Fuel cell separator with compressible sealing flanges

Claim 2

A fuel cell separator comprising: a substantially flat, planar, gas-impermeable plate and gas-impermeable seal means along a peripheral edge of said plate projecting from the plane thereof, said seal means including adjustment means accommodating resilient compression of said seal means toward the plane of said plate.

Claim 3

The fuel cell separator of claim 1, wherein said plate is substantially rectangular in shape, said separator including two of said seal means respectively disposed along opposite side edges of said plate and projecting therefrom in the same direction.

Claim 4

The fuel cell separator of claim 1, wherein said seal means includes a flexible gas-impermeable seal member, and said adjustment means includes resiliently compressible means associated with said seal member.

Claim 5

The fuel cell separator of claim 1, wherein said seal means includes a seal flange on said plate along said peripheral edge thereof, said seal flange having a gas-impermeable first portion integral with said plate and extending therefrom toward the one end of the stack and a second portion integral with said first portion and overlapping said plate and spaced therefrom, said adjustment means including resilient means associated with said seal flange for maintaining a spacing between said second portion and said plate while accommodating movement of said second portion with respect to said plate for varying the spacing therebetween.

Claim 6

The fuel cell separator of claim 4, wherein said seal flange is unitary with said plate and comprises a margin of said plate folded back upon itself.

Claim 7

The fuel cell separator of claim 4, wherein said resilient means is discrete from said seal flange.

Claim 8

The fuel cell separator of claim 1, wherein, said seal means comprises first seal means, and further including gas-impermeable seal means along a second peripheral edge of said plate projecting from the plane thereof in the opposite direction from said first seal means, said second seal means including second adjustment means accommodating resilient compression of said second seal means toward the plane of said plate.

Claim 9

The fuel cell separator of claim 7, wherein said plate is substantially rectangular in shape, said separator including two of said first seal means respectively disposed along opposite side edges of said plate, and two of said second seal means respectively disposed along the other side edges of said plate.

Claim 10

A fuel cell separator for separating two adjacent fuel cells in a stack of such cells, wherein each cell has a reactive region and a seal seat therealong, said separator comprising: a substantially flat, gas-impermeable plate disposed between the adjacent cells; a seal flange on said plate along a peripheral edge thereof, said seal flange including a gas-impermeable first portion integral with said plate and extending therefrom toward one end of the stack and a second portion integral with said first portion and overlapping said plate and spaced therefrom, said seal flange cooperating with said plate and with the seal seat of one of the adjacent cells for providing a gas-impermeable seal for the reactive region of the one cell along said peripheral edge, said seal flange cooperating with said plate to define an elongated channel along said peripheral edge; and a resiliently compressible stack of sheets disposed in and substantially filling said channel, compression of said stack of sheets accommodating slight movement of said second portion with respect to said plate for varying the spacing therebetween.

Claim 11

A fuel cell separator for separating two adjacent fuel cells in a stack of such cells, wherein each cell has a reactive region and a seal seat therealong, said separator comprising: a substantially flat, gas-impermeable plate disposed between the adjacent cells; a seal flange on said plate along a peripheral edge thereof, said seal flange including a gas-impermeable first portion integral with said plate and extending therefrom toward one end of the stack and a second portion integral with said first portion and overlapping said plate and spaced therefrom, said seal flange cooperating with said plate and with the seal seat of one of the adjacent cells for providing a gas-impermeable seal for the reactive region of the one cell along said peripheral edge, said seal flange cooperating with said plate to define an elongated channel along said peripheral edge; and a resiliently compressible stack of sheets disposed in and substantially filling said channel, compression of said stack of sheets accommodating slight movement of said second portion with respect to said plate for varying the spacing therebetween.

Claim 12

The fuel cell separator of claim 9, wherein said stack of sheets is secured to said seal flange and to said plate and adjacent ones of said sheets are secured together.

Claim 13

The fuel cell separator of claim 9, wherein each of said sheets is generally flat and has a nominal datum plane disposed substantially parallel to said plate, each of said sheets having resilient portions which project slightly above or below said datum plane and are resiliently deflectable toward the datum plane for flattening the sheet thereby to provide the compressibility of the stack of sheets.

Claim 14

The fuel cell separator of claim 11, wherein each of said sheets is a substantially flat fabricated thin metal sheet, each of said sheets in its as-fabricated condition having slight deviations from absolute flatness which deviations comprise said resilient portions.

Claim 15

The fuel cell separator of claim 12, wherein at least one of said sheets has additional resilient portions formed therein by mechanical working.

Claim 16

The fuel cell separator of claim 9, wherein said plate is substantially rectangular in shape, said separator including two of said seal flanges respectively disposed along opposite side edges of said plate and projecting therefrom toward the one end of the stack for sealing the reactive region of the one cell along opposite sides thereof, and two of said resiliently compressible stacks of sheets respectively disposed in and substantially filling the channels formed by said seal flanges.

Claim 17

The fuel cell separator of claim 14, and further including two second seal flanges respectively disposed along the other two sides of said plate and projecting toward the other end of the stack of cells, and two resiliently compressible stacks of sheets respectively disposed in and substantially filling the channels formed by said second seal flanges.

Claim 18

The fuel cell separator of claim 9, wherein said seal flange is unitary with said plate and comprises a marginal edge of said plate folded back upon itself.

Claim 19

A fuel cell separator for separating two adjacent fuel cells in a stack of such cells, wherein each cell is generally rectangular in shape and includes first and second reactive regions spaced apart by an electrolyte-retaining matrix having a seal seat along the margins thereof, and wherein the first and second reactive regions respectively communicate along adjacent sides of the cell with first and second reactant gas manifolds, said separator comprising: a substantially flat, rectangular, gas-impermeable plate disposed between the adjacent cells and having side edges respectively disposed substantially parallel to the sides of the adjacent cells; first and second seal flanges respectively disposed on adjacent edges of said plate, each of said seal flanges being unitary with said plate and comprising a margin of said plate folded back upon itself with said first and second flanges respectively folded over opposite surfaces of said plate, the portion of each of said flanges overlapping said plate being spaced therefrom, said first seal flange extending toward one end of the stack and cooperating with said plate and with the seal seat of one of the adjacent cells for providing a gas-impermeable seal between the first reactive region of the one cell and the second reactant gas manifold, said second seal flange extending toward the opposite end of the stack and cooperating with said plate and with the seal seat of the other of the adjacent cells for providing a gas-impermeable seal between the second reactive region of the other cell and the first reactant gas manifold; and two resilient means respectively associated with said seal flanges for maintaining a spacing between said overlapping portions and said plate while accommodating slight movement of said overlapping portions with respect to said plate for varying the spacing therebetween.

Claim 20

A fuel cell separator for separating two adjacent fuel cells in a stack of such cells, wherein each cell is generally rectangular in shape and includes first and second reactive regions spaced apart by an electrolyte-retaining matrix having a seal seat along the margins thereof, and wherein the first and second reactive regions respectively communicate along adjacent sides of the cell with first and second reactant gas manifolds, said separator comprising: a substantially flat, rectangular, gas-impermeable plate disposed between the adjacent cells and having side edges respectively disposed substantially parallel to the sides of the adjacent cells; first and second seal flanges respectively disposed on adjacent edges of said plate, each of said seal flanges being unitary with said plate and comprising a margin of said plate folded back upon itself with said first and second flanges respectively folded over opposite surfaces of said plate, the portion of each of said flanges overlapping said plate being spaced therefrom, said first seal flange extending toward one end of the stack and cooperating with said plate and with the seal seat of one of the adjacent cells for providing a gas-impermeable seal between the first reactive region of the one cell and the second reactant gas manifold, said second seal flange extending toward the opposite end of the stack and cooperating with said plate and with the seal seat of the other of the adjacent cells for providing a gas-impermeable seal between the second reactive region of the other cell and the first reactant gas manifold; and two resilient means respectively associated with said seal flanges for maintaining a spacing between said overlapping portions and said plate while accommodating slight movement of said overlapping portions with respect to said plate for varying the spacing therebetween.

Claim 21

The fuel cell separator of claim 17, wherein said resilient means is discrete from said seal flanges.

Claim 22

The fuel cell separator of claim 18, wherein each of said seal flanges cooperates with said plate to define an elongated channel along the associated side edge thereof, each of said seal means comprising a resiliently compressible stack of sheets disposed in and substantially filling said channel, compression of said stack of sheets accommodating slight movement of said overlapping portion of said flange with respect to said plate for varying the spacing therebetween.

Claim 23

The fuel cell separator of claim 17, wherein said plate includes two of said first seal flanges respectively disposed along opposite side edges of said plate and two of said second seal flanges respectively disposed along the other side edges of said plate.