Abstract: The present invention provides membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more external manifolds which deliver reagents and/or coolant to one or more reactant or coolant flow fields of the membrane cassettes. In particular, the present invention describes the insert molding method, whereby the plenums of the external manifolds are created during the stack encapsulation step. The invention describes several methods for creating the manifold runner geometry via insert-molding, machining, or with separate components.

Abstract: The invention provides a fuel cell stack including a layer of encapsulating material disposed about the separator plate, MEA, and reactant manifold, wherein the reactant manifold is bounded at least in part by the encapsulating material. The fuel cell stack also includes a first opening through the plate body to the first face from the second face, and an open channel in the second face extending from the opening toward a periphery of the plate. The invention also provides a fuel cell stack having a first face including an opening for passage of a reactant therethrough, a first reactant flow field defined thereon, and a first raised surface formed thereon substantially surrounding the opening. The first raised surface is configured and adapted to mate with a second surface on a face of an adjacent plate to create a flow obstruction for encapsulating material.

Abstract: The invention provides a fuel cell stack including a layer of encapsulating material disposed about the separator plate, MEA, and reactant manifold, wherein the reactant manifold is bounded at least in part by the encapsulating material. The fuel cell stack also includes a first opening through the plate body to the first face from the second face, and an open channel in the second face extending from the opening toward a periphery of the plate. The invention also provides a fuel cell stack having a first face including an opening for passage of a reactant therethrough, a first reactant flow field defined thereon, and a first raised surface formed thereon substantially surrounding the opening. The first raised surface is configured and adapted to mate with a second surface on a face of an adjacent plate to create a flow obstruction for encapsulating material.

Abstract: The present invention provides, among other things, membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more external manifolds which deliver reagents and/or coolant to one or more reactant or coolant flow fields of the membrane cassettes. In particular, the present invention describes the insert molding method, whereby the plenums of the external manifolds are created during the stack encapsulation step. The invention describes several methods for creating the manifold runner geometry via insert-molding, machining, or with separate components.

Abstract: The present invention provides, among other things, membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more external manifolds which deliver reagents and/or coolant to one or more reactant or coolant flow fields of the membrane cassettes. In particular, the present invention describes the insert molding method, whereby the plenums of the external manifolds are created during the stack encapsulation step. The invention describes several methods for creating the manifold runner geometry via insert-molding, machining, or with separate components.

Abstract: The present invention provides membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more external manifolds which deliver reagents and/or coolant to one or more reactant or coolant flow fields of the membrane cassettes. In particular, the present invention describes the insert molding method, whereby the plenums of the external manifolds are created during the stack encapsulation step. The invention describes several methods for creating the manifold runner geometry via insert-molding, machining, or with separate components.