Patent ID: 7553578
Filing Date: 2009-06-30
Classification: H01M,Y02E,Y02P

Abstract:
1. A method of making a gasketed fuel cell membrane electrode assembly comprising: a) a polymer electrolyte membrane having an anode face with an outer edge portion, a cathode face with an outer edge portion, and an outer perimeter; b) a layer of anode catalyst material in contact with at least a portion of the anode face of said polymer electrolyte membrane; c) a layer of cathode catalyst material in contact with at least a portion of the cathode face of said polymer electrolyte membrane; d) an anode-side fluid transport layer having an outer edge portion, said anode-side fluid transport layer being in contact with said layer of anode catalyst material, said anode-side fluid transport layer not extending over the outer edge portion of the anode side of said polymer electrolyte membrane; e) a cathode-side fluid transport layer having an outer edge portion, said cathode-side fluid transport layer being in contact with said layer of cathode catalyst material, said cathode-side fluid transport layer not extending over the outer edge portion of the cathode side of said polymer electrolyte membrane; f) an anode-side gasket comprising an elastomeric gasket material extending over the outer edge portion of the anode side of said polymer electrolyte membrane, said anode-side gasket having a contact face and an outer perimeter; and g) a cathode-side gasket comprising an elastomeric gasket material extending over the outer edge portion of the cathode side of said polymer electrolyte membrane, said cathode-side gasket having a contact face and an outer perimeter; wherein the elastomeric material of each gasket is impregnated into the outer edge portions of the respective fluid transport layer; which comprises the steps of: i) positioning between platens of a press: 1) an anode-side fluid transport layer, 2) a layer of anode catalyst material, 3) a polymer electrolyte membrane having an anode face with an outer edge portion and a cathode face with an outer edge portion, 4) a layer of cathode catalyst material, 5) a cathode-side fluid transport layer; 6) a rigid, non-elastomeric anode-side shim having an outer perimeter, said anode-side shim being positioned over the outer edge portion of the anode side of said polymer electrolyte membrane, said anode-side shim having a thickness which is less than 90% of the thickness of the anode-side fluid transport layer; and 7) a rigid, non-elastomeric cathode-side shim having an outer perimeter, said cathode-side shim being positioned over the outer edge portion of the cathode side of said polymer electrolyte membrane, said cathode-side shim having a thickness which is less than 90% of the thickness of the cathode-side fluid transport layer; 1) bind together parts i)1), i)2), i)3), i)4), i)5); 2) impregnate said uncured elastomeric gasket material into the outer edge portions of each fluid transport layer; and 3) substantially cure said uncured elastomeric gasket material so as to form anode-side and cathode-side gaskets.