Abstract: A fuel cell flow field plate providing a uniform gas flow pressure includes a first metal plate and a second metal plate. The first metal plate defines a first opening for providing a first reactant gas to a fuel cell with a first metal bead that surrounds the first opening. The first metal bead is an embossment that defines a first channel. A first plurality of tunnels provides a passage into and out of the first metal bead. Each tunnel of the first plurality of tunnels has an inlet tunnel section that leads to the first metal bead and an outlet tunnel section that extends from the first metal bead to provide the first reactant gas to first reactant gas flow channels defined by the first metal plate. Characteristically, the inlet tunnel section and the outlet tunnel section each having a curved cross section with an opened base side.

Abstract: A number of variations may include a product that may include a fuel cell stack assembly that may include at least one bipolar plate including at least one first raised bead which may include a first split corner which may include a first connection.

Abstract: A fuel cell flow field plate providing a uniform gas flow pressure includes a first metal plate and a second metal plate. The first metal plate defines a first opening for providing a first reactant gas to a fuel cell with a first metal bead that surrounds the first opening. The first metal bead is an embossment in the second metal plate that defines a first channel. The first metal plate also defines a first pressure distributing structure that decreases pressure variation is a seal formed with the first metal bead. A second metal plate aligns with the first metal plate.

Abstract: A bipolar plate assembly and fuel cell stack with reduced leakage and a method of assembling a bipolar plate and fuel cell stack. The bipolar plates include—in addition to reactant channels and coolant channels that are fluidly coupled to inlet and outlet flowpaths, integrally-formed seals to help reduce leakage by maintaining fluid isolation of the reactants and coolant as they flow through their respective channels and flowpaths. The size and shape of the seals promotes secure plate-to-plate contact, even during plate side-to-side misalignment that can occur when arranging the various plates into the stack.

Abstract: A fuel cell flow field plate providing a uniform gas flow pressure includes a first metal plate and a second metal plate. The first metal plate defines a first opening for providing a first reactant gas to a fuel cell with a first metal bead that surrounds the first opening. The first metal bead is an embossment in the second metal plate that defines a first channel. The first metal plate also defines a first pressure distributing structure that decreases pressure variation is a seal formed with the first metal bead. A second metal plate aligns with the first metal plate.

Abstract: A number of variations may include a product that may include a fuel cell stack assembly that may include at least one bipolar plate that may include at least one raised bead and at least one raised limiter.

Abstract: A number of variations may include a product that may include a fuel cell stack assembly that may include at least one bipolar plate including at least one first raised bead which may include a first split corner which may include a first connection.

Abstract: A fuel cell flow field plate providing a uniform gas flow pressure includes a first metal plate and a second metal plate. The first metal plate defines a first opening for providing a first reactant gas to a fuel cell with a first metal bead that surrounds the first opening. The first metal bead is an embossment that defines a first channel. A first plurality of tunnels provides a passage into and out of the first metal bead. Each tunnel of the first plurality of tunnels has an inlet tunnel section that leads to the first metal bead and an outlet tunnel section that extends from the first metal bead to provide the first reactant gas to first reactant gas flow channels defined by the first metal plate. Characteristically, the inlet tunnel section and the outlet tunnel section each having a curved cross section with an opened base side.

Abstract: A bipolar plate assembly and fuel cell stack with reduced leakage and a method of assembling a bipolar plate and fuel cell stack. The bipolar plates include—in addition to reactant channels and coolant channels that are fluidly coupled to inlet and outlet flowpaths, integrally-formed seals to help reduce leakage by maintaining fluid isolation of the reactants and coolant as they flow through their respective channels and flowpaths. The size and shape of the seals promotes secure plate-to-plate contact, even during plate side-to-side misalignment that can occur when arranging the various plates into the stack.

Abstract: Systems and methods are disclosed that provide for a bipolar plate for a fuel cell system that includes cross flow channels facilitating reactant flow between primary reactant flow channels. In certain embodiments, the cross flow channels may allow for improved reactant flow distribution across catalyst layers of the fuel cell system. In further embodiments, the cross flow channels may increase a reaction interface area in the fuel system, thereby improving the performance of the system.

Abstract: An alignment system and method for assembling a fuel cell stack. Components of the fuel cell stack have internal alignment features and are aligned to a predetermined orientation during assembly. The system and method allow fuel cell stacks to be assembled within high tolerance levels while improving access to each component during assembly. Additionally, the system and method can provide additional rigidity to a fuel cell stack.

Abstract: An alignment system and method for assembling a fuel cell stack. Components of the fuel cell stack have internal alignment features and are aligned to a predetermined orientation during assembly. The system and method allow fuel cell stacks to be assembled within high tolerance levels while improving access to each component during assembly. Additionally, the system and method can provide additional rigidity to a fuel cell stack.

Abstract: A unitized plate such as a bipolar plate for a fuel cell assembly is provided. The unitized plate includes a plurality of active regions electrically insulated from one another, and a plurality of inlet and outlet apertures formed in the plate. Each of the active regions is in fluid communication with a dedicated inlet aperture adapted to selectively deliver gaseous reactants thereto. A fuel cell assembly having a plurality of independently operable fuel cell stack units, and a method for operating the fuel cell assembly, is also provided.

Abstract: An alignment system and method for assembling a fuel cell stack. Components of the fuel cell stack have internal alignment features and are aligned to a predetermined orientation during assembly. The system and method allow fuel cell stacks to be assembled within high tolerance levels while improving access to each component during assembly. Additionally, the system and method can provide additional rigidity to a fuel cell stack.

Abstract: A unitized plate such as a bipolar plate for a fuel cell assembly is provided. The unitized plate includes a plurality of active regions electrically insulated from one another, and a plurality of inlet and outlet apertures formed in the plate. Each of the active regions is in fluid communication with a dedicated inlet aperture adapted to selectively deliver gaseous reactants thereto. A fuel cell assembly having a plurality of independently operable fuel cell stack units, and a method for operating the fuel cell assembly, is also provided.

Abstract: A WVT unit that humidifies a cathode inlet airflow to a fuel cell stack in a fuel cell system. In one embodiment, the WVT unit includes a series of membranes separated by plates defining flow channels at both sides of the membrane. The humidifying gas, typically a cathode outlet gas from the fuel cell stack, flows down the flow channels on one side of each membrane and the cathode inlet air flows down the flow channels on an opposite side of each membrane. According to the invention, the plates have a hydrophilic film so that more water vapor in the humidifying flow channels is exposed to the membrane, and therefore more water is transferred to the cathode airflow.

Abstract: A non-functional fuel cell for a fuel cell stack includes a shim disposed between gas diffusion media, a bipolar plate at one end, and either a bipolar plate or a unipolar plate at the other end. The shim of the non-functional cell replaces the membrane electrode assembly (MEA) in a normal fuel cell located in the middle or the end of the fuel cell stack. The shim is coated with electrically conductive, corrosion-resistant protective coating. The shim may be cleaned prior to applying the protective coating to remove an oxide layer from the surface of the shim. The non-functional fuel cell may be included in the initial design of the fuel cell stack, or may be used to replace one or more damaged or inoperative fuel cells to increase the overall performance of the fuel cell stack.