Abstract: A microseal for a metal bead seal joint includes a substantially horizontal surface, first and second substantially vertical surfaces disposed on opposite ends of the substantially horizontal surface, and a contoured surface operatively configured to adhere to a portion of a metal bead. The contoured surface may be disposed opposite the substantially horizontal surface and may be integral to the first and second substantially vertical surfaces. The substantially horizontal surface may be operatively configured to substantially maintain its horizontal surface orientation in both a compression state and a non-compression state.

Abstract: A plate includes a planar portion and a circular bead, or circular bead seal, that is offset from the planar portion. An axis is substantially perpendicular to the planar portion, and the circular bead arcs about the axis. The axis may be defined by a hole through the planar portion that is substantially surrounded by the circular bead. One or more displacement absorption tunnels is offset from the planar portion and extends radially relative to the axis. Each of the displacement absorption tunnels intersects the circular bead. In some configurations the displacement absorption tunnels may have an arcuate shape, and in some configurations the displacement absorption tunnels may have a trapezoidal shape. A plurality of plates having similar, though not identical, features may be stacked together.

Abstract: A power generation cell (fuel cell) includes a membrane electrode assembly and first and second metallic separators arranged respectively on opposite sides of the membrane electrode assembly. An oxygen containing gas supply passage, a communication passage bead section (bead seal) that surrounds the oxygen containing gas supply passage, and a bridge section are disposed on the first metallic separator. At a location where the bridge section is disposed, the width of a root section of the communication passage bead section is greater than the width of the root section of the communication passage bead section at other locations thereof.

Abstract: Systems and methods including a header flange to evenly distribute contact pressure across seals include, in some aspects, a plate including a bead and a flange edge. The bead includes a bead-side and a bead-corner. The flange edge defines an aperture through the plate. The flange edge also includes a first edge-portion proximate the bead-side and a second edge-portion proximate the bead-corner. The bead-side and the first edge-portion define a first edge-distance therebetween. The bead-corner and the second edge-portion define a second edge-distance therebetween. The second edge-distance is greater than the first edge-distance.

Abstract: Methods for designing one or a pair of half plates of a fuel cell include providing a first half plate defining a first half plate metal bead, wherein the first half plate metal bead protrudes from the first half plate forming a convex side, providing a second half plate defining a second plate metal bead, wherein the second half plate metal bead protrudes from the second half plate forming a convex side, determining a pressure profile between the convex sides of the first half plate metal bead and the second half plate metal bead in a compressed state, and adjusting a height of the first half plate metal bead and/or the second half plate metal bead in one or more locations to increase the uniformity of the pressure profile. Increasing the uniformity of the pressure profile can include reducing a range of the plurality of pressure measurements.

Abstract: A plate includes a planar portion and a circular bead, or circular bead seal, that is offset from the planar portion. An axis is substantially perpendicular to the planar portion, and the circular bead arcs about the axis. The axis may be defined by a hole through the planar portion that is substantially surrounded by the circular bead. One or more displacement absorption tunnels is offset from the planar portion and extends radially relative to the axis. Each of the displacement absorption tunnels intersects the circular bead. In some configurations the displacement absorption tunnels may have an arcuate shape, and in some configurations the displacement absorption tunnels may have a trapezoidal shape. A plurality of plates having similar, though not identical, features may be stacked together.

Abstract: An end plate unit for use in a fuel cell stack in an electric vehicle is provided wherein the end plate includes an outer surface, an inner surface disposed opposite the outer surface and a current collector. The inner surface defines at least a first region and a second region which is spaced apart from and substantially parallel to the first region. The current collector may be affixed to the inner surface.

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 plate includes a working face and a header portion. The working face defines a plurality of reactant channels thereon. The header portion is disposed in a peripheral area of the plate and includes a plurality of flanges and a plurality of beads. The flanges are disposed on the header portion and define a plurality of apertures through the plate. Each flange defines a respective one of the apertures. At least one of the apertures is fluidly connected to the reactant channels. The plurality of beads is disposed on the working face. Each bead is disposed about a respective one of the apertures and thereby defines a respective one of the flanges. Each bead defines a shape consisting of bead-corners and bead-sides. Each bead has a sealing surface thereon. The sealing surface is configured to deflect when exposed to a contact pressure to thereby provide a substantially fluid-tight seal.

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 plate assembly includes a first plate having a planar portion and a first bead seal formed therein. The first bead seal includes a first end surface spaced away from the planar portion. The first bead seal includes first and second opposing sides extending away from the first end surface and contiguous with the planar portion. The first bead seal includes a first reinforcement structure having a first plurality of walls each intersecting the first opposing side of the first bead seal. The first plate includes a second bead seal formed therein. The first bead seal and the second bead seal may be joined via the first reinforcement structure such that the first plurality of walls of the first reinforcement structure each intersect a third opposing side of the second bead seal.

Abstract: Methods for designing one or a pair of half plates of a fuel cell include providing a first half plate defining a first half plate metal bead, wherein the first half plate metal bead protrudes from the first half plate forming a convex side, providing a second half plate defining a second plate metal bead, wherein the second half plate metal bead protrudes from the second half plate forming a convex side, determining a pressure profile between the convex sides of the first half plate metal bead and the second half plate metal bead in a compressed state, and adjusting a height of the first half plate metal bead and/or the second half plate metal bead in one or more locations to increase the uniformity of the pressure profile. Increasing the uniformity of the pressure profile can include reducing a range of the plurality of pressure measurements.

Abstract: The present disclosure provides a fuel cell stack having a plurality of bipolar plates aligned between a pair of end plates. Each of the bipolar plates further includes a first bead and a second bead. The first bead defines a first bead height, and the second bead defines a second bead height wherein the second bead height is less than the first bead height.

Abstract: Systems and methods including a header flange to evenly distribute contact pressure across seals include, in some aspects, a plate including a bead and a flange edge. The bead includes a bead-side and a bead-corner. The flange edge defines an aperture through the plate. The flange edge also includes a first edge-portion proximate the bead-side and a second edge-portion proximate the bead-corner. The bead-side and the first edge-portion define a first edge-distance therebetween. The bead-corner and the second edge-portion define a second edge-distance therebetween. The second edge-distance is greater than the first edge-distance.

Abstract: A fuel cell stack assembly for a vehicle is provided which includes a first end plate, a second end plate; and a first plurality of fuel cells disposed between the first and second end plates. The first plurality of fuel cells may define a repeating pattern of a thick fuel cell adjacent to a thin fuel cell. Each fuel cell in the first plurality of fuel cells having an active area thickness. The fuel cell stack assembly of the present disclosure may further include a second plurality of nominal fuel cells.

Abstract: A method for manufacturing a bipolar plate includes forming two half-plates by stamping a metal substrate to form a plurality of flow channels and a plurality of beads projecting from a first surface of the metal substrate, wherein the plurality of beads include a peripheral bead and one or more aperture beads, each aperture bead being proximate to one or more aperture locations, and wherein each bead has a convex surface and a concave surface, and subsequently compressing the plurality of beads in a die such that the cross-sectional perimeter of each bead is reduced. The half-plates can be joined subsequent to compressing such that at least portions of a second side of the first half-plate are contiguous with at least portions of a second side of the second half-plate, and the one or more aperture locations of each plate align. The beads can be trapezoidal.

Abstract: A number of variations may include at least one bipolar plate which may include at least one bead, the bead may include a plurality of crest portions and a plurality of trough portions having at least one tangent portion disposed between adjacent crest portions and trough portions; the bipolar plate further may include at least one tunnel defining at least one through hole within the at least one tangent portion.

Abstract: A bipolar plate for a fuel cell includes a first plate having a first bead seal, and a second plate having a second bead seal. The first bead seal and the second bead seal are disposed opposite each other and extend along a centerline. An outer weld connects the first plate and the second plate together, and extends along an outer weld line. The outer weld line is laterally spaced an outer gap distance from an outer lateral edge of the first and second bead seals. The outer gap distance varies with a position along the centerline to control a stiffness of the bead seals. Positioning the weld line nearer the outer lateral edge increases the stiffness of the raised bead seals in low stiffness areas, whereas positioning the weld line farther from the lateral edge decreases the stiffness of the raised bead seals in high stiffness areas.

Abstract: A method for assembling a fuel cell stack for a vehicle is provided wherein the method includes the steps of: (1) providing a batch of fuel cells having varying active area thicknesses among each fuel cell; (2) measuring an active area thickness for each fuel cell in the batch of fuel cells and sorting each fuel cell in the batch of fuel cells into one of a first group, a second group, and a third group based on the active area thickness for each fuel cell; (3) assembling a target number of fuel cells to a target height from at least one of the first, second and third groups onto a first end plate; and (4) affixing a second end plate to the target number of fuel cells and the first end plate thereby creating a fuel cell stack.

Abstract: A microseal for a metal bead seal joint includes a substantially horizontal surface, first and second substantially vertical surfaces disposed on opposite ends of the substantially horizontal surface, and a contoured surface operatively configured to adhere to a portion of a metal bead. The contoured surface may be disposed opposite the substantially horizontal surface and may be integral to the first and second substantially vertical surfaces. The substantially horizontal surface may be operatively configured to substantially maintain its horizontal surface orientation in both a compression state and a non-compression state.