UNIT CELL ASSEMBLY FOR FUEL CELL STACKS AND METHOD FOR MAKING

Unique unit cell assemblies (20) for a solid polymer electrolyte fuel cell stack and improved methods for making them are disclosed in which the methods initially comprise bonding a single gas diffusion layer to a flow field plate assembly (6) using an elastomeric seal (17), e.g. a liquid injection mold seal. Sealing of the unit cell assembly (20) does not rely on penetrating the gas diffusion layer with elastomer. The method provides for reliable unit cell assemblies (20) while advantageously allowing for use of higher viscosity elastomers and reducing waste.