Continuous processes for high-precision unitisation of membrane electrode assemblies

The demand for membrane electrode assemblies (MEAs) from a future automotive market is such that continuous manufacturing processes will be required. In such a process it would be advantageous to be able to produce fully integrated MEAs by attaching the gas diffusion layers (GDL) to the edge sealed catalyst coated membrane (CCM). This is currently completed off-line using slow manual-based methods. This project will identify and test methodologies for rapid, accurate placement and attachment of the GDLs to the CCMs. Following initial trials to identify the appropriate sealing materials and processes that can effect sealing in fractions of a second, a full manufacturing design study will be prepared that would be capable of accurately placing the GDL onto the CCM with similarly fast cycle times.