A molding die for molding, on a surface of a plate-like base material, an endless-shaped gasket made of an elastic material includes a cavity which is formed on the opposing surface opposed to the surface of the base material and corresponds to the shape of the gasket, a gate for introducing a molding material which is cured to become an elastic material, a first intermediate portion connecting a gate opening and the cavity and a cross section along the base surface has an area equal to or larger than an opening area of the gate opening, a vent discharging gas unnecessary for molding, and a second intermediate portion connecting an opening on the cavity portion side of the vent extending along the base surface and the cavity and a cross section along the base surface has a cross-sectional area equal to or larger than an area of the gate opening.

A molding die for molding, on a surface of a plate-like base material, an endless-shaped gasket made of an elastic material includes a cavity which is formed on the opposing surface opposed to the surface of the base material and corresponds to the shape of the gasket, a gate for introducing a molding material which is cured to become an elastic material, a first intermediate portion connecting a gate opening and the cavity and a cross section along the base surface has an area equal to or larger than an opening area of the gate opening, a vent discharging gas unnecessary for molding, and a second intermediate portion connecting an opening on the cavity portion side of the vent extending along the base surface and the cavity and a cross section along the base surface has a cross-sectional area equal to or larger than an area of the gate opening.

The invention relates to a method for producing a fuel cell with a membrane electrode assembly (1), wherein at least sections thereof are surrounded by a sub-gasket (2). According to the invention, in order to form the sub-gasket (2), at least sections of the membrane electrode assembly (1) are introduced into a film sleeve (3), the film sleeve (3) is pressed together so that at least regions of two film sleeve halves lie on top of one another, and the overlapping film sleeve halves are connected, preferably adhered, to one another.

The invention also relates to a fuel cell.

Various embodiments include fuel cell interconnects having a fuel distribution portion having an inlet opening, a fuel collection portion having an outlet opening, and a primary fuel flow field containing channels, wherein the fuel distribution portion comprises at least one raised feature defining a fuel distribution flow path, and the fuel distribution flow path is not continuous with the channels in the primary fuel flow field. The at least one raised feature may include, for example, a network of ribs and/or dots. Further embodiments include interconnects having a fuel distribution portion with a variable surface depth to provide variable flow restriction and/or a plenum with variable surface depth and raised a raised relief feature on the cathode side, and/or varying flow channel depths and/or rib heights adjacent a fuel hole.

Various embodiments include fuel cell interconnects having a fuel distribution portion having an inlet opening, a fuel collection portion having an outlet opening, and a primary fuel flow field containing channels, wherein the fuel distribution portion comprises at least one raised feature defining a fuel distribution flow path, and the fuel distribution flow path is not continuous with the channels in the primary fuel flow field. The at least one raised feature may include, for example, a network of ribs and/or dots. Further embodiments include interconnects having a fuel distribution portion with a variable surface depth to provide variable flow restriction and/or a plenum with variable surface depth and raised a raised relief feature on the cathode side, and/or varying flow channel depths and/or rib heights adjacent a fuel hole.

The present invention provides a process of manufacturing a sub-gasketed membrane electrode assembly in which ultrasonic energy is applied to a single face of an intermediate construct to form bonds between the gas diffusion layers and the sub-gaskets.

The present invention provides a process of manufacturing a sub-gasketed membrane electrode assembly in which ultrasonic energy is applied to a single face of an intermediate construct to form bonds between the gas diffusion layers and the sub-gaskets.

In order to provide an electrochemically active unit for an electrochemical device including a membrane electrode assembly, at least one gas diffusion layer and a seal that is linked to at least one of the at least one gas diffusion layers, in the manufacture whereof as even as possible a construction of the penetration region in which the gas diffusion layer of the electrochemically active unit is penetrated by the sealing material of the seal over the periphery of the gas diffusion layer is achievable, the seal includes a linking region, a distribution region and a connection region that connects the linking region and the distribution region to one another, wherein the connection region has a minimum height that is less than a quarter of the maximum height of the distribution region and less than a quarter of the maximum height of the linking region.

A fuel cell separator includes a coolant flow field formed between first and second metal separator plates. A first communication hole is formed in an outer peripheral wall of each of passage sealing beads that surround respectively an air vent passage and a coolant drain passage which are formed so as to penetrate in a separator thickness direction. A second communication hole is formed in an inner peripheral wall of each of the passage sealing beads. The first communication hole and the second communication hole are positioned to be displaced from each other in an extending direction of a first internal channel or a second internal channel.

A fuel cell separator includes a coolant flow field formed between first and second metal separator plates. A first communication hole is formed in an outer peripheral wall of each of passage sealing beads that surround respectively an air vent passage and a coolant drain passage which are formed so as to penetrate in a separator thickness direction. A second communication hole is formed in an inner peripheral wall of each of the passage sealing beads. The first communication hole and the second communication hole are positioned to be displaced from each other in an extending direction of a first internal channel or a second internal channel.