Abstract: A method of manufacturing a porous structure for a fuel cell is disclosed. The method includes providing the porous structure, and processing the porous structure to selectively produce a non-porous region on the porous structure. In one example, the non-porous region is provided at the perimeter of the porous structure, an edge of an internal manifold and/or a surface or recess that supports a seal or gasket. The non-porous region has a porosity that is less than the porosity of the porous structure. The non-porous region prevents undesired leakage of fluid from the porous structure and prevents migration of adhesive associated with the seals.

Abstract: A fuel cell stack (30) includes an integrated end plate assembly having a current collector (40) secured adjacent and end cell (36) of the stack, a pressure plate (42) secured adjacent the current collector (40), and a backbone (60) secured within a backbone-support plane (44) defined within the plate (42). Tie rod ends (62, 64, 66, 68) of the backbone (60) extend over a gap (84) defined between the backbone-support plane (44) and a deflection plane (50) defined within the pressure plate (42) so that the tie rod ends deflect within the gap (84) upon tightening of tie rods (78, 80). Deflection of the backbone enables the backbone (60) to permit limited expansion of the fuel cell stack (30) during operation, and the backbone (60) has adequate flexural strength to prohibit expansion of the stack (30) beyond operating dynamic limits of the stack (30).

Abstract: A method of manufacturing a fuel cell plate is disclosed that includes machining a part to produce tailings. At least some of the tailings are mixed with a material to produce a mixture. The mixture is formed into a fuel cell plate. In one example, the tailings are recycled flake graphite laminated with binder, and the material is virgin flake graphite mixed with binder. The fuel cell plate has a structure with surfaces extending in the in-plane direction. At least some of the natural flake graphite is arranged out of the in-plane direction.

Abstract: A method of manufacturing a porous structure for a fuel cell is disclosed. The method includes providing the porous structure, and processing the porous structure to selectively produce a non-porous region on the porous structure. In one example, the non-porous region is provided at the perimeter of the porous structure, an edge of an internal manifold and/or a surface or recess that supports a seal or gasket. The non-porous region has a porosity that is less than the porosity of the porous structure. The non-porous region prevents undesired leakage of fluid from the porous structure and prevents migration of adhesive associated with the seals.

Abstract: A fuel cell stack (30) includes an integrated end plate assembly having a current collector (40) secured adjacent and end cell (36) of the stack, a pressure plate (42) secured adjacent the current collector (40), and a backbone (60) secured within a backbone-support plane (44) defined within the plate (42). Tie rod ends (62, 64, 66, 68) of the backbone (60) extend over a gap (84) defined between the backbone-support plane (44) and a deflection plane (50) defined within the pressure plate (42) so that the tie rod ends deflect within the gap (84) upon tightening of tie rods (78, 80). Deflection of the backbone enables the backbone (60) to permit limited expansion of the fuel cell stack (30) during operation, and the backbone (60) has adequate flexural strength to prohibit expansion of the stack (30) beyond operating dynamic limits of the stack (30).