The present invention provides a gasketed fuel cell membrane electrode
assembly comprising: a polymer electrolyte membrane; layers of anode and
cathode catalyst; anode-side and cathode-side fluid transport layer; and
anode-side and cathode-side gaskets; where the gaskets comprise an
elastomeric gasket material which is impregnated into the outer edge
portions of the respective fluid transport layer; and where at least a
portion of the contact face of each gasket bears a raised-ridge
microstructured contact pattern. The gasketed fuel cell membrane
electrode assembly according to the present invention may additionally
comprise a rigid, non-elastomeric anode-side and cathode-side shims
positioned between at least a portion of the gasket and the polymer
electrolyte membrane. The raised-ridge microstructured contact pattern
preferably comprises ridges which meet at joining points, wherein no more
than three ridges meet at any one joining point. Such raised-ridge
microstructured contact patterns may be hexagonal patterns or degenerate
hexagonal patterns. In another aspect, the present invention provides a
method of making a gasketed fuel cell membrane electrode assembly by
simultaneously binding together the parts of the MEA, impregnating
uncured elastomeric gasket material into the outer edge portions of each
fluid transport layer, and substantially curing the uncured elastomeric
gasket material so as to form anode-side and cathode-side gaskets. In
order to form a raised-ridge microstructured contact pattern on the
contact face of each gasket, patterning plates bearing a negative relief
of a raised-ridge microstructured contact pattern may be positioned
between the press platens and the uncured elastomeric gasket material.