Abstract: The disclosure relates to fuel cell systems including a multiplicity of unit fuel cells arranged in a stack, with each unit fuel cell separated by an electrode separator assembly. Each unit fuel cell includes a membrane electrode assembly with an anode, a cathode, and a solid polymer electrolyte membrane disposed between the anode and the cathode. An anode separator is positioned between each membrane electrode assembly of adjoining unit fuel cells within the stack in contact with an anode, and a cathode separator is positioned between each membrane electrode assembly of adjoining unit fuel cells within the stack in contact with a cathode. A surface of an anode separator is joined to a surface of a cathode separator of an adjoining unit fuel cell to form an electrode separator assembly. The disclosure also relates to a method of making a fuel cell assembly.

Abstract: A method and system for fabricating solid-state energy-storage devices including fabrication films for devices without an anneal step. A film of an energy-storage device is fabricated by depositing a first material layer to a location on a substrate. Energy is supplied directly to the material forming the film. The energy can be in the form of energized ions of a second material. Supplying energy directly to the material and/or the film being deposited assists in controlling the growth and stoichiometry of the film. The method allows for the fabrication of ultrathin films such as electrolyte films and dielectric films.

Abstract: A battery module comprises: first and second rechargeable batteries, each of which includes a casing for storing an electrode assembly and a cap assembly provided on top of the casing; an interconnector provided between an upper portion of the first rechargeable battery and a lower portion of the second rechargeable battery so as to connect the first and second rechargeable batteries with each other; and an insulation cover which covers interconnected portions of the first and second rechargeable batteries, and which has at least one ventilation outlet.

Abstract: A lithium-ion polymer battery, and methods and apparatus for manufacturing the same, are disclosed. The methods include placing a bottom surface of an electrode on a coating surface, such that a top surface of the electrode is exposed, forming a removable retention boundary on the coating surface and surrounding the electrode, including a space between the electrode edges and the retention boundary, depositing polymer electrolyte solution on the electrode, on the coating surface, and within the retention boundary, and allowing the polymer electrolyte solution to dry until all of the deposited polymer electrolyte solution becomes a solid polymer composite that extends beyond the electrode edges.

Abstract: A lithium-ion polymer battery and method and apparatus for manufacturing the same, are disclosed. The battery includes an anode comprising a first electrolytic solution and a cathode comprising a second electrolytic solution, and the first and second electrolytic solutions are different. The method includes activating the anode and the cathode in the different electrolytic solutions prior to battery assembly and prior to forming an SEI layer on the anode surface.

Abstract: A lithium-ion polymer battery, and methods and apparatus for manufacturing the same, are disclosed. The methods include forming an anode with a porous material having spaces that contain an electrolytic solution, placing the anode surface in contact with a layer of lithium metal, and shorting the layer of lithium metal to a current collector so that lithium ions are released from the layer of lithium metal and forming SEI layer on the anode surface through the reaction with the electrolyte reduction products.

Abstract: When lead plates (10) for industrial batteries are jacketed the lead plate (10) is surrounded with a first layer (12) of fiber nonwoven, with a second layer (24) of fiber nonwoven, with a layer (28) of punched or perforated plastic film and with a sleeve (30) of separator material. To simplify the jacketing, the second layer (24) of nonwoven and the layer (28) of plastic film are folded jointly around the lengthwise edges (20, 22) of the lead plate (10) and immediately after the first layer (12) of nonwoven has been folded around the lead plate (10). To do this, the lead plate (10) which has been jacketed in the first layer (12) of nonwoven and the second layer (24) and the layer (28) of plastic film are moved jointly into a folding station (C). In the folding station (C) the layer (28) of plastic film for purposes of securing the two nonwoven layers (12) and (24) which have been placed around the lead plates (10) are closed into a sleeve by joining their lengthwise edges to one another.

Abstract: A device of the present invention is used for forming a layered battery cell having at least first electrode and at least one second electrode of charge opposite from said first electrode and a separator layer positioned between the first and second electrodes and at least one of a first current collector connected to at least one of the first and second electrodes and at least one of a second current collector connected to at least one of the first and second electrodes. At least one support member is integrated with an assembly line. A plurality of pins extend from the support member for receiving the first and second electrodes and the first and second current collectors layered with one another to assemble the same into a unitary package.

Abstract: A method of coupling a shunt to a printed circuit board (PCB) of an energy management system is provided. The method includes coupling flexible electrical connectors to the shunt and soldering the flexible electrical connectors to connection points on the PCB of the energy management system. An energy management system that includes a shunt coupled to a printed circuit board using the above method is also provided.

Abstract: A registration arrangement for a fuel cell stack assembly incorporates registration posts and registration apertures or recesses. Fuel cell assemblies of the stack may include first and second flow field plates and a membrane electrode assembly (MEA) having an active area. Registration apertures are defined in each of the MEA and the first and second flow field plates. The respective registration apertures are situated within non-active areas of the MEA when the first and second flow field plates and the MEA are in axial alignment. Registration posts are configured for reception within the registration apertures. Each of the registration posts has an outer surface differing in shape from a shape of the inner surface of the registration apertures. The inner surface of the registration apertures contact the outer surface of the registration posts at a plurality of discrete press-fit locations.

Abstract: A cordless welding machine includes first and second batteries being connected in parallel, a ground clamp connected to the first and second batteries, and a first welding electrode connected to the first and second batteries. The batteries providing a current output of at least about 40 amps.

Abstract: An apparatus for forming groups of battery plates includes at least first and second plate supply lines each including a separation station and a downstream plate supply. The apparatus further includes a first common plate feed line for the envelopers and a second common plate feed line for the downstream plate supplys.

Abstract: A sealing technique is provided for forming complex and multiple seal configurations for fuel cells and other electrochemical cells. To provide a seal, for sealing chambers for oxidant, fuel and/or coolant, a groove network is provided extending through the various elements of the fuel cell assembly. A source of seal material is then connected to an external filling port and injected into the groove network, and the seal material is then cured to form the seal. There is thus formed a “seal in place”, that is robust and can accommodate variations in tolerances and dimensions, and that can be bonded, where possible, to individual elements of the fuel cell assembly. This avoids the difficulty, labor intensive cost and complexity of manually assembling many individual gaskets into complex groove shapes and the like. The seal material can be selected to be comparable with a wide variety of gases, liquid coolants and the like.

Abstract: A method and system for fabricating solid-state energy-storage devices including fabrication films for devices without an anneal step. A film of an energy-storage device is fabricated by depositing a first material layer to a location on a substrate. Energy is supplied directly to the material forming the film. The energy can be in the form of energized ions of a second material. Supplying energy directly to the material and/or the film being deposited assists in controlling the growth and stoichiometry of the film. The method allows for the fabrication of ultrathin films such as electrolyte films and dielectric films.

Abstract: A method of making an electrolytic cell in which an electrolyte layer of an intermediate sintered form is coated with a pre-coat layer containing electrically non-conductive particles of less than about one-tenth of a micron in size to fill in defects existing within the electrolyte layer. The pre-coat layer is removed so that the electrically non-conductive particles remain within the defects of the electrolyte layer. The cathode layer is then applied to the electrolyte layer with the electrically non-conductive particles in place within the defects. The intermediate sintered form is fired with the applied cathode layer to produce the electrolytic cell.

Abstract: A fuel cell assembly including a liquid metal seal and/or a liquid metal interconnect.

Abstract: A method and apparatus for cold forming a battery terminal having a base and an insert. The insert includes a first portion encapsulated within the base and a second portion that extends beyond a first side of the base.

Abstract: Electrocatalyst powders and methods for producing electrocatalyst powders, such as carbon composite electrocatalyst powders. The powders have a well-controlled microstructure and morphology. The method includes forming the particles from an aerosol of precursors by heating the aerosol to a relatively low temperature, such as not greater than about 400° C.

Abstract: A method for fabricating membrane electrode assembly includes providing an anode side diffusion layer structure and a cathode side diffusion layer structure with a layer of membrane electrolyte therebetween. The diffusion layer structures include diffusion segments, which are coupled to each other by a first engaging member having one or more portions configured for engagement with a feed or aligning mechanism. Also, one or more of the segments of the diffusion layer structures may be connected to other segments or the first engaging member by one or more bridges. Bridges of each diffusion layer structure may be offset to avoid electrical contact with each other in response to diffusion layer structures being assembled with each other and with the layer of membrane electrolyte.

Abstract: A system for making a thin-film device includes a substrate-supply station that supplies a substrate having a major surface area. The substrate has a first layer on a first surface area of the substrate's major surface area. Also included is a device for depositing a second layer onto the first layer, wherein the device supplies energy to the second layer to aid in layer formation without substantially heating the substrate.

Abstract: A method of manufacturing a lithium secondary cell capable of preventing an active material layer from oxidation and moisture absorption is obtained. This method of manufacturing a lithium secondary cell comprises steps of forming an active material layer on a collector by a method supplying raw material through discharge into a vapor phase and holding the collector formed with the active material layer at least under an inert atmosphere or under a vacuum atmosphere up to preparation of the cell. Thus, the collector formed with the active material layer is prevented from exposure to the atmosphere, whereby the active material layer is prevented from oxidation and moisture absorption. Consequently, a lithium secondary cell having excellent characteristics can be prepared.

Abstract: A method for placing an edge piece on a battery plate includes bending a thin strip of bendable plastic material into an open top, U-shaped channel. The channel is then cut into an edge piece having a length which is substantially equal to the edge of the battery plate which is to be covered. The edge piece is supported with this open top oriented towards a battery plate that is transported toward it in a manner such that the battery plate edge will be inserted into it. Once the edge of the battery plate has been inserted into the edge piece the edge piece is released so that the battery plate can be carried out of the apparatus. An apparatus for accomplishing this includes a feed mechanism which transports the strip of bendable plastic material. A bending mechanism forms this strip into the open top, U-shaped channel. The channel is then fully inserted into an assembly station where a first sensor stops the feed mechanism and a cutter cuts the channel into the proper-sized edge piece.

Abstract: An automated manufacturing system of a secondary lithium battery is disclosed.

Abstract: Epitatial thin films for use as buffer layers for high temperature superconductors, electrolytes in solid oxide fuel cells (SOFC), gas separation membranes or dielectric material in electronic devices, are disclosed. By using CCVD, CACVD or any other suitable deposition process, epitaxial films having pore-free, ideal grain boundaries, and dense structure can be formed. Several different types of materials are disclosed for use as buffer layers in high temperature superconductors. In addition, the use of epitaxial thin films for electrolytes and electrode formation in SOFCs results in densification for pore-free and ideal gain boundary/interface microstructure. Gas separation membranes for the production of oxygen and hydrogen are also disclosed. These semipermeable membranes are formed by high-quality, dense, gas-tight, pinhole free sub-micro scale layers of mixed-conducting oxides on porous ceramic substrates. Epitaxial thin films as dielectric material in capacitors are also taught herein.

Abstract: This specification discloses a thin-film gas diffusion electrode (GDE) and the method for making the same. The thin-film GDE is formed in a unitary way. A dual-nature porous thin film is used as the substrate. A surface processing is performed to make one surface of the thing film hydrophlic while the other surface hydrophobic. The hydrophlic area serves as the active layer for electrochemical reactions after chemical processing. The hydrophobic area is kept dry to form a smooth gas channel, functioning as a gas diffusion layer. In this method, the thin-film GDE is free from the use of binders and high-temperature high-pressure manufacturing processes.

Abstract: A solid polymer electrolyte membrane and a catalytic layer are properly assembled even when the solid polymer electrolyte membrane and an ion exchange resin in the catalytic layer are formed of different materials. In a fuel cell, a solid polymer electrolyte membrane 20 is provided with a first solid polymer electrolyte membrane 200, and second solid polymer electrolyte membranes 202 and 204 provided at respective sides thereof. The second solid polymer electrolyte membranes 202 and 204 are formed of the same material as the ion exchange resin (not shown) included in a catalytic layer 26 and a catalytic layer 30.

Abstract: A sheet supply section disposed along a transport way of a substrate feeds a sheet wound in a roll shape. A sheet cutting section cuts a sealing sheet to be set on the substrate from a fed portion of the sheet. A sheet set section including a transfer head of a vacuum suction type with a plurality of suction holes disposed therein reciprocates/moves the transfer head over a sheet receiving position in the sheet cutting section and a sheet covering position in the transport way. The sheet set section lowers the transfer head in the sheet receiving position, raises the transfer head at the sheet covering position. The transfer head attracts the sheet at the sheet-receiving position and does not attract the sheet at the sheet covering position the sheet covers the substrate.

Abstract: A method and system for fabricating solid-state energy-storage devices including fabrication films for devices without an anneal step, especially a cathode anneal of thin-film batteries. A film of an energy-storage device is fabricated by depositing a first material layer to a location on a substrate. Energy is supplied directly to the material forming the film. The energy can be in the form of energized ions of a second material. Supplying energy directly to the material and/or the film being deposited assists the growth of the crystalline structure of film. For lithium-ion energy-storage devices, the first material is an intercalation material, which releasably stores lithium ions therein. Supercapacitors and energy-conversion devices are also fabricated according the methods.

Abstract: A process for producing a lead-acid battery, in which a lead bushing cast in a lid b of an assembled lead-acid battery A and a pole inserted through an insertion hole in the lead bushing are welded together by applying a laser beam thereto. At the time of the laser welding, as desired, a jig is so placed around the lead bushing as to surround it and the laser welding is carried out.

Abstract: A single step method and apparatus for the production of expanded metal mesh from deformable metal strip such as lead or lead-alloy strip for use in lead-acid battery manufacture. The apparatus comprises a pair of opposed rolls each having a plurality of spaced discs having opposite side walls and circumferential, equally spaced, convexly shaped tool surfaces alternating with substantially flat surfaces, said discs having radial notches formed in the opposite sidewalls of alternate circumferential flat surfaces, whereby peripheral surfaces of opposing rolls are adapted to interact on deformable strip passing therebetween to concurrently slit and form convex wire segments and alternate nodes in said strip by intermeshing of said shaped tool surfaces.

Abstract: A prismatic battery case (3) has a configuration wherein a rectangular shorter-side plate (3a) has a thickness (A) larger than a thickness (B) of a longer-side plate (3b). When the prismatic battery case (3) is manufactured, a battery case material (8) punched into a predetermined shape undergoes deep drawing to form a first intermediate cup element (1) having a substantially elliptic cross section; the first intermediate cup element (1) undergoes redrawing successively in a plural stages to form a second intermediate cup element (2) having a substantially elliptic cross section which is smaller in minor-axis-diameter to major-axis-diameter ratio; and the second intermediate cup element (2) undergoes DI processing to form the prismatic battery case (3) having a substantially rectangular cross section wherein the thickness (A) of the shorter-side plate (3a) is made larger than the thickness (B) of the longer-side plate (3b).

Abstract: A method for producing a fuel cell unit including a membrane electrode assembly formed by a solid polymer electrolyte membrane and a pair of electrodes located at both sides of the solid polymer electrolyte membrane, and a pair of separators which hold the membrane electrode assembly. The method includes the steps of applying liquid sealant to one of a marginal portion of the solid polymer electrolyte membrane, the marginal portion being not covered by the pair of electrodes when assembled, and a surface of each of the pair of separators, the surface corresponding to the marginal portion of the solid polymer electrolyte membrane; holding the solid polymer electrolyte membrane with the pair of separators to perform temporary assembling; and solidifying the liquid sealant while maintaining a temporary assembling state.

Abstract: An apparatus for producing a thin film electrolyte is provided wherein a volatile lithium-containing precursor and a volatile phosphate-containing precursor are mixed into a plasma generated from a plasma source. The mixture is then deposited upon a substrate. The apparatus has a plasma source (13) having a primary plenum (16) and a secondary plenum (23). The primary plenum is in fluid communication with a source of nitrogen gas (47) and a source of hydrogen gas (51). The secondary plenum is in fluid communication with a first bubbler (31) and a second bubbler (38).

Abstract: An electrochemical application that utilizes amorphous fluoropolymers providing a membrane electrode assembly that is durable, uniform and possesses a good structural integrity, produced by a method that avoids a long, complicated sintering of the fluoropolymers incorporated at undesirably high temperatures.

Abstract: A polymer battery module (2) provided with tabs (4) is put in a package (5) and an open end part of the package (5) is heat-sealed by a heat-sealing machine (10). The heat-sealing machine (10) is provided with a pair of sealing heads (10a, 10b) respectively having sealing surfaces (12). The sealing surfaces (12) of the sealing heads (10a, 10b) are provided with recesses (11) in parts thereof corresponding to the tabs (4) of the polymer battery module (2) contained in the package (5) as located in place between the sealing heads (10a, 10b) for heat-sealing.

Abstract: A receptacle having an end cap, a pliable sidewall, and a fastener, for receiving and retaining a fuel cell stack in its stacked configuration during fabrication of a multi-stack fuel cell assembly, is shown and described. Methods of fabricating the assembly include stacking the fuel cell in the receptacle, compressing the fuel cell, and engaging the fastener to retain the stack in its stacked configuration and, or to retain the stack under at least partial compression.

Abstract: The present invention relates to a battery using a case of which the section of the lower part containing an electric element is square or hexagonal and the section of the upper part containing a sealing plate is circular or elliptic. By virtue of the shape of the lower part the space efficiency of the battery pack is enhanced and by virtue of the shape of the upper part the productivity of the battery is improved. Further, preferably, the corners of the lower part of the case are rounded or chamferred, whereby the temperature rise in the battery pack is suppressed.

Abstract: A machine for the automated assembly of wafers such as solar cells into strings, comprising a control system, a cell loader with wafer inspection station, a cell tab loader, a string assembly station, and a platen with adjacent pairs of individual cell, opposing edge grippers having multiple sets of vertically operable pincer action fingers for holding cells in string alignment during soldering. The string assembly station has a cooperating cell support and tab tail support mechanism providing for a tab tail hand off from one to the other with a platen indexing movements of cell pitch distance. The platen moves from the string assembly station through a soldering station consisting of a preheat, soldering, and cooling zones spaced a cell pitch distance apart. A string unloader moves completed strings through a string inspection station placing strings in a good or bad string holding area.

Abstract: An alkaline cell having a flat casing, preferably of cuboid shape. The cell can have an anode comprising zinc and a cathode comprising nickel oxyhydroxide. The casing can have a relatively small overall thickness, typically between about 5 and 10 mm, but may be larger. Cell contents can be supplied through an open end in the casing and an end cap assembly inserted therein to seal the cell. The end cap assembly includes a vent mechanism, preferably a grooved vent, which can activate, when gas pressure within the cell reaches a threshold level typically between about 250 and 800 psig (1724×103 and 5515×103 pascal gage). The cell can have a supplemental vent mechanism such as a laser welded region on the surface of the casing which may activate at higher pressure levels.

Abstract: A fuel cell in which optimum proton conductivity is maintained even in a dry atmosphere and in which the output is not lowered is provided. The fuel cell of the present invention includes a fuel electrode, an oxygen electrode and a proton conductor film disposed therebetween. The fuel electrode and the oxygen electrode are formed of powders of a carbonaceous material as an electrode material. A proton conductor composed of a carbonaceous material mainly composed of carbon and proton dissociative groups introduced into the carbonaceous material is present on the surfaces of the fuel and/or oxygen electrodes. The proton conductor can exhibit optimum proton conductivity without humidification.

Abstract: Seal means for sealing a bipolar plate to a membrane in a PEM fuel cell stack. The seal includes a thin layer of a cross-linkable silicone composition disposed between the bipolar plate and the membrane. The layer is applied as a liquid to either the plate or the membrane and preferably is polymerized prior to assembly of the stack. A preferred means for applying the composition to the bipolar plate is screen printing. Preferably, the layer has a thickness between 0.001 and 0.005 inch. The resulting fuel cell stack exhibits superior leak resistance. In a currently preferred embodiment, a layer of the silicone composition is provided at interfaces between a membrane and both an anode side and a cathode side of a bipolar plate.

Abstract: Described is a battery holding portion integrated into a mobile device and a method for its manufacturing. In particular, the battery holding portion may include a battery having an anode and/or a cathode formed in a shape corresponding to a shape of an outer surface of the battery holding portion and a connector connecting the battery to the circuitry of the mobile unit. In addition, the battery holding portion may include a protective material coating a portion of the anode and/or the cathode and a covering material coating the protective material to form an outer surface of the battery holding portion.

Abstract: When lead plates (10) for industrial batteries are jacketed the lead plate (10) is surrounded with a first layer (12) of fiber nonwoven, with a second layer (24) of fiber nonwoven, with a layer (28) of punched or perforated plastic film and with a sleeve (30) of separator material. To simplify the jacketing, the second layer (24) of nonwoven and the layer (28) of plastic film are folded jointly around the lengthwise edges (20, 22) of the lead plate (10) and immediately after the first layer (12) of nonwoven has been folded around the lead plate (10). To do this, the lead plate (10) which has been jacketed in the first layer (12) of nonwoven and the second layer (24) and the layer (28) of plastic film are moved jointly into a folding station (C). In the folding station (C) the layer (28) of plastic film for purposes of securing the two nonwoven layers (12) and (24) which have been placed around the lead plates (10) are closed into a sleeve by joining their lengthwise edges to one another.

Abstract: A workpiece, in which a lead is laid on top of a three-dimensional porous metal body, is placed between an ultrasonic horn and an anvil with a lead portion facing the ultrasonic horn. A support is raised so that the lead portion of the workpiece is pressed between the ultrasonic horn and the anvil. While being rotated around a central shaft with a motor, the ultrasonic horn vibrates at a frequency of 20 kHz in the shaft direction. Thus, the workpiece is advanced continuously, so that the lead is bonded ultrasonically to the three-dimensional porous metal body (i.e., metal-to-metal bonding is established). It is possible to provide a battery electrode that can be produced continuously at a lower running cost, reduce the faulty welding with a current collecting plate, and prevent short-circuits.

Abstract: The invention provides a fuel cell manufacturing apparatus having improved productivity and a fuel cell manufacturing method that uses the fuel cell manufacturing apparatus. The invention provides on a first substrate that is transferred by use of a belt conveyer that is driven by a driver based on a signal from a controller, by use of discharge devices, a first gas flow path for supplying a first reaction gas is formed. Subsequently, on the first substrate that is transferred by the belt conveyer, by use of discharge devices, a first current collecting layer and a first reaction layer are formed, respectively. In the next place, on the first substrate, by use of a discharge device, an electrolyte film is formed. Similarly, by use of discharge devices, a second reaction layer and a second current collecting layer are formed, respectively.

Abstract: A manufacturing method of the present invention includes ejecting a melt 61 of a solid electrolyte onto at least one electrode plate selected from a positive electrode plate 20 and a negative electrode plate 30, thereby depositing the melt 61 onto the at least one electrode plate, and compressing the positive electrode plate 20 and the negative electrode plate 30 while sandwiching the melt 61, thereby forming a layered body including the positive electrode plate 20, an electrolyte layer 62 including the solid electrolyte, and the negative electrode plate 30. In accordance with this manufacturing method, a thin lithium secondary battery having excellent characteristics can be manufactured in a highly productive manner.

Abstract: A nonaqueous electrolyte battery that includes a unit cell and a battery case that encloses the unit cell. The battery case includes a laminate film that encloses the unit cells by heat welding at least a portion of the laminate film. Upon heat welding, the unit cell further includes a number of electrode terminal leads in which a portion of the electrical terminal leads extend from the battery case. A sealant layer is further applied to at least a portion of the electrode terminal leads so as to contact the battery case upon heat welding in order to further seal the case and to further prevent short circuiting of the nonaqueous-electrolyte battery.

Abstract: Instrument set for fitting an intervertebral prosthesis, comprising a guide device (4) for an instrument or a prosthesis part, which guide device (4) is to be secured on at least one vertebral body (2). To be able to attach the guide device (4) precisely on the vertebral bodies despite the difficult operating conditions, an adjustment instrument (10) is provided which positions the guide device when this is being arranged on the vertebral body (2). This adjustment instrument (10) expediently comprises an intervertebral plate (11) which is fitted into the intervertebral space so as to be positioned exactly in relation to the vertebral bodies.

Abstract: A manufacturing process and an apparatus to carry out the process are disclosed which eliminate or at least significantly reduce the occurrence of damaging localized short circuits in the production of electrochemical generators. The process and apparatus include cauterization by oxidation of the anode edges of multiple electrochemical cell laminates thereby rendering the anode edges electrically insulated from adjacent cathodes and/or current collectors.

Abstract: An apparatus and method provide for automated converting of a web of a thin patterned catalyst-coated membrane to separate membrane sheets for fuel cell assembly. The membrane typically has a thickness of about one thousandth of an inch. Automated web converting involves transporting, with use of a movable vacuum, an end portion of the membrane web from a first location to a second location. With use of respective first and second vacuums at the first and second locations, and after removal of the movable vacuum, the end portion of the membrane web is releasably secured at the first and second locations. The membrane web is cut within a gap defined between a single catalyst pattern of the membrane web end portion and an adjacent catalyst pattern to produce a membrane sheet. The membrane sheet is precisely positioned to a desired orientation to facilitate subsequent processing of the membrane sheet.