Method for producing a catalytically coated membrane and membrane electrode assembly and fuel cell stack having same

1. A method, comprising:

producing a catalyst coated membrane that has a membrane material and a catalyst layer of a catalytic material on a flat side of the membrane material including a nonrectangular active area, which is restricted in one direction by two outer sides opposite one another and extending parallel to each other, the producing including:

continuously applying the catalytic material to the flat side of the membrane material in a coating direction, the catalytic material having a constant coating width, the area of the membrane material coated with the catalytic material at least covers the nonrectangular active area of the catalyst coated membrane, the applying including:

coating the membrane material with the catalytic material such that the coating direction has an angle that is not equal to 90° and not equal to 0° with respect to the two outer sides of the nonrectangular active area.

2. The method according to claim 1 wherein the nonrectangular active area has at least four corners, which is restricted by the two outer sides and at least one first pair of sides opposite one another, and

wherein the coating direction has an angle that is a maximum of 10° with respect to the first pair of sides.

3. The method according to claim 2 wherein the area of the membrane material coated is bounded laterally by the at least one first pair of sides of the nonrectangular active area, wherein each of the at least one first pair of sides have a length that is less than a length of each of the two outer sides.

4. A method, comprising:

producing a plurality of catalyst coated membranes using a membrane material, the plurality of catalyst coated membranes each having a portion of the membrane material and a catalyst layer of a catalytic material on a flat side of the portion of the membrane material, each portion including a nonrectangular active area, which is restricted in one direction by two outer sides opposite one another and extending parallel to each other, the producing including:

continuous coating of the membrane material with the catalytic material in a coating direction, the catalytic material having a constant coating width, the area of each portion of the membrane material coated with the catalytic material at least covers the nonrectangular active area of a respective catalyst coated membrane, the coating including:

coating the membrane material with the catalytic material such that the coating direction has an angle that is not equal to 90° and not equal to 0° with respect to the two outer sides of each of the nonrectangular active areas;

wherein the two outer sides of the nonrectangular active area of the respective catalyst coated membrane and the two outer sides of the nonrectangular active area of an adjacent catalyst coated membrane are oriented parallel with respect to one another on the membrane material.

5. The method according to claim 4 wherein the membrane material is a strip-like cut with parallel longitudinal sides and the coating direction is parallel to the longitudinal sides of the membrane material.

6. The method according to claim 5 wherein each nonrectangular active area has at least four corners bounded by the two outer sides and a first pair of sides, wherein each of the first pair of sides have a length that is less than a length of each of the two outer sides; and

wherein the plurality of catalyst coated membranes is arranged on the membrane material such that the first pair of sides are oriented parallel to the longitudinal sides of the membrane material.

7. The method according to claim 1 , further comprising after applying the catalytic material, fabricating the membrane material to a desired shape of the catalyst coated membrane.

8. The method according to claim 1 , further comprising:

removing the catalytic material that was applied to the membrane material in areas outside of the catalyst coated membrane from the membrane material; and

recycling the catalytic material that had been removed.

9. The method according to claim 1 wherein the nonrectangular active area has at least at least six corners.

10. The method according to claim 1 wherein the angle of the coating direction has a maximum of 5° with respect to a first pair of sides, the nonrectangular active area defined, at least in part, by the first pair of sides and the two outer sides.

11. The method according to claim 1 wherein the angle of the coating direction is no more than 0° with respect to a first pair of sides, the nonrectangular active area defined, at least in part, by the first pair of sides and the two outer sides.

12. The method according to claim 4 wherein the membrane material is a continuous strip.

13. The method according to claim 1 wherein the producing of the catalyst coated membrane further includes forming operating media ports arranged outside of the nonrectangular active area of the catalyst coated membrane for supplying and removing operating media to and from a fuel cell.

14. The method according to claim 1 , further comprising:

after the producing, arranging the catalyst coated membrane between bipolar plates in a fuel cell.

15. The method according to claim 4 wherein the producing of the catalyst coated membrane further comprises, after coating the membrane material with the catalytic material, fabricating the membrane material of each of the plurality of catalyst coated membranes to a desired shape of the catalyst coated membrane.

16. The method according to claim 4 , further comprising:

after the producing, stacking each of the plurality of catalyst coated membranes alternately with bipolar plates in a fuel cell.