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A bipolar plate assembly for a fuel cell is provided. The bipolar plate assembly includes a first electroformed unipolar plate disposed adjacent a second electroformed unipolar plate. The first and second unipolar plates are bonded by a plurality of localized electrically and thermally conductive pl

A bipolar plate assembly for a fuel cell is provided. The bipolar plate assembly includes a first electroformed unipolar plate disposed adjacent a second electroformed unipolar plate. The first and second unipolar plates are bonded by a plurality of localized electrically and thermally conductive plugs by electroplated material deposited within apertures formed in the substrates onto which the unipolar plates are electroformed. A method for forming the bipolar plate assembly is also described.

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1. A bipolar plate assembly for a fuel cell, comprising: a first unipolar plate;a second unipolar plate, wherein the first unipolar plate and the second unipolar plate cooperate to form a space therebetween; andat least one electroformed plug connecting the first unipolar plate to the secondunipolar

1. A bipolar plate assembly for a fuel cell, comprising: a first unipolar plate;a second unipolar plate, wherein the first unipolar plate and the second unipolar plate cooperate to form a space therebetween; andat least one electroformed plug connecting the first unipolar plate to the secondunipolar plate, wherein the at least one electroformed plug, the first unipolar plate, and the second unipolar plate form a unitary structure, and the first unipolar plate is spaced apart from the second unipolar plate by a thickness of the at least one electroformed plug;wherein the space between the first and second unipolar plate comprises at least one open region and at least one filled region, the at least one open region forming at least one coolant channel, and the at least one filled region being filled by a non-metallic material. 2. The bipolar plate assembly of claim 1, wherein the first unipolar plate includes a first active surface having a plurality of first grooves formed therein, the plurality of first grooves defining a plurality of first lands disposed therebetween, and the second unipolar plate includes a second active surface having a plurality of second grooves formed therein, the plurality of second grooves defining a plurality of second lands disposed therebetween. 3. The bipolar plate assembly according to claim 2, wherein the at least one electroformed plug connects at least one of the first lands of the first unipolar plate to at least one of the second grooves of the second unipolar plate. 4. The bipolar plate assembly according to claim 3, wherein there are a plurality of electroformed plugs and at least one of the second lands of the second unipolar plate is connected to at least two of the first grooves of the first unipolar plate by at least two of the plurality of the electroformed plugs. 5. The bipolar plate assembly according to claim 4, wherein the first unipolar plate and the second unipolar plate cooperate to form at least one coolant channel between one of the first lands of the first unipolar plate and one of the second lands of the second unipolar plate. 6. The bipolar plate assembly according to claim 4, wherein the first unipolar plate and the second unipolar plate cooperate to form at least one coolant channel between the at least two of the plurality of the electroformed plugs connecting the second land of the second unipolar plate to the at least two first grooves of the first unipolar plate. 7. The bipolar plate assembly according to claim 2, wherein at least one of the first grooves of the first unipolar plate is connected to at least one of the second grooves of the second unipolar by the at least one electroformed plug. 8. The bipolar plate assembly according to claim 7, wherein a coolant channel is formed between at least one of the first grooves of the first unipolar plate and the at least one of the second lands of the second unipolar plate. 9. The bipolar plate assembly of claim 1, wherein the first unipolar plate and the second unipolar plate have a first thickness, and wherein a diameter of the at least one electroformed plug is about twice the first thickness. 10. The bipolar plate assembly of claim 1, wherein the at least one electroformed plug, the first unipolar plate, and the second unipolar plate are monolithically formed to each other. 11. A fuel cell stack comprising: a plurality of membrane electrode assemblies arranged in a stacked configuration, each of the plurality of membrane electrode assemblies having a cathode and an anode; anda bipolar plate assembly disposed between adjacent membrane electrode assemblies, the bipolar plate assembly including a first unipolar plate having a first inner surface disposed adjacent a second inner surface of a second unipolar plate, the first unipolar plate and the second unipolar plate cooperating to form a space therebetween, the first unipolar plate electroformingly bonded to the second unipolar plate, at least one electroformed plug connecting the first unipolar plate to the second unipolar plate, wherein the first unipolar plate is spaced apart from the second unipolar plate by a thickness of the at least one electro formed plug;wherein the space between the first and second unipolar plate comprises at least one open region and at least one filled region, the at least one open region forming at least one coolant channel, and the at least one filled region being filled by a non-metallic material. 12. The fuel cell stack of claim 11, wherein the first unipolar plate is an electroformed unipolar plate and the second unipolar plate is an electroformed unipolar plate, wherein the first unipolar plate and the second unipolar plate are formed to a desired first thickness on at least one substrate by an electroforming process. 13. The fuel cell stack of claim 12, wherein the at least one substrate includes a plurality of vias adapted to receive a plating material, the plating material filling the plurality of vias to form a plurality of plugs that interconnect the first and second unipolar plates. 14. The fuel cell stack of claim 13, wherein a diameter of the vias is about twice the first thickness.