Patent ID: 7625833

Claim:
A method of making a five-layer membrane electrode assembly comprising the steps of: a) providing a catalyst coated membrane web which comprises: 1) a polymer electrolyte membrane having a first and second face; 2) a plurality of first patterned catalyst layer segments laminated on said first face of said membrane such that adjacent patterned catalyst layer segments are not in contact with each other; and 3) a plurality of second patterned catalyst layer segments laminated on said second face of said membrane such that adjacent patterned catalyst layer segments are not in contact with each other; b) providing a laminating station wherein said catalyst coated membrane web is drawn between a pair of laminating rollers which form a laminating nip; c) die-cutting a first web of first gas diffusion layer material to make a first gas diffusion layer; d) die-cutting a second web of second gas diffusion layer material to make a second gas diffusion layer; e) transporting said first gas diffusion layer to said laminating station; f) transporting said second gas diffusion layer to said laminating station; g) feeding said first gas diffusion layer into said laminating nip adjacent to said catalyst coated membrane web; h) feeding said second gas diffusion layer into said laminating nip adjacent to said catalyst coated membrane web concurrently with said first gas diffusion layer; and i) laminating said first gas diffusion layer, said catalyst coated membrane web and said second gas diffusion layer to form a laminate; wherein the first gas diffusion layer has an area greater than the first patterned catalyst layer segments.