Abstract: A trailer includes front and rear ends spaced in a longitudinal direction to define a cargo area. A frame includes a rear bolster extending in a transverse direction across the rear end below a bottom rear edge of the cargo area. Spaced rear frame posts extend upwardly from respective distal ends of the rear bolster. A rear impact guard includes a bumper extending transversely and spaced below the rear bolster, a pair of outboard posts extending between the bumper and the rear bolster adjacent the respective distal ends of the rear bolster, and at least one inboard post. Each of the outboard posts has a rearward-extending horizontal first flange and an upward-extending vertical second flange spaced forwardly of the first flange, these flanges including multiple apertures aligned with apertures in the trailer frame, each of the apertures accommodating a removable fastener securing the rear impact guard to the trailer frame.

Abstract: A trailer includes front and rear ends spaced in a longitudinal direction to define a cargo area. A frame includes a rear bolster extending in a transverse direction across the rear end below a bottom rear edge of the cargo area. Spaced rear frame posts extend upwardly from respective distal ends of the rear bolster. A rear impact guard includes a bumper extending transversely and spaced below the rear bolster, a pair of outboard posts extending between the bumper and the rear bolster adjacent the respective distal ends of the rear bolster, and at least one inboard post. Each of the outboard posts has a rearward-extending horizontal first flange and an upward-extending vertical second flange spaced forwardly of the first flange, these flanges including multiple apertures aligned with apertures in the trailer frame, each of the apertures accommodating a removable fastener securing the rear impact guard to the trailer frame.

Abstract: A trailer includes front and rear ends spaced in a longitudinal direction to define a cargo area. A frame includes a rear bolster extending in a transverse direction across the rear end below a bottom rear edge of the cargo area. Spaced rear frame posts extend upwardly from respective distal ends of the rear bolster. A rear impact guard includes a bumper extending transversely and spaced below the rear bolster, a pair of outboard posts extending between the bumper and the rear bolster adjacent the respective distal ends of the rear bolster, and at least one inboard post. Each of the outboard posts has a rearward-extending horizontal first flange and an upward-extending vertical second flange spaced forwardly of the first flange, these flanges including multiple apertures aligned with apertures in the trailer frame, each of the apertures accommodating a removable fastener securing the rear impact guard to the trailer frame.

Abstract: A trailer includes front and rear ends spaced in a longitudinal direction to define a cargo area. A frame includes a rear bolster extending in a transverse direction across the rear end below a bottom rear edge of the cargo area. Spaced rear frame posts extend upwardly from respective distal ends of the rear bolster. A rear impact guard includes a bumper extending transversely and spaced below the rear bolster, a pair of outboard posts extending between the bumper and the rear bolster adjacent the respective distal ends of the rear bolster, and at least one inboard post. Each of the outboard posts has a rearward-extending horizontal first flange and an upward-extending vertical second flange spaced forwardly of the first flange, these flanges including multiple apertures aligned with apertures in the trailer frame, each of the apertures accommodating a removable fastener securing the rear impact guard to the trailer frame.

Abstract: A subgasket for a fuel cell is provided. The subgasket includes a barrier layer having an elongate primary seal formed thereon. The seal has at least one inwardly extending baffle adapted to militate against a reactant bypass flow in the fuel cell. A fuel cell and fuel cell stack having the subgasket are also provided.

Abstract: A fuel cell stack and a bipolar plate assembly is provided that may include straight-through tunnels to transport fluids from one side of a header seal to an opposite side of a header seal, fluidly connecting fuel cell stack reactant headers and bipolar plate reactant flow channels.

Abstract: A method of depositing a thin gold coating on bipolar plate substrates for use in fuel cells includes depositing a gold coating onto at least one surface of the bipolar plate substrate followed by annealing the gold coating at a temperature between about 200° C. to 500° C. The annealed gold coating has a reduced porosity in comparison with a coating which has not been annealed, and provides improved corrosion resistance to the underlying metal comprising the bipolar plate.

Abstract: A subassembly for a fuel cell stack includes a fuel cell plate and a datum hole formed in the fuel cell plate for alignment of the fuel cell plate during assembly of the fuel cell stack. The subassembly also includes a datum insert disposed adjacent the datum hole of the fuel cell plate. The datum insert is configured to militate against a bending of the fuel cell plate at the datum hole during the assembly of the fuel cell stack.

Abstract: A subassembly for a fuel cell includes a fuel cell plate having a first side and a second side. Each of the first side and the second side has a flow field disposed between a pair of headers. An insulating spacer abuts the first side of the fuel cell plate and is disposed adjacent a perimeter of the fuel cell plate. A unitized electrode assembly includes a subgasket, a membrane electrode assembly, and a pair of diffusion medium layers. The membrane electrode assembly has an electrolyte membrane sandwiched between a pair of electrodes. The membrane electrode assembly is sandwiched between the pair of diffusion medium layers. The subgasket surrounds, and is coupled to, the membrane electrode assembly. The subgasket abuts the insulating spacer. An elastomeric seal abuts the second side of the fuel cell plate.

Abstract: A method of depositing a thin gold coating on bipolar plate substrates for use in fuel cells includes depositing a gold coating onto at least one surface of the bipolar plate substrate followed by annealing the gold coating at a temperature between about 200° C. to 500° C. The annealed gold coating has a reduced porosity in comparison with a coating which has not been annealed, and provides improved corrosion resistance to the underlying metal comprising the bipolar plate.

Abstract: A fluid distribution insert adapted to be received within an inlet header of a fuel cell assembly. The fluid distribution insert includes a hollow insert with a first end and a second end. An inlet is formed at the first end of the hollow insert in fluid communication with a source of a reactant gas and adapted to receive the reactant gas therein. An outlet is formed intermediate the first end and the second end. The outlet is adapted to deliver the reactant gas to a plurality of fuel cells of the fuel cell assembly, wherein the hollow insert delivers the reactant gas to the fuel cells in a substantially simultaneous and uniform manner.

Abstract: A bipolar plate for a fuel cell includes a pair of plates. Each plate has an active area, a header area, and a perimeter area. The perimeter area is disposed adjacent an edge of the plate. The perimeter area is also disposed adjacent to each of the active area and the header area. At least one of the plates includes a raised support feature having an inboard side and an outboard side. The plates are joined in the perimeter area between the outboard side of the raised support feature and the edges of the plates.

Abstract: An integrated fuel cell assembly is described. The integrated fuel cell assembly includes a polymer membrane; an anode electrode and a cathode electrode on opposite sides of the polymer membrane; a pair of gas diffusion media on opposite sides of the polymer membrane, the gas diffusion media comprising a microporous layer and a gas diffusion layer, the anode electrode and the cathode electrode positioned between the polymer membrane and the pair of gas diffusion media; a subgasket positioned around a perimeter of one of the gas diffusion media, the subgasket defining an active area inside the perimeter, the subgasket having a layer of thermally activated adhesive thereon; and a bipolar plate sealed to the subgasket by the layer of thermally activated adhesive. Methods of making the integrated fuel cell assembly and assembling fuel cell stacks are also described.

Abstract: A fuel cell plate assembly is disclosed that comprises a first plate having a plurality of protuberances formed in a bottom of flow channels formed thereon, wherein the protuberances abut a bottom of flow channels formed on a second plate when the first plate and the second plate are disposed adjacent one another.

Abstract: A fuel cell assembly is disclosed, the fuel cell assembly including a pair of terminal plates, one terminal plate disposed at each end of the fuel cell assembly, a fuel cell disposed between a pair of end fuel cells and the terminal plates, and a thermally insulating, electrically conductive layer formed between the fuel cell and one of the terminal plates adapted to mitigate thermal losses from the end plate, and fluid condensation and ice formation in an end fuel cell. The end fuel cells of the fuel cell assembly have a membrane and/or a cathode having a thickness greater than an average thickness of a membrane and/or a cathode disposed in the fuel cell that may be used in conjunction with, or instead of, the insulating layer to further mitigate thermal losses from the end plate, and fluid condensation and ice formation in the end fuel cells.

Abstract: A fuel cell stack and a bipolar plate assembly is provided that may include straight-through tunnels to transport fluids from one side of a header seal to an opposite side of a header seal, fluidly connecting fuel cell stack reactant headers and bipolar plate reactant flow channels.

Abstract: A bipolar plate for a fuel cell includes a pair of plates. Each plate has an active area, a header area, and a perimeter area. The perimeter area is disposed adjacent an edge of the plate. The perimeter area is also disposed adjacent to each of the active area and the header area. At least one of the plates includes a raised support feature having an inboard side and an outboard side. The plates are joined in the perimeter area between the outboard side of the raised support feature and the edges of the plates.

Abstract: A subassembly for a fuel cell includes a fuel cell plate having a first side and a second side. Each of the first side and the second side has a flow field disposed between a pair of headers. An insulating spacer abuts the first side of the fuel cell plate and is disposed adjacent a perimeter of the fuel cell plate. A unitized electrode assembly includes a subgasket, a membrane electrode assembly, and a pair of diffusion medium layers. The membrane electrode assembly has an electrolyte membrane sandwiched between a pair of electrodes. The membrane electrode assembly is sandwiched between the pair of diffusion medium layers. The subgasket surrounds, and is coupled to, the membrane electrode assembly. The subgasket abuts the insulating spacer. An elastomeric seal abuts the second side of the fuel cell plate.

Abstract: A subassembly for a fuel cell stack includes a fuel cell plate and a datum hole formed in the fuel cell plate for alignment of the fuel cell plate during assembly of the fuel cell stack. The subassembly also includes a datum insert disposed adjacent the datum hole of the fuel cell plate. The datum insert is configured to militate against a bending of the fuel cell plate at the datum hole during the assembly of the fuel cell stack.

Abstract: An integrated fuel cell assembly is described. The integrated fuel cell assembly includes a polymer membrane; an anode electrode and a cathode electrode on opposite sides of the polymer membrane; a pair of gas diffusion media on opposite sides of the polymer membrane, the gas diffusion media comprising a microporous layer and a gas diffusion layer, the anode electrode and the cathode electrode positioned between the polymer membrane and the pair of gas diffusion media; a subgasket positioned around a perimeter of one of the gas diffusion media, the subgasket defining an active area inside the perimeter, the subgasket having a layer of thermally activated adhesive thereon; and a bipolar plate sealed to the subgasket by the layer of thermally activated adhesive. Methods of making the integrated fuel cell assembly and assembling fuel cell stacks are also described.