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 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 fuel cell includes a first bipolar plate, a second bipolar plate and a gas diffusion layer. The first bipolar plate defines a first metal bead seal and a first plate embossment in fluid communication with the first metal bead seal. The second bipolar plate defines a second metal bead seal and a second plate embossment in fluid communication with the second metal bead seal. The first plate embossment and the second plate embossment are offset from one another along the length of the first and second metal bead seals. The second metal bead seal is operatively configured to abut the first metal bead seal to form a joint between the first and second bipolar plate. The gas diffusion layer may be disposed between the first bipolar plate and the second bipolar plate.

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. 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 is offset from the outlet tunnel section.

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 that may include at least one raised bead and at least one raised limiter.

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 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 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: 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 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 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 bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made generally from a stainless steel, and in a more preferable form from a ferritic stainless steel. In one configuration, a stamping or related metal forming tool operation will introduce a negative clearance as a way to move or otherwise reallocate a portion of the material making up the sheet into other portions as a way to reduce stretching, necking, thinning and related thickness deviations associated with the bends formed in the bipolar plate.

Abstract: A bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made generally from a stainless steel, and in a more preferable form from a ferritic stainless steel. In one configuration, a stamping or related metal forming tool operation will introduce a negative clearance as a way to move or otherwise reallocate a portion of the material making up the sheet into other portions as a way to reduce stretching, necking, thinning and related thickness deviations associated with the bends formed in the bipolar plate.

Abstract: A method for manufacturing a stamped part, such as a bipolar plate for a fuel cell, includes the steps of: providing an original model of the bipolar plate; and performing a compensation process on the original model, the compensation process including a two step morphing process based upon a prediction of spring back. The two step morphing process provides a compensated model of the stamped part. A compensated die face may be created based on the compensated model of the stamped part. The stamped part manufactured with the compensated die face has spring back compensation.

Abstract: A bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made from a ferritic or austenitic stainless steel, and defines an undulated surface pattern such that the patterned sheet may be formed into the bipolar plate. In one configuration, a stamping or related metal forming tool operation will further deform the patterned sheet into the bipolar plate shape such that the wall thickness is substantially uniform throughout the surface. In this way, there is a substantial reduction in stretching/thinning/necking at an intersection between bends and side walls that define the undulations of the pattern. In one form, the pattern defines a repeating serpentine shape. In a particular embodiment, the bends may include surface modifications to reduce the effects of sheet-to-tool misalignment.

Abstract: A bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made from a ferritic or austenitic stainless steel, and defines an undulated surface pattern such that the patterned sheet may be formed into the bipolar plate. In one configuration, a stamping or related metal forming tool operation will further deform the patterned sheet into the bipolar plate shape such that the wall thickness is substantially uniform throughout the surface. In this way, there is a substantial reduction in stretching/thinning/necking at an intersection between bends and side walls that define the undulations of the pattern. In one form, the pattern defines a repeating serpentine shape. In a particular embodiment, the bends may include surface modifications to reduce the effects of sheet-to-tool misalignment.

Abstract: A bipolar plate for a fuel cell includes a pair of plates. Each plate has an active area, a header area, and a perimeter area. The perimeter area is disposed adjacent an edge of the plate. The perimeter area is also disposed adjacent to each of the active area and the header area. At least one of the plates includes a raised support feature having an inboard side and an outboard side. The plates are joined in the perimeter area between the outboard side of the raised support feature and the edges of the plates.

Abstract: A method for manufacturing a stamped part, such as a bipolar plate for a fuel cell, includes the steps of: providing an original model of the bipolar plate; and performing a compensation process on the original model, the compensation process including a two step morphing process based upon a prediction of spring back. The two step morphing process provides a compensated model of the stamped part. A compensated die face may be created based on the compensated model of the stamped part. The stamped part manufactured with the compensated die face has spring back compensation.

Abstract: A bipolar plate for a fuel cell includes a pair of plates. Each plate has an active area, a header area, and a perimeter area. The perimeter area is disposed adjacent an edge of the plate. The perimeter area is also disposed adjacent to each of the active area and the header area. At least one of the plates includes a raised support feature having an inboard side and an outboard side. The plates are joined in the perimeter area between the outboard side of the raised support feature and the edges of the plates.