Method and apparatus for fabricating roll good fuel cell subassemblies

A method of forming membrane electrode assemblies via a roll-to-roll process, comprising:

• forming first and second gas diffusion layer incorporating a gasket (GIG) subassemblies, wherein each GIG subassembly consists essentially of a gas diffusion layer, a first gasket layer, a second gasket layer, an adhesive layer, and optionally, a removable liner, the formation of each GIG subassembly comprising:
• transporting a material processable by one or both of heat and pressure having spaced apart apertures to a bonding station;
• transporting a first gasket layer having gas diffusion layers arranged in relation to spaced apart apertures of the first gasket layer to the bonding station;
• aligning the heat/pressure processable material with the first gasket layer and the gas diffusion layers;
• at the bonding station, bonding the heat/pressure processable material to the first gasket layer and the gas diffusion layers, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer;
• and
• exposing an adhesive layer on the first gasket layer;
• delivering one or more electrolyte membranes;
• bonding the first GIG subassembly to a surface of the one or more electrolyte membranes;
• and
• bonding the second GIG subassembly to an opposite surface of the one or more electrolyte membranes.

A method of making gas diffusion layer incorporating a gasket (GIG) fuel cell subassemblies, comprising:

• transporting a first gasket layer having spaced apart apertures to a deposition station;
• depositing a heat/pressure processable material on the first gasket layer;
• aligning the first gasket layer having the heat/pressure processable material disposed thereon with gas diffusion layers;
• and
• at a bonding station, bonding the heat/pressure processable material to the first gasket layer and the gas diffusion layers, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer, wherein each GIG fuel cell subassembly consists essentially of a gas diffusion layer, a first gasket layer, a second gasket layer, an adhesive layer, and optionally, a removable liner.