Abstract: A low compressive load seal for a solid polymer fuel cell employs two offset peripheral projections, one on each of the anode and cathode separator plates, for compressing a gasket. The design can achieve a seal against a given burst pressure with a lower load normal to the separator plates by creating significant compression parallel to the separator plates in the gap between the offset projections. The design allows for thinner fuel cell constructions while avoiding the issues that arise in prior art designs (e.g., stress on seal material and component crushing) if reasonable tolerances were allowed for variations in component thickness.

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 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.

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: 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: 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.