A method of addressing one MEA failure mode by controlling MEA catalyst
layer overlap, and the apparatus formed thereby is disclosed. The present
invention addresses a feature of membrane electrode assembly (MEA)
architecture that is associated with field failures due to the loss of
ionomer from the edges of the electrolyte. To address ionomer
degradation, the present invention provides a MEA design in which the
cathode catalyst edges are closer than the anode catalyst edges to the
edges of the electrolyte.