Abstract: An elastically averaged alignment system includes a first component comprising a plurality of alignment pins forming a first group of alignment pins, and a second component comprising an inner wall defining an alignment aperture, the alignment aperture configured to receive the first group of alignment pins to couple the first component and the second component. The alignment pins comprise an elastically deformable material such that when the first group of alignment pins is inserted into the alignment aperture, at least a portion of the alignment pins of the plurality of alignment pins elastically deform to an elastically averaged final configuration to facilitate coupling and aligning the first component and the second component in a desired orientation.

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.

Abstract: An elastic convex wall alignment and retention system includes a first component, second component, a plurality of elastic convex walls disposed on at least one of the first component and second component each having a convex wall surface, non-convex wall surface and a longitudinal axis and a pair of spaced-apart, retention features that oppose one another about the axis, each retention feature extending outwardly from the convex wall surface; and a plurality of apertures formed in at least one of the first component and second component, each aperture having an aperture wall, the plurality of apertures configured and arranged such that each elastic convex wall is receivable into a respective aperture, wherein each elastic convex wall is configured to elastically deform at an interface between the convex wall and the aperture wall upon insertion to establish an elastically averaged position of the first component to the second component.

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.

Abstract: An elastic tube alignment system for the mating of components utilizing the principle of elastic averaging. A plurality of geometrically separated elastic tube (male) alignment and attachment features are disposed on a first component, while a plurality of one-to-one corresponding aperture (female) alignment and attachment features are provided on a second component. During the mating of the components, each elastic tube and its respective aperture provide elastic deformation, which, on average, precisely aligns and attaches the components.