Abstract: An electrochemical cell having a membrane electrode assembly (MEA), and a gas diffusion layer (GDL) disposed proximate a side of the MEA with an edge of the GDL disposed inboard of an edge of the MEA is disclosed. A sealing member is disposed proximate the edge of the GDL and extends outward toward the edge of the MEA, thereby defining a discontinuity between the GDL and the sealing member. A protector member is disposed between the MEA and the GDL such that the protector member traverses the discontinuity.

Abstract: A bipolar plate for an electrochemical cell having a first side with a first fluid flow region bordered by a first sealing region, and a second side with a second fluid flow region bordered by a second sealing region is disclosed. The first and second sealing regions each include a plurality of non-continuous sealing features having overlapping ends that extend around the perimeter of the respective fluid flow region.

Abstract: A bipolar plate for an electrochemical cell is disclosed. The bipolar plate includes a unitary plate having first and second inlet ports, first and second outlet ports, first flow channels, and second flow channels. A first inlet header channel at one end of the first flow channels is in fluid communication with the first inlet port, and a first outlet header channel at the other end of the first flow channels is in fluid communication with the first outlet port. A second inlet header channel at one end of the second flow channels is in fluid communication with the second inlet port, and a second outlet header channel at the other end of the second flow channels is in fluid communication with the second outlet port. Each of the header channels includes a support surface sufficient to support a membrane-electrode-assembly while providing a fluid flow channel from one end of the respective header channel to the other end.

Abstract: A bipolar plate for an electrochemical cell having a first layer, a second layer, and a third layer is disclosed. The first layer has a first plurality of through channels oriented in a first direction. The second layer has a second plurality of through channels oriented in a second different direction. The third layer is disposed between and bonded to the first and second layers. The third layer has a first set of header channels in fluid communication with the first plurality of channels, and a second set of header channels in fluid communication with the second plurality of channels. A first inlet port and a first outlet port are in fluid communication with the first set of header channels, and a second inlet port and a second outlet port are in fluid communication with the second set of header channels. The bonded third layer prevents fluid communication between the first plurality of channels and the second plurality of channels.

Abstract: An electrochemical cell having a membrane electrode assembly (MEA), and a gas diffusion layer (GDL) disposed proximate a side of the MEA with an edge of the GDL disposed inboard of an edge of the MEA is disclosed. A sealing member is disposed proximate the edge of the GDL and extends outward toward the edge of the MEA, thereby defining a discontinuity between the GDL and the sealing member. A protector member is disposed between the MEA and the GDL such that the protector member traverses the discontinuity.

Abstract: A bipolar plate for an electrochemical cell having a first side with a first fluid flow region bordered by a first sealing region, and a second side with a second fluid flow region bordered by a second sealing region is disclosed. The first and second sealing regions each include a plurality of non-continuous sealing features having overlapping ends that extend around the perimeter of the respective fluid flow region.

Abstract: A bipolar plate for an electrochemical cell is disclosed. The bipolar plate includes a unitary plate having first and second inlet ports, first and second outlet ports, first flow channels, and second flow channels. A first inlet header channel at one end of the first flow channels is in fluid communication with the first inlet port, and a first outlet header channel at the other end of the first flow channels is in fluid communication with the first outlet port. A second inlet header channel at one end of the second flow channels is in fluid communication with the second inlet port, and a second outlet header channel at the other end of the second flow channels is in fluid communication with the second outlet port. Each of the header channels includes a support surface sufficient to support a membrane-electrode-assembly while providing a fluid flow channel from one end of the respective header channel to the other end.

Abstract: A bipolar plate for an electrochemical cell having a first layer, a second layer, and a third layer is disclosed. The first layer has a first plurality of through channels oriented in a first direction. The second layer has a second plurality of through channels oriented in a second different direction. The third layer is disposed between and bonded to the first and second layers. The third layer has a first set of header channels in fluid communication with the first plurality of channels, and a second set of header channels in fluid communication with the second plurality of channels. A first inlet port and a first outlet port are in fluid communication with the first set of header channels, and a second inlet port and a second outlet port are in fluid communication with the second set of header channels. The bonded third layer prevents fluid communication between the first plurality of channels and the second plurality of channels.

Abstract: An electrochemical cell includes a first electrode, a second electrode, a proton exchange membrane disposed between and in intimate contact with the electrodes, and a pressure pad disposed in electrical communication with the first electrode. The pressure pad is compatible with the cell environment and is configured to support the electrodes and the membrane. The pressure pad includes an electrically conductive member and a compression member disposed at the electrically conductive member. A method of maintaining compression within the cell includes disposing the electrically conductive member and the compression member at the first electrode, applying a load at the cell to compress the cell components, and maintaining electrical communication through the electrically conductive member.

Abstract: A method of forming a pressure pad can comprise: disposing a first electrically conductive member at a first compression member to form a first ring assembly; disposing a second electrically conductive member at a second compression member to form a second ring assembly; and arranging the first ring assembly at the second ring assembly in a concentric pattern.

Abstract: A unique electrically conductive pressure pad is employed in an electrochemical cell stack. The pressure pad includes integral mixture of electrically conductive material and polymeric material, generally formed of materials compatible with the electrochemical cell. The electrically conductive pressure pad is at least in partial fluid communication with the first electrode, the second electrode, or both the first and second electrodes.

Abstract: An electrochemical cell in which the cell frame is integrated with the flow field support member defining a contiguous surface includes an electrode, a proton exchange membrane and a flow field support member disposed at the electrode, a cell frame disposed at the flow field support member, and a membrane support element disposed intermediate the flow field support member and the frame. A resilient seal may be disposed at the cell frame. A method of integrating the frame with the flow field support member includes disposing the membrane support element in a gap between the frame and the flow field support member and melting the membrane support element into the frame and the flow field support member to form a contiguous surface. A method of sealing a flow field of the cell includes disposing a resilient seal at the cell frame.

Abstract: A unitary, porous, electrically conductive pressure pad is employed in an electrochemical cell stack. The pressure pad includes integral mixture of electrically conductive material and polymeric material, generally formed of materials compatible with the electrochemical cell. The electrically conductive pressure pad is preferably in at least in partial fluid communication with the first electrode, the second electrode, or both the first and second electrodes.

Abstract: An electrochemical cell system is disclosed, wherein at least one electrochemical cell is provided in a vessel. The electrochemical cells each include a membrane electrode assembly having a first electrode, a second electrode, and a membrane disposed between and in intimate contact with the first electrode and the second electrode. The vessel is disposed around the membrane electrode assembly. The vessel defines at least a portion of a first storage area that is in fluid communication with the first electrode. Further vessel defines at least a portion of a second storage area that is in fluid communication with the second electrode.

Abstract: A unitary, porous, electrically conductive pressure pad is employed in an electrochemical cell stack. The pressure pad includes integral mixture of electrically conductive material and polymeric material, generally formed of materials compatible with the electrochemical cell. The electrically conductive pressure pad is preferably in at least in partial fluid communication with the first electrode, the second electrode, or both the first and second electrodes.

Abstract: An electrochemical cell includes first and second electrodes, a proton exchange membrane disposed between and in intimate contact with the electrodes, and a pressure pad disposed in electrical communication with the first electrode. The pressure pad is configured to support the electrodes and the membrane and includes an electrically conductive member and a compression member disposed at the electrically conductive member. The compression member includes alternating rows of first and second perforations. The first perforations are dimensioned to threadedly receive the electrically conductive member therethrough, and the second perforations are configured and dimensioned to facilitate the distribution of pressure across a face of the pressure pad. A method of forming a pressure pad for an electrochemical cell includes disposing alternating rows of first and second perforations in an elastomeric member and threading an electrically conductive member through each row of the first perforations.

Abstract: An electrochemical cell includes a first electrode, a second electrode, a proton exchange membrane disposed between and in intimate contact with the electrodes, and a pressure pad disposed in electrical communication with the first electrode. The pressure pad is compatible with the cell environment and is configured to support the electrodes and the membrane. The pressure pad includes an electrically conductive member and a compression member disposed at the electrically conductive member. A method of maintaining compression within the cell includes disposing the electrically conductive member and the compression member at the first electrode, applying a load at the cell to compress the cell components, and maintaining electrical communication through the electrically conductive member.

Abstract: An electrochemical cell in which the cell frame is integrated with the flow field support member defining a contiguous surface includes an electrode, a proton exchange membrane and a flow field support member disposed at the electrode, a cell frame disposed at the flow field support member, and a membrane support element disposed intermediate the flow field support member and the frame. A resilient seal may be disposed at the cell frame. A method of integrating the frame with the flow field support member includes disposing the membrane support element in a gap between the frame and the flow field support member and melting the membrane support element into the frame and the flow field support member to form a contiguous surface. A method of sealing a flow field of the cell includes disposing a resilient seal at the cell frame.

Abstract: An electrochemical cell system is disclosed, wherein at least one electrochemical cell is provided in a vessel. The electrochemical cells each include a membrane electrode assembly having a first electrode, a second electrode, and a membrane disposed between and in intimate contact with the first electrode and the second electrode. The vessel is disposed around the membrane electrode assembly. The vessel defines at least a portion of a first storage area that is in fluid communication with the first electrode. Further vessel defines at least a portion of a second storage area that is in fluid communication with the second electrode.