein the bipolar plate includes an upper surface having a plurality of lands and channels formed therein; removing the fuel cell bipolar plate from the bath so that a coating comprising nanoparticles adheres to the fuel cell bipolar plate; while the coating is wet and before the coating is dried and solidified, removing the coating comprising nanoparticles from the lands of the bipolar plate, leaving coating comprising nanoparticle in the channels; and drying the coating in the channels.

Abstract: A reduced gas crossover fuel cell membrane and method of making. The fuel cell member includes an electrode layer with a catalyst and an electrochemically-active first ionomer and an overcoat layer disposed on the electrode layer. The overcoat layer is made of the same or different second ionomer relative to the first ionomer of the electrode layer with at least one reduced gas crossover characteristic.

Abstract: An electrode assembly and a method of making an electrode assembly. One embodiment of the method includes coating an ionomer solution onto a catalyst coated diffusion media to form a wet ionomer layer, and applying a porous reinforcement layer to the wet ionomer layer such that the wet ionomer layer at least partially impregnates the reinforcement layer. Drying the wet ionomer layer with the impregnated reinforcement layer and joining it to the catalyst coated diffusion media forms an assembly that includes an integrally-reinforced proton exchange membrane layer. This layer may be additionally joined to other ionomer layers and other catalyst coated diffusion media such that a membrane electrode assembly is formed.

Abstract: A unitized electrode assembly for a fuel cell comprising an electrolyte membrane, a subgasket, and a sealing bead disposed therebetween is disclosed. The sealing bead adapted to fill a tenting region formed between the membrane and the subgasket to maximize an operating life of the electrolyte membrane by militating against wear of membrane expansion during use of the fuel cell.

Abstract: Methods of making a substantially crack-free electrode layer are described. The methods include depositing an electrode ink on a substrate; placing a layer of porous reinforcement layer on a surface of the wet electrode ink; and drying the electrode ink to form the substantially crack-free electrode layer on the substrate. Substantially crack-free electrode layers and fuel cells incorporating substantially crack-free electrode layers are also described.

Abstract: A process including coating a fuel cell component using a coating solution including nanoparticles.

Abstract: A unitized electrode assembly for a fuel cell comprising an electrolyte membrane, a subgasket, and a sealing bead disposed therebetween is disclosed. The sealing bead adapted to fill a tenting region formed between the membrane and the subgasket to maximize an operating life of the electrolyte membrane by militating against wear of membrane expansion during use of the fuel cell.

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

Abstract: A method of making a fuel cell component using a mask, which is removed after further processing to yield a surface with variable properties.