Novel Processes and Designs for High Volume MEA Manufacture

The project aim is to develop, evaluate and prove the functionality of innovative MEA design concepts and to identify and assess assembly process options for these novel MEA designs that would be compatible with a process route for lower cost, higher volume MEA manufacturing with the capability of an output of several millions of MEAs per annum. Process measurement techniques will be developed and evaluated to provide for improved process control. Current processes for MEA production are not geared to cost-effective automated manufacture and rely heavily on scaled up and semi-automated versions of original batch processes. In addition, the MEA design does not efficiently utilise valuable materials. The overall project focus will be to develop and validate an innovative MEA design incorporating a new approach to seal material and application that utilises the seal material more effectively and also minimises unnecessary use of non-functional ion exchange membrane; and to assess the process options for producing this MEA by a fully-automated handling and assembly process for the key MEA components (catalyst coated GDLs or membranes, seals, gaskets, thin films).