[특허]Fuel cell bipolar separator plate and current collector assembly and method of manufacture

GenCell Corporation

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Fuel cell bipolar separator plate and current collector assembly and method of manufacture

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	H01M-008/02
미국특허분류(USC)	429/034; 429/035; 429/036; 429/038; 429/039; 429/026
출원번호	US-0714526 (2000-11-16)
발명자 / 주소	Allen, Jeffrey P.
출원인 / 주소	GenCell Corporation
대리인 / 주소	Banner & Witcoff, Ltd.
인용정보	피인용 횟수 : 25 인용 특허 : 65

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A fuel cell bipolar separator plate of variable length is formed from a sheet having a fixed width. The sheet is passed through a tool a predetermined distance and a pattern of ribs is formed on a central portion of the sheet with the tool to define a segment along the length of the sheet. The ribs define a fuel flow path on a first side of the sheet and an oxidant flow path on an opposed second side of the sheet. The sheet is passed through a tool a predetermined distance and the steps of forming the pattern on the sheet and passing the sheet through th...

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1. A repeatable segment of a fuel cell bipolar separator plate comprising, in combination:a plate having a first surface and an opposing second surface;a plurality of ribs on the plate defining flow channels along the first surface and the second surface of the plate;a seal area extending along each of opposed side edges of the plate, the seal areas being formed by folding over edge portions of the plate onto one of the first surface and the second surface of the plate and including mating pairs of apertures configured to line up with one another when the edge portions are folded over, the seal areas and mating apertures forming internal inlet and outlet manifolds in fluid communication with the flow channels of one of the first surface and the second surface; anda seal member secured along each seal area on the other of the first surface and the second surface of the plate to define external inlet and outlet manifolds along side edges of the plate in fluid communication with the flow channels of the other of the first surface and the second surface. 2. The repeatable segment of claim 1, wherein the seal members include apertures configured to line up with corresponding apertures of the seal areas, the apertures of the seal members being eyeleted to the corresponding apertures of the seal areas. 3. The repeatable segment of claim 2, wherein the apertures of the seal members are double eyeleted to the corresponding apertures of the seal areas. 4. The repeatable segment of claim 2, wherein the eyeleted apertures further comprise a sealant. 5. The repeatable segment of claim 1, further comprising a pair of shims, each shim positioned between a seal member and the other of the first surface and the second surface of the plate. 6. The repeatable segment of claim 1, wherein at least some of the internal inlet and outlet manifolds comprise fuel inlet and fuel outlet manifolds. 7. The repeatable segment of claim 1, wherein at least some of the internal inlet and outlet manifolds comprise oxidant inlet and oxidant outlet manifolds. 8. The repeatable segment of claim 1, wherein at least some of the external inlet and outlet manifolds comprise fuel inlet and fuel outlet manifolds. 9. The repeatable segment of claim 1, wherein at least some of the external inlet and outlet manifolds comprise oxidant inlet and oxidant outlet manifolds. 10. The repeatable segment of claim 1, wherein cross-sectional areas of the flow channels on the first surface are one of larger than and smaller than cross-sectional areas of the flow channels on the second surface. 11. The repeatable segment of claim 1, wherein the seal areas include a plurality of dimples extending outwardly from the first surface of the plate and a plurality of dimples extending outwardly from the second surface of the plate. 12. The repeatable segment of claim 1, wherein the flow channels on the first and second surfaces extend substantially perpendicular to a direction of manufacture of the repeatable segment. 13. The repeatable segment of claim 1, wherein a portion of each end of the plate is folded over onto one of the first surface and the second surface of the plate to form first end seals. 14. The repeatable segment of claim 13, further comprising end seal members, the end seal members being secured to the other of the first surface and the second surface of the plate to form second end seals. 15. The repeatable segment of claim 1, further comprising an additional plate having a first surface and an opposing second surface, and a plurality of ribs defining flow channels along the second surface of the additional plate, the ribs of the plate having a height that is different than a height of the ribs of the additional plate, the first surface of the additional plate abutting the second surface of the plate such that the ribs of the additional plate are nested within the ribs of the plate to form center flow channels between the plate and the additional plate. 16. The repeatable se gment of claim 15, wherein the center flow channels are coolant flow channels. 17. The repeatable segment of claim 15, wherein the center flow channels house a reformer. 18. The repeatable segment of claim 15, wherein a portion of each of the opposed ends of the plate are folded over onto the second surface of the additional plate to form opposed first end seals. 19. The repeatable segment of claim 15, further comprising a pair of end seal members, each end seal member being secured to the first surface of the plate at a respective end of the plate to form opposed second end seals. 20. The repeatable segment of claim 19, further comprising a pair of shims, each shim positioned between an end seal member and the first surface of the plate. 21. The repeatable segment of claim 15, wherein edge portions of the additional plate are folded over onto one of the second surface of the additional plate and the first surface of the plate. 22. The repeatable segment of claim 15, wherein edge portions of the plate and the additional plate are folded over onto the second surface of the additional plate. 23. The repeatable segment of claim 15, wherein edge portions of the additional plate are folded over onto the second surface of the additional plate and edge portions of the plate are folded over onto the first surface of the plate. 24. The repeatable segment of claim 23, wherein a sealant is applied to edge portions of the sheet between the plate and the additional plate. 25. The repeatable segment of claim 1, further comprising a pair of dividing sections, each dividing section being positioned between a corresponding seal area and the flow channels. 26. The repeatable segment of claim 25, wherein a plane of the dividing sections is closer to a plane of one of the first and second surfaces of the plate than it is to the plane of the other of the first and second surfaces of the plate. 27. The repeatable segment of claim 1, further comprising an additional plate having a first surface and an opposing second surface, and a plurality of ribs defining flow channels along the second surface of the additional plate, the first surface of the additional plate abutting the second surface of the plate such that the ribs of the additional plate are aligned with the ribs of the plate to form center flow channels between the plate and the additional plate. 28. The repeatable segment of claim 1, wherein comers of the plate are folded over and crimped to provide a seal. 29. The repeatable segment of claim 1, further comprising a plurality of flat wires spaced apart from one another and secured to one of the first surface and the second surface of the plate. 30. A fuel cell bipolar separator plate comprising, in combination:a plate having a first surface and an opposing second surface;a plurality of ribs on the plate defining flow channels along the first surface and the second surface of the plate;a seal area extending along each of opposed side edges of the plate, the seal areas being formed by folding over edge portions of the plate onto one of the first surface and the second surface of the plate and including mating pairs of apertures configured to line up with one another when the edge portions are folded over, the seal areas and mating apertures forming internal inlet and outlet manifolds in fluid communication with the flow channels of one of the first surface and the second surface; anda seal member secured along each seal area on the other of the first surface and the second surface of the plate to define external inlet and outlet manifolds along side edges of the plate in fluid communication with the flow channels of the other of the first surface and the second surface. 31. The separator plate of claim 30, wherein the plate comprises at least one repeatable segment, each repeatable segment including an internal inlet manifold in one seal area and an internal outlet manifold in an opposing seal area. 32. The separator plate of claim 31, wherei n each repeatable segment is separated from adjacent repeatable segments by dividing ribs. 33. The separator plate of claim 32, wherein the dividing ribs comprise fluid flow channels. 34. The separator plate of claim 31, wherein each repeatable segment includes an external inlet manifold in one seal area and an external outlet manifold in an opposing seal area. 35. The separator plate of claim 34, wherein each repeatable segment is separated from adjacent repeatable segments by dividing ribs that comprise fluid flow channels, the fluid flow channels extending beyond the flow channels on the first and second surfaces and into the opposing seal areas of the plate such that they are in fluid communication with the external manifolds. 36. The separator plate of claim 30, further comprising a pair of shims, each shim positioned between a seal member and the other of the first surface and the second surface of the plate. 37. The separator plate of claim 30, wherein the seal members include apertures configured to line up with corresponding apertures of the seal areas, the apertures of the seal members being eyeleted to the corresponding apertures of the seal areas. 38. The separator plate of claim 30, wherein the plate comprises a plurality of segments positioned between first and second end segments. 39. The separator plate of claim 30, wherein a portion of each end of the plate is folded over onto one of the first and second surfaces of the plate to form opposed first end seals. 40. The separator plate of claim 39, further comprising a pair of end seal members, each end seal member being secured to the other of the first and second surfaces of the plate at a respective end of the plate to form opposed second end seals. 41. The separator plate of claim 40, further comprising a pair of shims, each shim positioned between an end seal member and the other of the first and second surfaces of the plate. 42. The separator plate of claim 30, wherein comers of the plate are folded over and crimped to provide a seal. 43. The separator plate of claim 30, further comprising a plurality of flat wires spaced apart from one another and secured to one of the first surface and the second surface of the plate. 44. A bipolar separator plate comprising, in combination:a first sheet of metal having a plurality of ribs in a central area thereof, the ribs forming flow channels on a first surface of the first sheet;a second sheet of metal having a plurality of ribs in a central area thereof, the ribs of the second sheet having a depth shallower than a depth of the ribs of the first sheet and forming flow channels on a second surface of the first sheet, a first surface of the second sheet abutting a second surface of the first sheet such that the ribs of the second sheet are nested within the ribs of the first sheet to form center flow channels between the first and second sheets;opposing edge seal areas of the first and second sheets having mating pairs of apertures and being folded over themselves onto one of the first surface of the first sheet and the second surface of the second sheet, such that the apertures of each pair of apertures are aligned with one another and the folded over seal areas form opposing internal inlet and outlet manifolds; anda pair of strips of sheet metal, each strip being attached to the first sheet at an intersection of a seal area and the flow channels on the first surface of the first sheet and having a plurality of apertures that align with corresponding apertures of the first and second sheets, the strips forming external inlet and outlet manifolds at open edges of the bipolar plate. 45. The separator plate of claim 44, wherein the plate is composed of repeated segments. 46. The separator plate of claim 44, wherein at least some apertures of the first and second sheets and the strips of metal are eyeleted together such that an internal inlet manifold and an internal outlet manifold in opposing seal areas are in fluid comm unication with flow channels on the first surface of the first sheet. 47. The separator plate of claim 44, wherein at least some apertures of the first and second sheets and the strips of metal are eyeleted together such that an internal inlet manifold and an internal outlet manifold in opposing seal areas are in fluid communication with flow channels on the second surface of the second sheet. 48. The separator plate of claim 44, wherein at least some apertures of the first and second sheets and the strips of metal are eyeleted together such that an internal inlet manifold and an internal outlet manifold in opposing seal areas are in fluid communication with the center flow channels. 49. The separator plate of claim 44, wherein the external inlet and outlet manifolds are in fluid communication with the center flow channels. 50. The separator plate of claim 44, wherein at least some of the internal inlet and outlet manifolds comprise fuel inlet and fuel outlet manifolds. 51. The separator plate of claim 44, wherein at least some of the internal inlet and outlet manifolds comprise oxidant inlet and oxidant outlet manifolds. 52. The separator plate of claim 44, wherein at least some of the external inlet and outlet manifolds comprise fuel inlet and fuel outlet manifolds. 53. The separator plate of claim 44, wherein at least some of the external inlet and outlet manifolds comprise oxidant inlet and oxidant outlet manifolds. 54. The separator plate of claim wherein edge portions of the first sheet and the second sheet are folded over onto the second surface of the second sheet. 55. The separator plate of claim 44, wherein edge portions of the second sheet are folded over onto the second surface of the second sheet and edge portions of the first sheet are folded over onto the first surface of the first sheet. 56. The separator plate of claim 44, wherein a sealant is applied between the first sheet and the second sheet along edges thereof. 57. The separator plate of claim 44, wherein cross-sectional areas of the flow channels on the first surface of the first sheet are one of larger than and smaller than cross-sectional areas of the flow channels on the second surface of the second sheet. 58. The separator plate of claim 44, wherein the seal areas include a plurality of dimples extending outwardly from the surfaces of the first and second sheet. 59. The separator plate of claim 44, wherein the separator plate is divided into segments, each segment including at least one internal inlet manifold in one seal area and at least one internal outlet manifold in the opposing seal area. 60. The separator plate of claim 59, wherein each segment is separated from adjacent segments by dividing ribs. 61. The separator plate of claim 60, wherein the dividing ribs comprise fluid flow channels. 62. The separator plate of claim 59, wherein each segment includes an external inlet manifold in one seal area and an external outlet manifold in the opposing seal area. 63. The separator plate of claim 59, wherein each segment is separated from adjacent segments by dividing ribs that comprise fluid flow channels, the fluid flow channels extending beyond the flow channels on the first and second surfaces and into the opposing seal areas of the plate such that they are in fluid communication with the external manifolds. 64. The separator plate of claim 44, wherein the flow channels on the first surface of the first sheet and the second surface of the second sheet extend substantially perpendicular to a direction of manufacture of the separator plate. 65. The separator plate of claim 44, wherein the first plate has a thickness sufficient to withstand a compressive force applied to a fuel cell stack comprising a plurality of nested first and second sheets. 66. The separator plate of claim 44, wherein the second sheet has a thickness sufficient to withstand a differential gas pressure between the flow channels on the second surface of the second sheet and the cen ter flow channels, and insufficient to withstand a compressive force applied to a fuel cell stack comprising a plurality of nested first and second sheets. 67. The separator plate of claim 44, wherein the center flow channels are coolant flow channels. 68. The separator plate of claim 44, wherein the center flow channels house a reformer. 69. The separator plate of claim 44, wherein a portion of each of the opposed ends of the first and second sheets are folded over onto the second surface of the second sheet to form opposed first end seals. 70. The separator plate of claim 44, further comprising a pair of end seal members, each end seal member being secured to the first surface of the first sheet at a respective end of the first sheet to form opposed second end seals. 71. The separator plate of claim 44, wherein the first and second sheets each further comprise a pair of dividing sections, each dividing section being positioned between a corresponding seal area and the flow channels. 72. The separator plate of claim 44, wherein a plane of each dividing section is closer to a plane of one of the first and second sheets than it is to the plane of the other of the first and second sheets. 73. The separator plate of claim 44, wherein corners of the first and second sheets of metal are folded over and crimped to provide a seal. 74. The separator plate of claim 44, further comprising a plurality of flat wires spaced apart from one another and secured to one of the first surface of the first sheet of metal and the second surface of the second sheet of metal. 75. A fuel cell assembly comprising, in combination:a housing;a fuel cell stack disposed in the housing, the fuel cell stack comprisinga first sheet of metal having a plurality of ribs in a central area thereof, the ribs having a first depth and forming flow channels on a first surface of the first sheet;a second sheet of metal having a plurality of ribs in a central area thereof, the ribs of the second sheet having a second depth shallower than the first depth and forming flow channels on a second surface of the first sheet, a first surface of the second sheet abutting a second surface of the first sheet such that the ribs of the first and second sheets are nested with one another to form center flow channels between the first and second sheets;opposing edge seal areas of the first and second sheets having mating pairs of apertures and being folded over themselves onto one of the first surface of the first sheet and the second surface of the second sheet, such that the apertures of each pair of apertures are aligned with one another and the folded over seal areas form opposing internal inlet and outlet manifolds; anda pair of strips of sheet metal, each strip being attached to the first sheet at an intersection of a seal area and the flow channels on the first surface of the first sheet and having a plurality of apertures that align with corresponding apertures of the first and second sheets, the strips forming external inlet and outlet manifolds at open edges of the bipolar plate; anda pair of seals, each seal positioned between the fuel cell stack and the housing. 76. A fuel cell bipolar separator plate comprising, in combination:a first plate having a first surface and an opposing second surface;a plurality of ribs on the first plate defining a fuel flow path along the first surface of the first plate;a second plate having a first surface and an opposing second surface;a plurality of ribs on the second plate defining an oxidant flow path along the second surface of the second plate;wherein the ribs on one of the first and second plates have a height different than the ribs on the other plate, and peaks of the ribs on one side of one of the first and second plates are in abutting relationship with corresponding peaks of the ribs on one side of the other of the first and second plates to define a coolant flow path between the first and second plates. 77. The separator plate of claim 76, wherein the fuel flow path, oxidant flow path, and coolant flow path are substantially parallel to one another. 78. The separator plate of claim 76, wherein the fuel flow path, oxidant flow path, and coolant flow path are substantially perpendicular to a direction of manufacture of the first and second plate. 79. The separator plate of claim 76, further comprising seal areas along each side edges of the first plate. 80. The separator plate of claim 79, wherein the seal areas are formed by folding over a portion of the first plate onto itself. 81. The separator plate of claim 80, wherein the seal areas include a plurality of dimples defining a fluid flow path within the folded over portions of the plate. 82. The separator plate of claim 80, wherein the first and second plates include a plurality of segments, each segment including at least one fuel inlet in one seal area and at least one corresponding fuel outlet in the opposing seal area of that segment, the inlet and outlet communicating with one another through the fuel flow path of that segment. 83. The separator plate of claim 82, wherein each fuel inlet and fuel outlet comprises a mating pair of apertures formed in the seal areas such that the mating pair of apertures line up with one another when the first plate is folded over onto itself. 84. The separator plate of claim 80, wherein the first and second plates include a plurality of segments, each segment including an oxidant inlet in one seal area and a corresponding oxidant outlet in the opposing seal area of that segment, the oxidant inlet and outlet communicating with one another through the oxidant flow path of that segment. 85. The separator plate of claim 84, further comprising an oxidant seal member secured along each edge of the plate to define the oxidant inlet and oxidant outlet 86. The separator plate of claim 85, wherein the seal areas include a plurality of dimples defining a fluid flow path between the seal members and the plate. 87. The separator plate of claim 76, wherein a central portion of each end of each plate is folded over onto itself to form a seal along the respective end of each plate. 88. The separator plate of claim 87, further comprising recesses formed along sides of each end of each plate outward of the central portions and shaped to receive the central portions when the central portions are folded over. 89. The separator plate of claim 80, wherein each segment further includes at least one coolant inlet in one seal area and at least one corresponding coolant outlet in the opposing seal area of that segment, the coolant inlet and coolant outlet communicating with one another through the coolant flow path of that segment. 90. The separator plate of claim 89, wherein each coolant inlet and coolant outlet comprises a mating pair of apertures formed in the seal areas such that the mating pair of apertures line up with one another when the first plate is folded over onto itself. 91. The separator plate of claim 76, wherein the ribs of the first and second plate are of a height sufficient to withstand a compressive force applied to a fuel cell stack comprising a plurality of first and second plates.

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Fuel cell bipolar separator plate and current collector assembly and method of manufacture

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