Abstract: A method of manufacturing a metal separator for a fuel cell includes providing an opening in a metal plate which is to be a part of the metal separator for the fuel cell, integrally molding a sealing member on both sides of an outer peripheral edge of the metal plate to cover the opening, and trimming the sealing member to remove a covering portion of the sealing member that covers the opening and to provide a fluid communication hole, at least one of a fuel gas, an oxidant gas, and a cooling medium being to pass through the fluid communication hole in the fuel cell.

Abstract: An example fuel cell system includes a fuel cell power plant and a tank providing a volume that is configured to hold a fuel cell fluid. The fuel cell power plant is at least partially disposed within the volume.

Abstract: A cell unit of a fuel cell includes a first membrane electrode assembly, a first metal separator, a second membrane electrode assembly, and a second metal separator. A resin frame member is provided integrally with an outer circumference of the first membrane electrode assembly. An oxygen-containing gas supply passage, a fuel gas supply passage, a coolant supply passage, an oxygen-containing gas discharge passage, a fuel gas discharge passage, and a coolant discharge passage extend through the resin frame member in a stacking direction. At each of both ends of the resin frame member in a longitudinal direction, a pair of projections are provided. The projections protrude toward both sides in a lateral direction.

Abstract: A fuel cell device having an exterior surface defining an interior ceramic support structure. An active zone is along a first portion of the length for undergoing a fuel cell reaction, and at least one non-active end region is along an end portion extending away from the active zone without being heated. Fuel and oxidizer passages extend within the interior support structure from respective first and second inlets in the non-active end region to the active zone. The active zone has an anode associated with each of the fuel passages and a cathode associated with each of the oxidizer passages in opposing relation to a respective one of the anodes with an electrolyte therebetween. A plurality of ceramic support members in spaced-apart positions are provided throughout each one of the plurality of fuel and oxidizer passages that physically holds open the passages to prevent collapse.

Abstract: Various embodiments include interconnects and/or end plates having features for reducing stress in a fuel cell stack. In embodiments, an interconnect/end plate may have a window seal area that is recessed relative to the flow field to indirectly reduce stress induced by an interface seal. Other features may include a thicker protective coating and/or larger uncoated area of an end plate, providing a recessed portion on an end plate for an interface seal, and/or recessing the fuel hole region of an interconnect relative to the flow field to reduce stress on the fuel cell. Further embodiments include providing intermittent seal support to minimize asymmetric seal loading and/or a non-circular seal configuration to reduce stress around the fuel hole of a fuel cell.

Abstract: A method of making a solid oxide fuel cell (SOFC) includes providing a solid oxide electrolyte and depositing at least one electrode on the electrolyte by PVD, such as sputtering. A method of making an interconnect for a fuel cell stack includes providing an electrically conductive interconnect, and depositing a layer on the interconnect by PVD, such as depositing a LSM barrier layer by sputtering. The SOFC and the interconnect may be located in the same fuel cell stack.

Abstract: A molten carbonate fuel cell, which makes a separator unnecessary, cuts down the number of components, and markedly reduces the costs, is provided. In the cell, a cathode, an electrolyte plate holding an electrolyte, and an anode are provided concentrically with a tube body, the electrolyte plate is held by the anode, and the electrolyte plate is sandwiched between the anode and the cathode, so that the cell is constructed without the use of a separator.

Abstract: A tubular fuel cell module having improved current collecting efficiency. In one embodiment, the fuel cell module includes: a fuel cell unit; a first current collector extending along an outer side of the fuel cell unit; and a second current collector wound around the first current collector and around the outer side of the fuel cell unit. Here, the outer side of the fuel cell unit is a curved outer side, the first current collector has a curved inner side facing the curved outer side of the fuel cell unit, and the curved inner side of first current collector is shaped to match the curved outer side of the fuel cell unit.

Abstract: Provided is a fuel cell stack having reduced thickness and weight and an improved output density. The fuel cell stack according to the present invention includes two or more stacked fuel cell layers, and is characterized in that at least one of the fuel cell layers is formed by arranging two or more composite unit cells in an identical plane with a gap provided therebetween, that the composite unit cell includes a plurality of unit cells and a fuel supply portion for supplying fuel to anode electrodes of the unit cells, and that the anode electrodes of the plurality of unit cells are arranged to face the fuel supply portion.

Abstract: Provided are a gas decomposition component, a power generation apparatus including the gas decomposition component, and a method for decomposing a gas. A gas decomposition component includes a cylindrical MEA including a first electrode layer, a cylindrical solid electrolyte layer, and a second electrode layer in order from an inside toward an outside, in a layered structure; a first gas channel through which a first gas that is decomposed flows, the first gas channel being disposed inside the cylindrical MEA; and a second gas channel through which a second gas flows, the second gas channel being disposed outside the cylindrical MEA, wherein the gas decomposition component further includes a heater for heating the entirety of the component; and a preheating pipe through which the first gas to be introduced into the first gas channel passes beforehand to be preheated.

Abstract: A fuel cell device having an exterior surface defining an interior ceramic support structure. An active zone is along an intermediate portion of the length for undergoing a fuel cell reaction, and opposing non-active end regions are along end portions extending away from the active zone without being heated. Fuel and oxidizer passages extend within the interior support structure from respective first and second inlets in respective ones of the opposing non-active end regions. The active zone has an anode associated with each of the fuel passages and a cathode associated with each of the oxidizer passages in opposing relation to a respective one of the anodes with an electrolyte therebetween. The opposing non-active end regions lack the anode and cathode in opposing relation so as to be incapable of undergoing a fuel cell reaction.

Abstract: A fuel cell stack includes a stack body formed by stacking a plurality of solid oxide fuel cells. The fuel cell stack includes a lower end plate, a load plate, and a fuel cell support member. The lower end plate is positioned at one end of the stack body in the stacking direction for placing the stack body on the lower end plate. The load plate is provided at the other end of the stack body for applying a load to the stack body in the stacking direction. The fuel cell support member is provided between the load plate and the stack body, and includes a composite layer made of alumina fiber and vermiculite.

Abstract: A bipolar plate for a fuel cell is provided. The bipolar plate having flow channels for oxidant gas; said flow channels for oxidant gas comprising one or more grooves each representing a serpentine path; wherein each said serpentine path independently comprises N consecutive legs L1, L2, . . . LN; connected to each other by N?1 consecutive turn sections, T1, T2, . . . TN-1; wherein each leg L1, L2, . . . LN-1 being lengthwise separated from its consecutive leg L2, L3, . . . LN by a wall section, W1, W2, . . . WN-1; wherein each turn section representing a 180° change of flow direction of oxidant gas; wherein N is an odd integer of 3 or more; and wherein one or more of the wall sections W1, W2, . . . WN-1 independently comprise one or more by-pass channels for allowing oxidant gas to flow via a short cut from one leg Lx to its consecutive leg Lx+1; 1?x?N?1; thereby by passing a part of the leg Lx and a part of the leg Lx+1. Furthermore, a cooling plate having a similar design is provided.

Abstract: A cell stack comprising a plurality of fuel cells or electrolysis cells has a combination of flow patterns between anode gas and cathode gas internally in each of the cells and between the cells relative to each other such that cathode and anode gas internally in a cell flows in either co-flow, counter-flow or cross-flow and further that anode and cathode gas flow in one cell has co-flow, counter-flow or cross-flow relative to the anode and cathode gas flow in adjacent cells.

Abstract: To an internal vessel that houses cells of a solid oxide fuel cell, an external vessel is further disposed. In the internal vessel, a plurality of planar cells is disposed vertically with a gap between the cells, a mixed gas of a fuel and air is descended from top down through the gap having a predetermined width between the cells, and, at a bottom portion of the housing space, the mixed gas is burned to generate electricity.

Abstract: A fuel cell stack (100) comprising a plurality of fuel cell assemblies (102) adjacent to one another. The fuel cell assemblies each comprise an extended portion (104, 106, 108) having an aperture (110, 112, 114) therein. The aperture (110, 112, 114) is configured to provide a fluid connection to a fluid flow channel of the fuel cell assembly (102). The fuel cell stack (100) also comprises a clip (120, 122, 124) located over and around at least part of the extended portions (104, 106, 108) of the plurality of the fuel cell assemblies (102). The clip (120, 122, 124) is configured to resist outward expansion of the extended portions (104, 106, 108).

Abstract: A fuel cell is provided with a separator that supports an electrolyte/electrode assembly sandwiched therebetween. The separator is provided with: first and second fuel gas supply parts in the center of which fuel gas supply holes are formed; first and second cross-link parts connected to the first and second fuel gas supply parts; and first and second surrounding support parts connected to the first and second cross-link parts. Each first surrounding support part is provided with a set of fuel gas exhaust passages that discharge fuel gas that has gone through a fuel gas passage and been used. The cross-sectional areas of the fuel gas exhaust passages are larger on the downstream sides than on the upstream sides, in terms of the direction of fuel gas flow.

Abstract: A polymer electrolyte fuel cell comprises a plurality of stacked cells each having an ionic conductive electrolyte membrane, an anode placed on one side of the electrolyte membrane, a cathode placed on the other side of the electrolyte membrane, and a conductive separator on which a first refrigerant channel for flow of a refrigerant is formed in center part thereof. The separator comprises penetration holes constituting a manifold which extend in a direction of stacking of the plurality of cells and through which the refrigerant flows and second refrigerant channels for communication between the penetration holes and the first refrigerant channel. A plurality of protrusions that protrude into the penetration holes from parts of wall surfaces of the penetration holes that are located peripherally in connection parts between the penetration holes and the second refrigerant channels.

Abstract: A solid oxide fuel cell (SOFC) stack is disclosed. The SOFC may include an oxidizing agent flow path fluidly connecting a first oxidizing agent chamber and a second oxidizing agent chamber. The first oxidizing agent chamber may include an oxidizing agent supply pipe through which an oxidizing agent is flowed from an outside thereof. The second oxidizing agent chamber may perform a reduction reaction on the oxidizing agent received from the first oxidizing agent chamber. In operation, a fluid flows between the first and second oxidizing agent chambers, and may be provided to an outside of the second oxidizing agent chamber. Further, the structure of the flow path may allow heat to be conducted from the second oxidizing agent chamber.

Abstract: A large stack redox flow battery system provides a solution to the energy storage challenge of many types of renewable energy systems. Independent reaction cells arranged in a cascade configuration are configured according to state of charge conditions expected in each cell. The large stack redox flow battery system can support multi-megawatt implementations suitable for use with power grid applications. Thermal integration with energy generating systems, such as fuel cell, wind and solar systems, further maximize total energy efficiency. The redox flow battery system can also be scaled down to smaller applications, such as a gravity feed system suitable for small and remote site applications.

Abstract: A fuel cell interconnect includes a first side containing a first plurality of channels and a second side containing a second plurality of channels. The first and second sides are disposed on opposite sides of the interconnect. The first plurality of channels are configured to provide a serpentine fuel flow field while the second plurality of channels are configured to provide an approximately straight air flow field.

Abstract: A fuel cell is provided that includes a water transport plate separating an air flow field and a water flow field. The driving force for moving water across the water transport plate into the water flow field is produced by a differential pressure across a restriction. The restriction is arranged between an air outlet of the cathode water transport plate and a head of a reservoir that is in fluid communication with the water flow field.

Abstract: A heater includes a heater housing with a support plate secured to one end. A fuel cell stack assembly is disposed within the heater housing and includes a plurality of fuel cells which convert chemical energy from a fuel into heat and electricity through a chemical reaction with an oxidizing agent. The fuel cell stack assembly includes a fuel cell manifold for receiving the fuel and distributing the fuel to the plurality of fuel cells and for receiving the oxidizing agent and distributing the oxidizing agent to the plurality of fuel cells. A fuel supply conduit supplies the fuel to the fuel cell manifold and an oxidizing agent supply conduit supplies the oxidizing agent to the fuel cell manifold. The fuel cell stack assembly is supported on the support plate by one of the fuel supply conduit and the oxidizing agent supply conduit.

Abstract: Fuel cell devices and systems are provided. In certain embodiments, the devices include a ceramic support structure having a length, a width, and a thickness. A reaction zone positioned along a portion of the length is configured to be heated to an operating reaction temperature, and has at least one active layer therein comprising an electrolyte separating first and second opposing electrodes, and active first and second gas passages adjacent the respective first and second electrodes. At least one cold zone positioned from the first end along another portion of the length is configured to remain below the operating reaction temperature. An artery flow passage extends from the first end along the length through the cold zone and into the reaction zone and is fluidicly coupled to the active first gas passage, which extends from the artery flow passage toward at least one side. The thickness of the artery flow passage is greater than the thickness of the active first gas passage.

Abstract: A metal halogen electrochemical energy cell system that generates an electrical potential. One embodiment of the system includes at least one cell including at least one positive electrode and at least one negative electrode, at least one electrolyte, a mixing venturi that mixes the electrolyte with a halogen reactant, and a circulation pump that conveys the electrolyte mixed with the halogen reactant through the positive electrode and across the metal electrode. Preferably, the positive electrode comprises porous carbonaceous material, the negative electrode comprises zinc, the metal comprises zinc, the halogen comprises halogen, the electrolyte comprises an aqueous zinc-halide electrolyte, and the halogen reactant comprises a halogen reactant. Also, variations of the system and a method of operation for the systems.

Abstract: A sensor cell (1010) for control purposes usable in an assembly (1000) of fuel cells of the type having a membrane electrode assembly (MEA) interposed between an anode gas diffusion layer and a cathode gas diffusion layer, and first and second current collectors coupled to the anode and cathode gas diffusion layers (GDL), respectively. The sensor cell (1010) is preferably coupled so that it shares the negative current collector (1050) with last fuel cell in the in-plane fuel cell assembly (1000), and is short-circuited by a resistor (1070) to provide a voltage signal, indicative of the status of the assembly in operation.

Abstract: Electrochemical system comprising a fuel cell comprising a stack (2) of electrochemical cells electrically connected to one another by bipolar plates (A, B, C) interposed between two successive electrochemical cells of the stack, where said stack (2) is positioned between two terminal plates (4), where said stack extends in a longitudinal axis (Z), where said electrochemical system comprises means for supplying the cells with reactive fluids, means of circulation of a heat-transfer fluid through the stack, and at least one induction heating system comprising a pair of inductors facing a lateral face of the stack, where the currents flowing in the two inductors flow in opposite directions.

Abstract: A separator for a fuel cell includes a metal plate which defines a passage and a manifold, frames having gaskets which are integrated therewith using injection, and a bonding unit for bonding the frames to the metal plate. The gaskets may be differently formed. This resolves process interference problems between conductive surface treatment and gasket cross-linking, obviates deburring of the gasket, and preventes poor injection of the gaskets, which ensures stable quality of the separator, increases productivity and decreases the manufacturing cost.

Abstract: Fluid distribution plate (1) for a fuel cell assembly, comprising a first plate (11) made of an electrically conductive material impermeable to all the fluids used in a fuel cell assembly, said distribution plate having a useful section (S) which is the surface over which the gases used by the electrochemical reaction are distributed, said useful section (S) being bordered all around by a peripheral section (P), said first plate having a given thickness e1 in the peripheral section and a smaller thickness e2 in the useful section so as to form a recess from the side facing the outer face and so as to have a flat inner surface, a flexible graphite foil (11C) being applied against said first plate (11) over the entire surface of the recess, the visible face of the flexible graphite foil having a distribution channel (111) for one of the fluids, said network being formed completely in the graphite foil.

Abstract: A fuel cell includes a plate-like cell, a separator on one side of the plate-like cell, and a separator on the other side of the plate-like cell. The plate-like cell includes a solid polymer electrolyte membrane, an anode, and a cathode. The anode has a stacked body composed of a catalyst layer and a gas diffusion layer. The cathode has a stacked body composed of a catalyst layer and a gas diffusion layer. The catalyst layer contains a porous carbon material formed with micro pores, which functions as an electric double layer, and an ion-exchange resin. At least part of the porous carbon material supports a catalytic metal such as platinum. The porous carbon material to be used is preferably a carbide-derived carbon. The carbide-derived carbon preferably has micro pores of 1 nm or less.

Abstract: A system for delivering an input fuel stream to a fuel cell stack to generate electrical current and to discharge an unused fuel stream is provided. A supply produces a supply fuel stream. An ejector combines a purged fuel stream and the supply fuel stream and controls the flow of the input fuel stream to the fuel cell stack. A purging arrangement receives the unused fuel stream which includes impurities and purges the impurities from the unused fuel stream to generate the purged fuel stream. A bypass valve is capable of delivering the purged fuel stream to the ejector. A blower is capable of delivering the purged fuel stream to the ejector. A controller controls one of the bypass valve and the blower for delivering the purged fuel stream to the ejector based on the amount of electrical current generated by the fuel cell stack.

Abstract: A fuel cell includes separators sandwiching electrolyte electrode assemblies. The separators each include first and second fuel gas supply sections through which a fuel gas supply passage extends centrally, first and second bridges extending radially outwardly from the first and second fuel gas supply sections, and first and second sandwiching sections connected to the first and second bridges. A fuel gas channel and an oxygen-containing gas channel are provided in the first and second sandwiching sections. Each of the first sandwiching sections has pairs of fuel gas outlets and a fuel gas consumed in the fuel gas channel is discharged through the fuel gas outlets.

Abstract: In preferred aspect, the present invention features a membrane humidifier for a fuel cell which can control the amount of air flow and the amount of humidification based on the amount of water produced in a fuel cell stack according to a power level of the fuel cell stack while humidifying dry air and supplying humidified air to the fuel cell stack.

Abstract: An electrochemical cell includes a permeable fuel electrode configured to support a metal fuel thereon, and an oxidant reduction electrode spaced from the fuel electrode. An ionically conductive medium is provided for conducting ions between the fuel and oxidant reduction electrodes, to support electrochemical reactions at the fuel and oxidant reduction electrodes. A charging electrode is also included, selected from the group consisting of (a) the oxidant reduction electrode, (b) a separate charging electrode spaced from the fuel and oxidant reduction electrodes, and (c) a portion of the permeable fuel electrode. The charging electrode is configured to evolve gaseous oxygen bubbles that generate a flow of the ionically conductive medium. One or more flow diverters are also provided in the electrochemical cell, and configured to direct the flow of the ionically conductive medium at least partially through the permeable fuel electrode.

Abstract: A fuel cell, having a first electrode, a second electrode, and a membrane element, in which the membrane element is disposed between the first electrode and the second electrode. At least one of the electrodes has a flow field plate and at least one flow conduit, through which a reactant can be conducted, extends in at least one outer surface of the flow field plate. The flow field plate has at least one microreaction chamber, and the microreaction chamber is disposed in the outer surface and on the flow conduit. A catalyst is disposed on at least a part of the microreaction chamber in such a way that the catalyst has contact simultaneously with the membrane element and the inflowing reactant.

Abstract: Tube electrochemical reactor bundle or stack, having a structure, in which a plurality of tube fuel cells, formed of a dense ion conductor (electrolyte) and cathode (air electrode) laminated to an anode (fuel electrode) material having a tube structure, are electrically connected by a thin metallic wire, and an electrochemical reactor system using them are provided.

Abstract: One embodiment of the invention includes a process including providing an electrically conductive fuel cell component having a first face, and depositing a graphitic/conductive carbon film on the first face of the electrically conductive fuel cell component comprising sputtering a graphite target using a closed field unbalanced magnetron field.

Abstract: A planar solid oxide fuel cell stack which can expand in both the vertical and horizontal directions is disclosed. The planar solid oxide fuel cell stack comprises an interconnect which consists of an interconnect body, a first flowing area and a second flowing area, wherein the first and the second flowing area are disposed on opposite side of the interconnect body, and have one gas inlet and two gas outlets, respectively. By employing multiple hexagonal interconnects for cell stack expanding in the horizontal direction, each three stacks can share the same pipeline of the flow channel, thereby reaching the goals of reducing the space and materials required and system complexity as well.

Abstract: A bipolar plate for a fuel cell is provided that includes a pair of unipolar plates having a separator plate disposed therebetween. One of the unipolar plates is produced from a porous material to minimize cathode transport resistance at high current density. A fuel cell stack including a fuel cell and the bipolar plate is also provided.

Abstract: Described herein are fuel cell systems that include a cover affecting reactant flow into an electrochemical cell array of the system. The cover includes one or more transport barrier regions and one or more opened regions. The transport barrier regions are in proximity to active regions of the electrochemical cell array.

Abstract: A fuel cell has a membrane electrode assembly including an electrolyte membrane, catalyst layers disposed on both sides of the electrolyte membrane, and three or more layers of porous bodies disposed on a front surface side of the catalyst layer, a frame body surrounding an outer periphery of the electrolyte membrane, and a separator that partitions and forms a gas passage between the membrane electrode assembly and the separator. Extended portions are provided at an outer edge of a first porous body adjacent to the separator among the three layers of the porous bodies, and at an outer edge of a second porous body adjacent to the first porous body, respectively, so as to extend to be superimposed over the frame body. The extended portions of the first and second porous bodies intervene between the frame body and the separator.

Abstract: A manifold insert installed in a fuel cell having distribution guides is provided. The manifold insert is configured to form a flow field from an inlet port of fluid to an outlet port connected to a fuel cell stack. This manifold insert includes a plurality of distribution guides that divide the flow field from the inlet port to the outlet port such that the fuel cell stack is divided into a plurality of regions according to the distance from the inlet port. The distribution guides have surfaces that are at least partially curved such that the flow of the fluid from the inlet port to the outlet port is changed by the curved surfaces and form a plurality of guide flow fields such that the fluid is supplied to the divided regions of the fuel cell stack along the plurality of guide flow fields at different flow rates.

Abstract: A method of manufacturing a metal separator for a fuel cell includes molding two plates such that each plate has a least one concave portion and at least one convex portion, applying a sealant to a sealing portion of at least one of the plates, arranging the plates such that the concave portions of each plate are opposite the convex portions of the other plate, and spot welding the plates together. The sealing portion may be near an edge of the separator, between a hydrogen manifold, an oxygen manifold, and a coolant manifold. A sealant leakage prevention groove may further be provided at the sealing portion. The sealing portion may be made by being inserted between a projection on a first mold and a recess on a second mold, and a spot welding gun may be inserted through a guide hole in one of the molds.

Abstract: A fuel cell system comprises a main body including a first partial header and a fastening point. The main body is adapted to be coupled to a plurality of plates forming a fuel cell stack, allowing a single plate design to be used for multiple fuel cell stack lengths having a large differential of energy requirements, affording a durable alignment mechanism for the fuel cell stack, and providing integration flexibility for components and configurations of the fuel cell system.

Abstract: A case configuring a fuel cell system is divided into a module section, a first fluid supply section, a second fluid supply section, and an electric section. The electric section is provided with a first intake vent for intake of an oxidant gas from outside the case into the electric section. The second fluid supply section is provided with a second intake vent for intake of the oxidant gas subjected to intake from the first intake vent, into an oxidant gas supply device. The case is internally provided with first and second internal partitions which generate a bypass path for blocking straight flow of the oxidant gas from the first intake vent to the second intake vent.

Abstract: A fuel cell stack system is configured to uniformly supply a fuel or an electrolytic solution to each of fuel cell elements, and an electronic device using the fuel cell stack system are provided. An electrolytic solution channel allowing an electrolytic solution to flow therethrough is arranged between a fuel electrode and an oxygen electrode, and a fuel channel allowing a fuel to flow therethrough is arranged outside of the fuel electrode. The electrolytic solution channels and the fuel channels of all fuel cell elements are connected in series to one another. That is, the fuel or the electrolytic solution emitted from an outlet of the fuel channel or the electrolytic solution channel of one fuel cell element enters into an inlet of the fuel channel or the electrolytic solution channel of the next fuel cell element through a connection channel.

Abstract: In one embodiment, a bipolar plate includes a wall area and a landing area defining a fluid flow channel, and a plurality of wires extending from at least one of the landing area and the wall area. In another embodiment, an electrochemical cell includes the aforementioned bipolar plate and a gas diffusion layer (GDL) adjacent the bipolar plate and contacting at least a portion of the plurality of wires.

Abstract: Systems and methods for shunt current and mechanical loss mitigation in electrochemical systems include a conduit providing at least a portion of an electrically conductive pathway between the first and second electrochemical cells, wherein the conduit includes at least one shunt current suppression device configured as a loop, and/or a connector assembly for maintaining first and second connecting portions in adjacent positioning.

Abstract: Diffusion media for use in PEM fuel cells are provided with silicone coatings. The media are made of a porous electroconductive substrate, a first hydrophobic fluorocarbon polymer coating adhered to the substrate, and a second coating comprising a hydrophobic silicone polymer adhered to the substrate. The substrate is preferably a carbon fiber paper, the hydrophobic fluorocarbon polymer is PTFE or similar polymer, and the silicone is moisture curable.

Abstract: A fuel distributor assembly for a fuel cell stack that includes an inner shell positioned within an outer shell. The outer shell is curved to define a central longitudinal chamber, a first longitudinal edge and a second longitudinal edge. The outer shell also has an inner wall surface and an outer wall surface. The first longitudinal edge and the second longitudinal edge in combination define a longitudinal slot. The first longitudinal edge is bent inwardly towards the longitudinal chamber to form a longitudinal lip. The inner shell includes a plurality of ribs extending outwardly and contacting the inner wall surface of the outer shell. The inner shell, the outer shell, the lip, and the ribs define a plurality of flow channels. The inner shell has a length along which a plurality of apertures are positioned in a partial helical pattern. A method of forming the fuel distributor is also provided.