The Small Business Innovation Research (SBIR) Phase I project will develop a polymer alloy material and sealing process using high-speed near-infrared radiation welding, to form a waterproof bond in the assembly of proton exchange membrane and direct methanol fuel cells. A key objective of the proposed work is to screen candidate polymers to formulate alloy seals with maximum sealing bonding strength and optimum resistance to chemical and mechanical degradation. . The proposed sealing material and welding process will provide a path for new high efficiency fuel cell manufacturing technology. The proposed technology will provide the flexibility to weld alloy seals at needed locations to produce a unitized fuel cell structure; thereby, reducing the number of individual components and assembly steps, increasing quality and reducing costs. Additionally, the infrared welding process will lend itself to high speed automated manufacturing.
