Abstract: Improved bipolar plates comprising complex features can be manufactured for fuel cells in a simple, low cost manner by starting with an appropriate extruded piece. The complex features include one or more fluid ports which connect to channels internal to the bipolar plate. The method includes extruding a continuous sheet with appropriate linear channels on each surface of the sheet as well as within the sheet, transversely cutting the sheet, machining a fluid port or ports through the sheet to intersect with appropriate internal linear channels, machining at least two sealing ports through the sheet to intersect with the internal linear channels on opposite sides of the fluid ports, and applying sealant into the sealing ports in order to make appropriate seals to the internal linear channels.

Abstract: Flow field plate constructions for bipolar plates are disclosed for use in fuel cell stacks that are subject to freezing temperatures. In designs having internal coolant flow fields and reactant backfeed ports, relief ducts are provided in the supporting walls surrounding the backfeed ports in order to allow for ice formation and thus prevent cracking of the plates.

Abstract: Flow field plate constructions for bipolar plates are disclosed for use in fuel cell stacks that are subject to freezing temperatures. In designs having internal coolant flow fields and reactant backfeed ports, relief ducts are provided in the supporting walls surrounding the backfeed ports in order to allow for ice formation and thus prevent cracking of the plates.

Abstract: A fuel cell electric power generation system using air as both a coolant and an oxidant comprises an electric power generation subsystem, an air filter subsystem, a power and control electronics unit (PEU) subsystem comprising a DC/DC converter, and an air fan subsystem. The subsystems are arranged such that air circulation through the system is improved and the risk of moisture damage to sensitive PEU components is reduced. In one embodiment, the air filter subsystem is positioned ahead of the PEU subsystem, which is positioned ahead of the power generation subsystem, which is positioned ahead of the air fan subsystem in the direction of air flow, such that air is drawn by the air fan subsystem through the air filter subsystem, over the PEU subsystem, and through the electric power generation subsystem, providing filtered air to cool the PEU prior to entering the fuel cell stack to provide oxygen for the electrochemical reaction.

Abstract: A membrane electrode assembly comprises an edge seal member, the edge seal member having a first compressive surface and an opposing second compressive surface wherein the first compressive surface comprises a seal protrusion and the opposing second compressive comprises an inner and outer seal protrusion. The seal protrusion on the first compressive surface is positioned asymmetrically in relation to the inner and outer seal protrusions on the second compressive surface such that the centerline of the seal protrusion on the first compressive surface is positioned between the centerline of the inner seal protrusion and the centerline of the outer seal protrusion on the second compressive surface. The seal protrusions may be shaped such that the base is wide and narrows toward a contacting end thereof, wherein the contacting end is in contact with a surface of a flow field plate.

Abstract: A membrane electrode assembly with an improved integrated seal comprises an edge seal having an inboard pad attached to the edge of the electrodes, a flexible coupling adjacent the pad, and a sealing element adjacent the coupling. The sealing element is significantly thicker than the pad, and the flexible coupling isolates the pad from stress experienced in the sealing element. Thus, greater compression can be applied to the sealing element, thereby providing an improved and more reliable seal, without overly compressing and damaging the attached pad.

Abstract: An electrically balanced fluid manifold assembly for supplying a fluid to an electrochemical fuel cell system comprising at least two fuel cell stacks electrically connected in series, each fuel cell stack comprising an inlet fluid port and an outlet fluid port, the manifold assembly comprising: a primary inlet fluid line; a primary outlet fluid line; at least two branch inlet fluid lines, fluidly connecting the primary inlet fluid line to each inlet fluid port of the at least two fuel cell stacks; and at least two branch outlet fluid lines, fluidly connecting each outlet fluid port of the at least two fuel cell stacks to the primary outlet fluid line, wherein the branch inlet fluid lines and the branch outlet fluid lines are configured such that the electrical resistance is essentially the same between (a) each inlet fluid port of the at least two fuel cell stacks and the primary inlet fluid line, and (b) each outlet fluid port of the at least two fuel cell stacks and the primary outlet fluid line.

Abstract: An integrated current collector and electrical component plate for a fuel cell stack is disclosed, comprising a printed circuit board comprising the following layers: a current collection layer, comprising a current collector; a first insulation layer, comprising a first surface and a second surface; an electrical component layer, comprising an electrical component having a first connection site and a second connection site; and a second insulation layer, comprising a first surface and a second surface, wherein the current collection layer is laminated to the first surface of the first insulation layer, and the electrical component layer is laminated between the second surface of the first insulation layer and the first surface of the second insulation layer. A fuel cell stack and methods for manufacturing a fuel cell stack comprising the integrated current collector and electrical component plate are also disclosed.