Abstract: Fuel cell stacks comprising stacked separator/membrane electrode assembly fuel cells in which the separators comprise a series of thin sheet platelets, having individually configured serpentine micro-channel reactant gas humidification active areas and cooling fields therein. The individual platelets are stacked with coordinate features aligned in contact with adjacent platelets and bonded to form a monolithic separator. Post-bonding processing includes passivation, such as nitriding. Preferred platelet material is 4-25 mil Ti, in which the features, serpentine channels, tabs, lands, vias, manifolds and holes, are formed by chemical and laser etching, cutting, pressing or embossing, with combinations of depth and through etching preferred. The platelet manufacturing process is continuous and fast. By employing CAD based platelet design and photolithography, rapid change in feature design can accommodate a wide range of thermal management and humidification techniques. One hundred H.sub.2 --O.sub.

Abstract: Improved fuel cell stacks constructed from a plurality of cells, each comprising a series of interrelated mono and bipolar collector plates (BSPs), which in turn are built up by lamination of a core of related non-conductiveplastic orceramic platelets sandwiched between conductive microscreen platelets of metal or conductive ceramic or plastic, with an electrode membrane (EMA) between adjacent BSPs. The platelets, both metal and plastic of the composite BSPs, are produced from sheet material with through and depth features formed by etching, pressing, stamping, casting, embossing and the like. Adjacent plates, each with correspondingly relieved features form serpentine channels within the resultant monolithic platelet/cell stack for integrated fluid and thermal management. The plastic platelets are particularly useful for PEM fuel cells employing H.sub.2 and Air/O.sub.2 as fuel. The platelets are easily made by printing (embossing) processes, and dies made by photolithographic etching for rapid redesign.

Abstract: Fuel cell stacks comprising stacked separator/membrane electrode assembly cells in which the separators comprise a series of stacked thin sheet platelets having individually configured serpentine micro-channel reactant gas humidification, active area and cooling fields therein. The individual platelets are stacked with coordinate features precisely aligned in contact with adjacent platelets and bonded to form a monolithic separator. Post bonding processing includes passivation, such as nitriding. Preferred platelet material is 4-25 mil Ti in which the features, serpentine channels, tabs, lands, vias, manifolds and holes, are formed by chemical or laser etching, cutting, pressing or embossing, with combinations of depth and through-etching being preferred. The platelet manufacturing process is continuous and fast. By employing CAD based platelet design and photolithography, rapid change in feature design to accommodate a wide range of thermal management and humidification techniques. 100 cell H.sub.2 --O.sub.