Abstract: A method for fabricating a fuel cell component includes the steps of providing a mask having a plurality of radiation transparent apertures, a radiation-sensitive material having a sensitivity to the plurality of radiation beams, and a flow field layer. The radiation-sensitive material is disposed on the flow field layer. The radiation-sensitive material is then exposed to the plurality of radiation beams through the radiation transparent apertures in the mask to form a diffusion medium layer with a micro-truss structure.

Abstract: A health monitoring system for a fuel cell stack using current fuel cell architecture to enable the electronic control unit (ECU) to continue to monitor the health of the fuel cell stack despite a component failure. The system uses an embedded measurement module (EMM) connected to a group of fuel cells in the fuel cell stack to monitor the health of that group of fuel cells. The EMM produces a pulse width modulation signal that is sent to the ECU. A total voltage value for the group of fuel cells is embedded into the calibration signal or end of frame sequence. The ECU uses an algorithm to determine a missing voltage of at least one fuel cell in the event of the component failure of that fuel cell by adding up the cumulative value for each fuel cell reporting their voltage and subtracting that value from the total voltage value found in the end of frame sequence.

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 method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and applying a second radiation-sensitive material to the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has a second sensitivity different from the first sensitivity. At least one mask is placed between at least one radiation source and the first and second radiation-sensitive materials. The mask has a plurality of substantially radiation-transparent apertures. The first and second radiation-sensitive materials are then exposed to a plurality of radiation beams through the radiation-transparent apertures in the mask to form a first construct in the first radiation-sensitive material and a second construct in the second radiation-sensitive material. The first construct and the second construct cooperate to form the radiation-cured structure.

Abstract: A method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and applying a second radiation-sensitive material to the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has a second sensitivity different from the first sensitivity. At least one mask is placed between at least one radiation source and the first and second radiation-sensitive materials. The mask has a plurality of substantially radiation-transparent apertures. The first and second radiation-sensitive materials are then exposed to a plurality of radiation beams through the radiation-transparent apertures in the mask to form a first construct in the first radiation-sensitive material and a second construct in the second radiation-sensitive material. The first construct and the second construct cooperate to form the radiation-cured structure.

Abstract: A fuel cell stack of at least two fuel cells, each fuel cell having a unitized electrode assembly (UEA) including a membrane electrode assembly (MEA), a sub-gasket and gas diffusion media (DM), and positioned between modified stamped field-flow plates. The sub-gasket frames the MEA resulting in an overlap area between the MEA and the inner perimeter of the sub-gasket. The UEA is disposed between a pair of stamped flow-field plates which align in adjacent fuel cells to form a bipolar plate. The bipolar plate has an active region, an overlap region and a seal region. The active region is configured with channel and land features which provide reactant flow channels and coolant passages for the fuel cell. The configuration of features in the overlap region, however, is modified from the configuration in the active region so that the overlap region may sustain sufficient mechanical sealing pressure, and to prevent coolant and reactant bypass without impeding coolant and reactant flow in the active area.

Abstract: A fuel cell system is provided which includes a compression retention enclosure with upper and lower compression shells and side sheet components coupled by interlocking hem joints. Methods for manufacturing compression retention enclosures with hem joints such that the enclosure remains sealed upon operational swelling of the fuel stack are also provided. A compression shell may be formed from a light weight composite structure having a polymeric layer interposed between steel skins, and an extension of the top steel skin may form a hemmed edge or may form a side sheet having a hemmed edge. Side sheet panels may be coupled to the end plates by interlocking two opposing hemmed edges to form the hem joint, or by sliding an opposing C-linking element between two hemmed edges held under compression force in an interlocking position.

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: Methods of making an integrated subgasket assembly, a unitized electrode assembly, an integrated fuel cell assembly, and products thereof. The methods include forming the subgasket by providing a base sheet having an initial thickness, stretching a first region of the base sheet a first distance, and forming an active area window in the base sheet.

Abstract: A fuel cell component includes a first fluid distribution layer, a second fluid distribution layer, a cap layer, a third fluid distribution layer, and a pair of fluid diffusion medium layers. The individual layers are polymeric, mechanically integrated, and formed from a radiation-sensitive material. The first fluid distribution layer, the second fluid distribution layer, the cap layer, the third fluid distribution layer, and the pair of fluid diffusion medium layers are coated with an electrically conductive material. A pair of the fuel cell components may be arranged in a stack with a membrane electrode assembly therebetween to form a fuel cell.

Abstract: A fuel cell component includes a first fluid distribution layer, a second fluid distribution layer, a cap layer, a third fluid distribution layer, and a pair of fluid diffusion medium layers. The individual layers are polymeric, mechanically integrated, and formed from a radiation-sensitive material. The first fluid distribution layer, the second fluid distribution layer, the cap layer, the third fluid distribution layer, and the pair of fluid diffusion medium layers are coated with an electrically conductive material. A pair of the fuel cell components may be arranged in a stack with a membrane electrode assembly therebetween to form a fuel cell.

Abstract: A health monitoring system for a fuel cell stack using current fuel cell architecture to enable the electronic control unit (ECU) to continue to monitor the health of the fuel cell stack despite a component failure. The system uses an embedded measurement module (EMM) connected to a group of fuel cells in the fuel cell stack to monitor the health of that group of fuel cells. The EMM produces a pulse width modulation signal that is sent to the ECU. A total voltage value for the group of fuel cells is embedded into the calibration signal or end of frame sequence. The ECU uses an algorithm to determine a missing voltage of at least one fuel cell in the event of the component failure of that fuel cell by adding up the cumulative value for each fuel cell reporting their voltage and subtracting that value from the total voltage value found in the end of frame sequence.

Abstract: A fuel cell component including a body disposed along a plane and having a boundary past which a reactant and water flows is provided. The boundary has a discontinuous edge adapted to militate against a pinning of the water at the edge. The fuel cell component may be a bipolar plate having a port hole with the discontinuous edge. The fuel cell component may be a subgasket for a fuel cell having a boundary with the discontinuous edge. The discontinuous edge facilitates a transportation of water from an upper surface of the fuel cell component to a lower surface of the fuel cell component.

Abstract: A separator plate for a fuel cell is provided, including a substrate having a radiation-cured first flow field layer disposed thereon. A method for fabricating the separator plate is also provided. The method includes the steps of providing a substrate; applying a first radiation-sensitive material to the substrate; placing a first mask between a first radiation source and the first radiation-sensitive material, the first mask having a plurality of substantially radiation-transparent apertures; and exposing the first radiation-sensitive material to a plurality of first radiation beams to form a radiation-cured first flow field layer adjacent the substrate. A fuel cell having the separator plate is also provided.

Abstract: Methods of making an integrated subgasket assembly, a unitized electrode assembly, an integrated fuel cell assembly, and products thereof. The methods include forming the subgasket by providing a base sheet having an initial thickness, stretching a first region of the base sheet a first distance, and forming an active area window in the base sheet.

Abstract: A combined subgasket and membrane support for a fuel cell is provided. The combined subgasket and membrane support includes a substantially fluid impermeable feed region circumscribing a porous membrane support region. The membrane support region is integrally formed with the feed region. At least one of the membrane support region and the feed region is at least partially formed by a radiation-cured structure. A method for fabricating the subgasket and membrane support for the fuel cell is also provided.

Abstract: A system for fabricating a radiation-cured structure is provided. The system includes a radiation-sensitive material configured to at least one of initiate, polymerize, crosslink and dissociate with exposure to radiation. At least one radiation source is configured to project a radiation beam toward the radiation-sensitive material. A smart glass device is disposed between the radiation-sensitive material and the at least one radiation source. The smart glass device includes at least one switchable layer selectively operable from an active state to an inactive state. The smart glass device is configured to expose the radiation-sensitive material to a desired exposure pattern when in one of the active state and the inactive state. A method for fabricating the radiation-cured structure is also provided.

Abstract: A method for fabricating a flowfield for a fuel cell includes the steps of: providing a substrate; providing a plurality of radiation sources configured to generate a plurality of radiation beams; disposing a radiation-sensitive material on the substrate; placing an imaging mask between the plurality of radiation sources and the radiation-sensitive material; and exposing the radiation-sensitive material to the plurality of radiation beams through a first portion of the radiation-transparent apertures and a second portion of the radiation-transparent apertures in the imaging mask to form the plurality of truss elements and the plurality of wall elements in the radiation-sensitive material, the truss elements forming a plurality of trusses configured to support an adjacent diffusion medium layer, and the wall elements defining a fluid path along a length of the substrate.

Abstract: A seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.

Abstract: A fuel cell component is provided, including a substrate disposed adjacent at least one radiation-cured flow field layer. The flow field layer is one of disposed between the substrate and a diffusion medium layer, and disposed on the diffusion medium layer opposite the substrate. The flow field layer has at least one of a plurality of reactant flow channels and a plurality of coolant channels for the fuel cell. The fuel cell component may be assembled as part of a repeating unit for a fuel cell stack. A method for fabricating the fuel cell component and the associated repeating unit for the fuel cell is also provided.