Abstract: An illustrative example method of making a fuel cell component includes mixing a catalyst material with a hydrophobic binder in a solvent to establish a liquid mixture having at least some coagulation of the catalyst material and the hydrophobic binder. The liquid mixture is applied to at least one side of a porous gas diffusion layer. At least some of the solvent of the applied liquid mixture is removed from the porous gas diffusion layer. The catalyst material remaining on the porous gas diffusion layer is dried under pressure.

Abstract: An illustrative example cell stack assembly includes a plurality of fuel cells that each include a cathode electrode, an anode electrode and a matrix for holding a liquid acid electrolyte. The electrodes have lateral outside edges that are generally coplanar. A plurality of separator plates are respectively between the cathode electrode of one of the fuel cells and the anode electrode of an adjacent one of the fuel cells. The separator plates have lateral outside edges that are generally coplanar with the lateral outside edges of the electrodes. A plurality of barriers along at least one of the lateral outside edges of respective ones of the separator plates extend outwardly beyond the lateral outside edges of the electrodes and separator plates. The barriers inhibit acid migration between one of the electrodes on one side of the barrier and one of the electrodes on an opposite side of the barrier.

Abstract: An illustrative example fuel cell electrolyte management device includes a first component having a first density and a second component having a second density that is less than the first density. The first component has a first side including a pocket and a second side facing opposite the first side. The second side of the first component includes a first plurality of fluid flow channels. The second component has a porosity configured for storing electrolyte in the second component. The second component fits within the pocket. The second component has a first side received directly against the first side of the first component. The second component has a second side including a second plurality of fluid flow channels.