Patent ID: 6946210

Claim:
A fuel cell cassette comprising at least two unit cells, each unit cell comprising: a membrane electrode assembly having at least one membrane electrode assembly manifold opening extending through the thickness thereof wherein each membrane electrode assembly manifold opening is bonded at the perimeter by a first sealant; a fuel flow field having at least one fuel flow field manifold opening extending through the thickness thereof wherein each fuel flow field manifold opening which does not correspond to a manifold providing fuel reactant for distribution to the fuel flow field is bonded at the perimeter by a second sealant; an oxidant flow field having at least one oxidant flow field manifold opening extending through the thickness thereof wherein each oxidant flow field manifold opening which does not correspond to a manifold providing oxidant reactant for distribution to the oxidant flow field is bonded at the perimeter by a third sealant; wherein the membrane electrode assembly, the fuel flow field, and the oxidant flow field are assembled in a stack relative to each other such that the membrane electrode assembly manifold openings, the fuel flow field manifold openings, and the oxidant flow field manifold openings are aligned; wherein the peripheral edges of the membrane electrode assembly, the fuel flow field, and the oxidant flow field are encapsulated together by a resin such that the entire periphery of the fuel cell cassette is encapsulated by the resin; and wherein the resin penetrates porous interstices of each of the membrane electrode assembly, fuel flow field and oxidant flow field, and penetrates spaces separating the membrane electrode assembly, fuel flow field and oxidant flow field about their peripheral edges, impregnating the resin there between.