Abstract: A die assembly for use in a stamping press is provided. The die assembly includes a first die plate, a first curved die stiffener, and a first die shoe. The first die plate may be configured to form at least a portion of material into a desired configuration. The first curved die stiffener may be affixed to the first die plate on a first curved side of the first curved die stiffener. The first die shoe may be affixed to a second side of the first curved die stiffener. The first die shoe may be operatively configured to be mounted on a first press base.

Abstract: A plate structure includes a plate having a planar portion defining a datum plane. The plate includes a raised bead seal and a tunnel protruding away from the datum plane. The raised bead seal extends along a centerline laying on the datum plane. The tunnel extends along a path laying on the datum plane. The tunnel intersects the raised bead seal. The path and the centerline intersect to form a first intersection angle and an adjacent second intersection angle on the datum plane. The first intersection angle and the second intersection angle are supplementary angles. The first intersection angle is an acute angle, and the second intersection angle is an obtuse angle. The path and the centerline are arranged to form a specific value of the first intersection angle and the second intersection angle to control a stiffness of the raised bead seal.

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 plate assembly includes a first plate and a second plate positioned adjacent to one another. The first plate includes a first sealing member formed thereon. The second plate includes a second sealing member formed thereon. The first sealing member includes a first end surface and first opposing sides extending from the first end surface. The second sealing member includes a second end surface and second opposing sides extending from the second end surface. The first and second sealing members are offset relative to one another by a first offset distance (D1) in a first longitudinal direction. By varying the sealing member's base width periodically, a greater sealing force is achieved. By offsetting alignment of pairs of sealing members along the seal path, uniform pressure along the seal path is achieved.

Abstract: The present disclosure provides a fuel cell stack having a plurality of bipolar plates aligned in a stack between a pair of bipolar plates wherein each of the bipolar plates includes an outer bead having an interior cavity; and an inner bead having a trough wherein the inner bead extends into the interior cavity of the outer bead. The trough of the inner bead may be at least about 50% filled with an elastomeric seal.

Abstract: A method for manufacturing a stamped member includes the steps of: (1) stamping sheet metal within a stamping press system; (2) assembling the stamped sheet metal with other stamped members to form a plurality of bipolar plates; (3) pre-compressing the first bipolar plate between a pair of flat fixture plates; (4) obtaining first contact pressure variation data; (5) providing a customized patterned fixture which corresponds to the first contact pressure measurement data; (6) pre-compressing the second bipolar plate with the customized patterned fixture; and (7) obtaining second contact pressure variation data.

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: The present disclosure provides a fuel cell stack having a plurality of bipolar plates aligned in a stack between a pair of bipolar plates wherein each of the bipolar plates includes an outer bead having an interior cavity; and an inner bead having a trough wherein the inner bead extends into the interior cavity of the outer bead. The trough of the inner bead may be at least about 50% filled with an elastomeric seal.

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 in the second metal plate that defines a first channel. The first metal plate also defines a first pressure distributing structure that decreases pressure variation is a seal formed with the first metal bead. A second metal plate aligns with the first metal plate.

Abstract: A bipolar plate assembly and fuel cell stack with reduced leakage and a method of assembling a bipolar plate and fuel cell stack. The bipolar plates include—in addition to reactant channels and coolant channels that are fluidly coupled to inlet and outlet flowpaths, integrally-formed seals to help reduce leakage by maintaining fluid isolation of the reactants and coolant as they flow through their respective channels and flowpaths. The size and shape of the seals promotes secure plate-to-plate contact, even during plate side-to-side misalignment that can occur when arranging the various plates into the stack.

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 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 the steps of: (1) providing sheet metal within a stamping press system; (2) stamping the sheet metal with a first die to define an interim flat land, a first interim sidewall, a second interim sidewall, and a first interim channel depth for a plurality of flow channels; and (3) stamping the sheet metal with a second die to widen the interim flat land in each flow channel in the plurality of flow channels forming a final flat land and to reduce each interim radii of each flow channel in the plurality of flow channels. The stamping press system may, but not necessarily, include a first press station having a first die set and a second press station having a second die set wherein the second press station is applied to the sheet metal after it has been formed by the first press station.

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 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: 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 plate structure includes a plate having a planar portion defining a datum plane. The plate includes a raised bead seal and a tunnel protruding away from the datum plane. The raised bead seal extends along a centerline laying on the datum plane. The tunnel extends along a path laying on the datum plane. The tunnel intersects the raised bead seal. The path and the centerline intersect to form a first intersection angle and an adjacent second intersection angle on the datum plane. The first intersection angle and the second intersection angle are supplementary angles. The first intersection angle is an acute angle, and the second intersection angle is an obtuse angle. The path and the centerline are arranged to form a specific value of the first intersection angle and the second intersection angle to control a stiffness of the raised bead seal.

Abstract: A die assembly for use in a stamping press is provided. The die assembly includes a first die plate, a first curved die stiffener, and a first die shoe. The first die plate may be configured to form at least a portion of material into a desired configuration. The first curved die stiffener may be affixed to the first die plate on a first curved side of the first curved die stiffener. The first die shoe may be affixed to a second side of the first curved die stiffener. The first die shoe may be operatively configured to be mounted on a first press base.

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: 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.