Abstract: A system and method for processing the electric signals from a plurality of fuel cells in a fuel cell system is disclosed. Groups of the plurality of fuel cells, such as five bipolar plates, are electrically coupled to a conductive compressible connector or a circuit board, where some of the bipolar plates have a plate contactor for providing the electrical contact to either the conductive compressible connector or the circuit board. The system allows for the processing of the electric signals of every cell using fewer electrical components, thereby reducing the amount of space required and the costs associated therewith.

Abstract: A bipolar plate for a fuel cell has a first end, a second end, a first side, and a second side. The bipolar plate also has an active region, a feed region, a perimeter region, a sealing region, and a hinge region. The sealing region is disposed between the perimeter region and each of the active region and the feed region. A plurality of outwardly extending tabs are disposed adjacent the perimeter region at each of the first end and the second end of the bipolar plate. The hinge region is disposed between the perimeter region and the outwardly extending tabs. The hinge region extends from the first side of the plate to the second side of the bipolar plate. The hinge region permits a flexing of the outwardly extending tabs to connect with peripheral electrical device without undesirably flexing the sealing region.

Abstract: A fuel cell stack of at least two fuel cells, each fuel cell having a unitized electrode assembly (UEA) including a membrane electrode assembly (MEA), a sub-gasket and gas diffusion media (DM), and positioned between modified stamped field-flow plates. The sub-gasket frames the MEA resulting in an overlap area between the MEA and the inner perimeter of the sub-gasket. The UEA is disposed between a pair of stamped flow-field plates which align in adjacent fuel cells to form a bipolar plate. The bipolar plate has an active region, an overlap region and a seal region. The active region is configured with channel and land features which provide reactant flow channels and coolant passages for the fuel cell. The configuration of features in the overlap region, however, is modified from the configuration in the active region so that the overlap region may sustain sufficient mechanical sealing pressure, and to prevent coolant and reactant bypass without impeding coolant and reactant flow in the active area.

Abstract: A system and method for processing the electric signals from a plurality of fuel cells in a fuel cell system is disclosed. Groups of the plurality of fuel cells, such as five bipolar plates, are electrically coupled to a conductive compressible connector or a circuit board, where some of the bipolar plates have a plate contactor for providing the electrical contact to either the conductive compressible connector or the circuit board. The system allows for the processing of the electric signals of every cell using fewer electrical components, thereby reducing the amount of space required and the costs associated therewith.

Abstract: A system and method for processing the electric signals from a plurality of fuel cells in a fuel cell system is disclosed. Groups of the plurality of fuel cells, such as five bipolar plates, are electrically coupled to a conductive compressible connector or a circuit board, where some of the bipolar plates have a plate contactor for providing the electrical contact to either the conductive compressible connector or the circuit board. The system allows for the processing of the electric signals of every cell using fewer electrical components, thereby reducing the amount of space required and the costs associated therewith.

Abstract: A fuel cell stack of at least two fuel cells, each fuel cell having a unitized electrode assembly (UEA) including a membrane electrode assembly (MEA), a sub-gasket and gas diffusion media (DM), and positioned between modified stamped field-flow plates. The sub-gasket frames the MEA resulting in an overlap area between the MEA and the inner perimeter of the sub-gasket. The UEA is disposed between a pair of stamped flow-field plates which align in adjacent fuel cells to form a bipolar plate. The bipolar plate has an active region, an overlap region and a seal region. The active region is configured with channel and land features which provide reactant flow channels and coolant passages for the fuel cell. The configuration of features in the overlap region, however, is modified from the configuration in the active region so that the overlap region may sustain sufficient mechanical sealing pressure, and to prevent coolant and reactant bypass without impeding coolant and reactant flow in the active area.

Abstract: A method for fabricating a flowfield for a fuel cell includes the steps of: providing a substrate; providing a plurality of radiation sources configured to generate a plurality of radiation beams; disposing a radiation-sensitive material on the substrate; placing an imaging mask between the plurality of radiation sources and the radiation-sensitive material; and exposing the radiation-sensitive material to the plurality of radiation beams through a first portion of the radiation-transparent apertures and a second portion of the radiation-transparent apertures in the imaging mask to form the plurality of truss elements and the plurality of wall elements in the radiation-sensitive material, the truss elements forming a plurality of trusses configured to support an adjacent diffusion medium layer, and the wall elements defining a fluid path along a length of the substrate.

Abstract: A seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.

Abstract: An embedded measurement circuit for a fuel cell stack. The fuel cell stack includes a plurality of bipolar plates that include recessed areas providing conduction and retention points for the measurement circuit. The measurement circuit has a length, a width and a thickness where the width and length of the circuit are greater than the thickness of the circuit. The measurement circuit includes a stepped cut-out portion defining steps along an edge of the length of the circuit. The measurement circuit is positioned between and among the plurality of bipolar plates so that each one of the steps of the stepped cut-out portion of the measurement circuit enables electrical contact with a separate plate and the width of the circuit is perpendicular to a plane of the plates and the thickness of the circuit is along the plane of the bipolar plates.

Abstract: A seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.

Abstract: A method for fabricating a flowfield for a fuel cell includes the steps of: providing a substrate; providing a plurality of radiation sources configured to generate a plurality of radiation beams; disposing a radiation-sensitive material on the substrate; placing an imaging mask between the plurality of radiation sources and the radiation-sensitive material; and exposing the radiation-sensitive material to the plurality of radiation beams through a first portion of the radiation-transparent apertures and a second portion of the radiation-transparent apertures in the imaging mask to form the plurality of truss elements and the plurality of wall elements in the radiation-sensitive material, the truss elements forming a plurality of trusses configured to support an adjacent diffusion medium layer, and the wall elements defining a fluid path along a length of the substrate.

Abstract: A seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.

Abstract: A seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.

Abstract: A bipolar plate for a fuel cell has a first end, a second end, a first side, and a second side. The bipolar plate also has an active region, a feed region, a perimeter region, a sealing region, and a hinge region. The sealing region is disposed between the perimeter region and each of the active region and the feed region. A plurality of outwardly extending tabs are disposed adjacent the perimeter region at each of the first end and the second end of the bipolar plate. The hinge region is disposed between the perimeter region and the outwardly extending tabs. The hinge region extends from the first side of the plate to the second side of the bipolar plate. The hinge region permits a flexing of the outwardly extending tabs to connect with peripheral electrical device without undesirably flexing the sealing region.

Abstract: An embedded measurement circuit for a fuel cell stack. The fuel cell stack includes a plurality of bipolar plates that include recessed areas providing conduction and retention points for the measurement circuit. The measurement circuit has a length, a width and a thickness where the width and length of the circuit are greater than the thickness of the circuit. The measurement circuit includes a stepped cut-out portion defining steps along an edge of the length of the circuit. The measurement circuit is positioned between and among the plurality of bipolar plates so that each one of the steps of the stepped cut-out portion of the measurement circuit enables electrical contact with a separate plate and the width of the circuit is perpendicular to a plane of the plates and the thickness of the circuit is along the plane of the bipolar plates.

Abstract: A system and method for processing the electric signals from a plurality of fuel cells in a fuel cell system is disclosed. Groups of the plurality of fuel cells, such as five bipolar plates, are electrically coupled to a conductive compressible connector or a circuit board, where some of the bipolar plates have a plate contactor for providing the electrical contact to either the conductive compressible connector or the circuit board. The system allows for the processing of the electric signals of every cell using fewer electrical components, thereby reducing the amount of space required and the costs associated therewith.

Abstract: A seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.