A fuel cell capable of reducing the stress exerted upon an electrolyte membrane resulting from the swelling and contraction of the electrolyte membrane. The fuel cell includes at least an MEGA with catalyst layers joined to the opposite sides of the electrolyte membrane, and a pair of separators disposed so as to sandwich the MEGA. The MEGA generates power with a hydrogen gas fed to one side of the MEGA and with an oxidant gas fed to the other side. Separators each have a plurality of projections formed on the side of the MEGA so as to form a gas channel through which the hydrogen gas or oxidant gas flows between the projections. The electrolyte membrane has a plurality of through-holes formed at positions facing the projections along the direction in which the projections extend.

The invention includes a reinforced membrane-seal assembly that comprises a reinforcing component, ion-conducting material, and seal material. The reinforcing component comprises a central region comprising a plurality of apertures extending from a first surface to a second surface of the reinforcing component, the central region having a first aperture area density; an inner peripheral border region surrounding the central region, where the inner peripheral border region is devoid of apertures; and an outer peripheral border region comprising a plurality of apertures extending from the first surface to the second surface of the reinforcing component, the outer peripheral border region having a second aperture area density. The outer peripheral border region surrounds the inner peripheral border region. The ion-conducting material at least partially fills each aperture in the central region of the reinforcing component and seal material fills each aperture in the outer peripheral border region of the reinforcing component.

The invention includes a reinforced membrane-seal assembly that comprises a reinforcing component, ion-conducting material, and seal material. The reinforcing component comprises a central region comprising a plurality of apertures extending from a first surface to a second surface of the reinforcing component, the central region having a first aperture area density; an inner peripheral border region surrounding the central region, where the inner peripheral border region is devoid of apertures; and an outer peripheral border region comprising a plurality of apertures extending from the first surface to the second surface of the reinforcing component, the outer peripheral border region having a second aperture area density. The outer peripheral border region surrounds the inner peripheral border region. The ion-conducting material at least partially fills each aperture in the central region of the reinforcing component and seal material fills each aperture in the outer peripheral border region of the reinforcing component.

In one aspect of the present invention, a fiber mat is provided. The fiber mat includes at least one type of fibers, which includes one or more polymers. The fiber mat may be a single fiber mat which includes one type of fibers, or may be a dual or multi fiber mat which includes multiple types of fibers. The fibers may further include particles of a catalyst. The fiber mat may be used to form an electrode or a membrane. In a further aspect, a fuel cell membrane-electrode-assembly has an anode electrode, a cathode electrode, and a membrane disposed between the anode electrode and the cathode electrode. Each of the anode electrode, the cathode electrode and the membrane may be formed with a fiber mat.

In polymer electrolyte membrane (PEM) fuel cells and electrolyzes, attaining and maintaining high membrane conductivity and durability is crucial for performance and efficiency. The use of low equivalent weight (EW) perfluorinated ionomers is one of the few options available to improve membrane conductivity. However, excessive dimensional changes of low EW ionomers upon application of wet/dry or freeze/thaw cycles yield catastrophic losses in membrane integrity. Incorporation of ionomers within porous, dimensionally-stable perforated polymer electrolyte membrane substrates provides improved PEM performance and longevity. The present invention provides novel methods using micromolds to fabricate the perforated polymer electrolyte membrane substrates. These novel methods using micromolds create uniform and well-defined pore structures. In addition, these novel methods using micromolds described herein may be used in batch or continuous processing.

In polymer electrolyte membrane (PEM) fuel cells and electrolyzes, attaining and maintaining high membrane conductivity and durability is crucial for performance and efficiency. The use of low equivalent weight (EW) perfluorinated ionomers is one of the few options available to improve membrane conductivity. However, excessive dimensional changes of low EW ionomers upon application of wet/dry or freeze/thaw cycles yield catastrophic losses in membrane integrity. Incorporation of ionomers within porous, dimensionally-stable perforated polymer electrolyte membrane substrates provides improved PEM performance and longevity. The present invention provides novel methods using micromolds to fabricate the perforated polymer electrolyte membrane substrates. These novel methods using micromolds create uniform and well-defined pore structures. In addition, these novel methods using micromolds described herein may be used in batch or continuous processing.

Disclosed are a polymer electrolyte membrane showing high ion conductivity even under the condition of low humidity and high temperature and a method for manufacturing the same. The polymer electrolyte membrane of the present invention comprises a porous substrate, a self proton conducting material dispersed in the porous substrate, and an ion conductor impregnated in the porous substrate. The self proton conducting material comprises an inorganic particle functionalized with an azole ring.

Disclosed are a polymer electrolyte membrane showing high ion conductivity even under the condition of low humidity and high temperature and a method for manufacturing the same. The polymer electrolyte membrane of the present invention comprises a porous substrate, a self proton conducting material dispersed in the porous substrate, and an ion conductor impregnated in the porous substrate. The self proton conducting material comprises an inorganic particle functionalized with an azole ring.

A fuel cell capable of reducing the stress exerted upon an electrolyte membrane resulting from the swelling and contraction of the electrolyte membrane. The fuel cell includes at least an MEGA with catalyst layers joined to the opposite sides of the electrolyte membrane, and a pair of separators disposed so as to sandwich the MEGA. The MEGA generates power with a hydrogen gas fed to one side of the MEGA and with an oxidant gas fed to the other side. Separators each have a plurality of projections formed on the side of the MEGA so as to form a gas channel through which the hydrogen gas or oxidant gas flows between the projections. The electrolyte membrane has a plurality of through-holes formed at positions facing the projections along the direction in which the projections extend.

A membrane electrode assembly for the fuel cell includes a solid polymer electrolyte membrane, an anode catalyst layer assembled to one surface of the solid polymer electrolyte membrane, and a cathode catalyst layer assembled to another surface of the solid polymer electrolyte membrane. The membrane electrode assembly contains cerium ions. The membrane electrode assembly includes a power-generation region and a non-power-generation region. The power-generation region includes the catalyst layers on both surfaces of the solid polymer electrolyte membrane in a center portion. The non-power-generation region is without the catalyst layer on at least one surface of the solid polymer electrolyte membrane in an outer periphery portion. A cerium ion content per area in the power-generation region is larger than a cerium ion content per area in the non-power-generation region.