METHOD OF FABRICATING FUEL CELLS AND MEMBRANE ELECTRODE ASSEMBLIES

摘要

The application relates to a method of fabricating micro fuel cells and membrane electrode assemblies by thin film deposition techniques using a dimensionally stable proton exchange membrane as a substrate. The applicatio n also relates to membrane electrode assemblies and fuel cells fabricated in accordance with the method. The method includes the steps of successively depositing catalyst, current collector and flow management layers on the membrane substrate in predetermined pat~terns. Since the fuel cell is formed layer by layer, the need for assem~bly and sealing of discrete components is avoided. The method im~proves the contact resistance between the current collectors and catalyst layers and reduce ohmic losses, thereby avoiding the need for end plates or other compressive elements. This in turn reduces the overall thick~ness of the manufactured fuel cell. Since the fuel cell layers are option~ally flexible, the devices may be fabricated using a continuous roller process or other automated means. The method minimizes production cos ts and costs of non-essential materials and is particularly suitable for low power battery replacement applications.