Abstract: In a method and apparatus for cutting expanded graphite sheet material, at least one cutting tool is urged against the sheet(s). The cutting tool has at least one ridge extending therefrom that includes a substantially tapered cross-section having sloping sides and an edge surface. At least a portion of the sheet material is displaced as the ridge is urged against the sheet. A region of the sheet material in contact with the ridge is compressed so that the density of the region reaches or exceeds the breaking density of the sheet.

Abstract: A flow field plate assembly for an electrochemical fuel cell comprises two flow field plates, each of which has channels formed on an inner surface of the plate. The plates are alignable with and engage each other such that their cooperating inner surfaces form at least one inner coolant fluid channel. The coolant channel has an essentially constant cross-sectional perimeter along its length, which is defined by the perimeters of the channels of the two plates and their difference in width at the cooperating plate surfaces. Additionally, a flow field plate assembly, which comprises a corrugated flow field plate and a staggered flow field plate, is structurally stronger under compressive load during the fuel cell operation.

Abstract: In a method and apparatus for cutting expanded graphite sheet material, at least one cutting tool is urged against the sheet(s). The cutting tool has at least one ridge extending therefrom, that includes a substantially tapered cross-section having sloping sides and an edge surface. At least a portion of the sheet material is displaced as the ridge is urged against the sheet. A region of the sheet material in contact with the ridge is compressed so that the density of the region reaches or exceeds the breaking density of the sheet.

Abstract: In a method and apparatus for cutting expanded graphite sheet material, at least one cutting tool is urged against the sheet(s). The cutting tool has at least one ridge extending therefrom that includes a substantially tapered cross-section having sloping sides and an edge surface. At least a portion of the sheet material is displaced as the ridge is urged against the sheet. A region of the sheet material in contact with the ridge is compressed so that the density of the region reaches or exceeds the breaking density of the sheet.

Abstract: A flow field plate assembly for an electrochemical fuel cell comprises two flow field plates, each of which has channels formed on an inner surface of the plate. The plates are alignable with and engage each other such that their cooperating inner surfaces form at least one inner coolant fluid channel. The coolant channel has an essentially constant cross-sectional perimeter along its length, which is defined by the perimeters of the channels of the two plates and their difference in width at the cooperating plate surfaces. Additionally, a flow field plate assembly, which comprises a corrugated flow field plate and a staggered flow field plate, is structurally stronger under compressive load during the fuel cell operation.

Abstract: An electrochemical fuel cell stack with improved reactant manifolding and sealing includes a pair of separator plates interposed between adjacent membrane electrode assemblies. Passageways fluidly interconnecting the anodes to a fuel manifold, and interconnecting the cathodes to an oxidant manifold, comprise at least one fluid passageway formed between adjoining non-active surfaces of the pairs of separator plates. The passageways extend through one or more ports penetrating the thickness of one of the plates thereby fluidly connecting the manifold to the opposite active surface of that plate, and the adjacent electrode. The ports comprise walls that have surfaces that are angled more than 0 degrees and less than 90 degrees with respect to the direction of fluid flow in the fluid passageway upstream of the port. During operation, electrochemical fuel cell stacks comprising fluid ports with angled walls benefit from reduced pressure loss.

Abstract: A method and apparatus for cutting an expanded graphite sheet comprises (a) urging at least one cutting tool against the sheet, the cutting tool having at least one ridge extending therefrom, the ridge comprising a substantially tapered cross-section having sloping sides and an edge surface; (b) displacing at least a portion of the material comprising the sheet as the ridge is urged against the sheet; and (c) compressing a region of the sheet in contact with the at least one ridge so that the density of the region at least reaches the breaking density of the sheet.

Abstract: An electrochemical fuel cell stack with improved reactant manifolding and sealing includes a pair of separator plates interposed between adjacent membrane electrode assemblies. Passageways fluidly interconnecting the anodes to a fuel manifold, and interconnecting the cathodes to an oxidant manifold, comprise at least one fluid passageway formed between adjoining non-active surfaces of the pairs of separator plates. The passageways extend through one or more ports penetrating the thickness of one of the plates thereby fluidly connecting the manifold to the opposite active surface of that plate, and the adjacent electrode. The ports comprise walls that have surfaces that are angled more than 0 degrees and less than 90 degrees with respect to the direction of fluid flow in the fluid passageway upstream of the port. During operation, electrochemical fuel cell stacks comprising fluid ports with angled walls benefit from reduced pressure loss.

Abstract: An electrochemical fuel cell stack with improved reactant manifolding and sealing includes a pair of separator plates interposed between adjacent membrane electrode assemblies. Passageways fluidly interconnecting the anodes to a fuel manifold, and interconnecting the cathodes to an oxidant manifold, comprise at least one fluid passageway formed between adjoining non-active surfaces of the pairs of separator plates. The passageways extend through one or more ports penetrating the thickness of one of the plates thereby fluidly connecting the manifold to the opposite active surface of that plate, and the adjacent electrode. The ports comprise walls that have surfaces that are angled more than 0 degrees and less than 90 degrees with respect to the direction of fluid flow in the fluid passageway upstream of the port. During operation, electrochemical fuel cell stacks comprising fluid ports with angled walls benefit from reduced pressure loss.