Patent ID: 7056612

Claim:
A method of preparing Membrane-Electrode-Gasket Assembly used for polymer electrolyte fuel cells comprising the steps of: (a) attaching a polytetrafluoroethylene gasket of 30 to about 400 μm in thickness to a portion of a first gas diffusion layer; (b) forming a first carbon powder layer by spraying a first carbon powder comprising about 10 to about 60 wt % of PTFE on the first gas diffusion layer in (a) except the portion wherein said gasket is attached; (c) forming a cathode catalyst layer by spraying a catalyst ink comprising catalyst powders, a polymer electrolyte ionomer, and an organic solvent on the first carbon powder layer in (b); (d) forming an electrolyte layer by spraying a polymer electrolyte ionomer solution on the cathode catalyst layer in (c); (e) forming an anode catalyst layer by spraying a catalyst ink comprising catalyst powders, a polymer electrolyte ionomer, and an organic solvent on the electrolyte layer in (d); (f) forming a second carbon powder layer by spraying a second carbon powder including about 10 to about 60 wt % of PTFE on the anode catalyst layer in (e); and (g) attaching a second gas diffusion layer to the carbon powder layer in (f).