Fully internal manifolded fuel cell stack

Claim 2

In a fuel cell stack comprising a plurality of fuel cell units, each said fuel cell unit comprising an anode and a cathode, an electrolyte in contact on one side with the electrolyte facing face of said anode and in contact on the opposite side with the electrolyte facing face of said cathode, and a separator plate separating said cell units between an anode and cathode forming an anode chamber between the anode facing face of said separator plate and said anode and forming a cathode chamber between the opposite cathode facing face of said separator plate and the separator facing face of the cathode of an adjacent said fuel cell unit, said anode chamber in gas communication with a fuel gas supply and outlet and said cathode chamber in gas communication with an oxidant gas supply and outlet the improvement comprising: said electrolytes comprising an ion exchange membrane; said electrolytes and said separator plates extending to the peripheral edge of said fuel cell stack; said separator plates having a flattened peripheral wet seal structure extending to contact less than about 1 inch width of said electrolytes on each face of said separator plates completely around their periphery, forming a peripheral wet seal less than about 1 inch width under cell operating conditions; said electrolytes and said separator plates each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure extending to contact less than about 1 inch width of said electrolyte on each face of said separator plate, forming a manifold wet seal less than about 1 inch width under cell operating conditions to form a plurality of gas manifolds extending through said cell stack; and conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chambers on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chambers on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack.

Claim 3

In a fuel cell stack according to claim 1 wherein cell stack end plates are configured the same as said separator plates on their inner faces and form half cells on each end of said fuel cell stack.

Claim 4

In a fuel cell stack according to claim 1, wherein said separator plates comprise an electronically conducting material and are about 0.005 to about 0.050 inches thick.

Claim 5

In a fuel cell stack according to claim 3, wherein said electronically conducting material is selected from the group consisting of stainless steel, graphite and a graphite/plastic composite.

Claim 6

In a fuel cell stack according to claim 4, wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended peripheral wet seal fastened to said other face of said separator plates.

Claim 7

In a fuel cell stack according to claim 5, wherein said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 8

In a fuel cell stack according to claim 1, wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended peripheral wet seal fastened to said other face of said separator plates.

Claim 9

In a fuel cell stack according to claim 1, wherein said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 10

In a fuel cell stack according to claim 1, wherein the width of said wet seals is about 0.25 to about 0.75 inches.

Claim 11

In a fuel cell stack according to claim 1, wherein said electrolytes comprise an organic polymer.

Claim 12

In a fuel cell stack according to claim 10, wherein said electrolytes comprise perfluorosulfonic acid.

Claim 13

In a fuel cell stack according to claim 1, wherein said ion exchange membrane is a proton exchange membrane.

Claim 14

In a fuel cell stack according to claim 12, wherein said electrolytes comprise an organic polymer.

Claim 15

In a fuel cell stack according to claim 13, wherein said electrolytes comprise perfluorosulfonic acid.

Claim 16

In a fuel cell stack according to claim 14, wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended peripheral wet seal fastened to said other face of said separator plates and said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 17

In a fuel cell stack according to claim 1, wherein a current collector is between at least one of said anode and said cathode and said separator plate.

Claim 18

In a fuel cell stack comprising a plurality of fuel cell units, each said fuel cell unit comprising an anode and a cathode, an electrolyte in contact on one side with the electrolyte facing face of said anode and in contact on the opposite side with the electrolyte facing face of said cathode, and a separator plate separating said cell units between an anode and cathode forming an anode chamber between the anode facing face of said separator plate and said anode and forming a cathode chamber between the opposite cathode facing face of said separator plate and the separator facing face of the cathode of an adjacent said fuel cell unit, said anode chamber in gas communication with a fuel gas supply and outlet and said cathode chamber in gas communication with an oxidant gas supply and outlet the improvement comprising: said electrolytes comprising an ion exchange membrane; said electrolytes, said anodes, said cathodes, and said separator plates extending to the peripheral edge region of said fuel cell stack; said separator plates having a flattened peripheral wet seal structure extending to contact less than about 1 inch width of at least one of an electrode and a current collector on each face of said separator plates completely around their periphery, forming a peripheral wet seal less than about 1 inch width under cell operating conditions; said electrolytes, said anodes, said cathodes, and said separator plates each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure extending to contact less than about 1 inch width of at least one of said electrode and said current collector on each face of said separator plate, forming a manifold wet seal less than about 1 inch width under cell operating conditions to form a plurality of gas manifolds extending through said cell stack; and conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chambers on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chambers on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack.

Claim 19

In a fuel cell stack comprising a plurality of fuel cell units, each said fuel cell unit comprising an anode and a cathode, an electrolyte in contact on one side with the electrolyte facing face of said anode and in contact on the opposite side with the electrolyte facing face of said cathode, and a separator plate separating said cell units between an anode and cathode forming an anode chamber between the anode facing face of said separator plate and said anode and forming a cathode chamber between the opposite cathode facing face of said separator plate and the separator facing face of the cathode of an adjacent said fuel cell unit, said anode chamber in gas communication with a fuel gas supply and outlet and said cathode chamber in gas communication with an oxidant gas supply and outlet the improvement comprising: said electrolytes comprising an ion exchange membrane; said electrolytes, said anodes, said cathodes, and said separator plates extending to the peripheral edge region of said fuel cell stack; said separator plates having a flattened peripheral wet seal structure extending to contact less than about 1 inch width of at least one of an electrode and a current collector on each face of said separator plates completely around their periphery, forming a peripheral wet seal less than about 1 inch width under cell operating conditions; said electrolytes, said anodes, said cathodes, and said separator plates each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure extending to contact less than about 1 inch width of at least one of said electrode and said current collector on each face of said separator plate, forming a manifold wet seal less than about 1 inch width under cell operating conditions to form a plurality of gas manifolds extending through said cell stack; and conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chambers on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chambers on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack.

Claim 20

In a fuel cell stack according to claim 17, wherein cell stack end plates are configured the same as said separator plates on their inner faces and form half cells on each end of said fuel cell stack.

Claim 21

In a fuel cell stack according to claim 18, wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended peripheral wet seal fastened to said other face of said separator plates.

Claim 22

In a fuel cell stack according to claim 19, wherein said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 23

In a fuel cell stack according to claim 17, wherein said separator plates comprise an electronically conducting material and are about 0,005 to about 0,050 inches thick.

Claim 24

In a fuel cell stack according to claim 21, wherein said electronically conducting material is selected from the group consisting of stainless steel, graphite and a graphite/plastic composite.

Claim 25

In a fuel cell stack according to claim 17, wherein the width of said wet seals is about 0.25 to about 0.75 inches.

Claim 26

In a fuel cell stack according to claim 17, wherein said ion exchange membrane is a proton exchange membrane.

Claim 27

In a fuel cell stack according to claim 17, wherein said electrolytes comprise an organic polymer.

Claim 28

In a fuel cell stack according to claim 25, wherein said electrolytes comprise perfluorosulfonic acid.

Claim 29

In a fuel cell stack according to claim 24, wherein said electrolytes comprise an organic polymer.

Claim 30

In a fuel cell stack according to claim 27, wherein said electrolytes comprise perfluorosulfonic acid.

Claim 31

In a fuel cell stack according to claim 28, wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended peripheral wet seal fastened to said other face of said separator plates and said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 32

In a fuel cell stack according to claim 17, wherein said current collector extends to the peripheral edge region of said fuel cell stack.

Claim 33

A subassembly for a fuel cell unit comprising: an anode, a separator plate, and a cathode, said fuel cell unit having said anode, said cathode, and said separator plate extending to the edge region of a fuel cell stack, said separator plate having a flattened peripheral wet seal structure less than about 1 inch width extending from each face completely around their periphery, said anode, said cathode, and said separator plate each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure less than about 1 inch width extending from each face of said separator plate completely around said perforations; conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chamber on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chamber on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack; said anode, said separator plate, and said cathode sealingly joined in each said seal areas; and said separator plate fabricated of a material selected from the group consisting of stainless steel, graphite and graphite/plastic composite.

Claim 34

A subassembly for a fuel cell unit comprising: an anode, a separator plate, and a cathode, said fuel cell unit having said anode, said cathode, and said separator plate extending to the edge region of a fuel cell stack, said separator plate having a flattened peripheral wet seal structure less than about 1 inch width extending from each face completely around their periphery, said anode, said cathode, and said separator plate each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure less than about 1 inch width extending from each face of said separator plate completely around said perforations; conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chamber on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chamber on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack; said anode, said separator plate, and said cathode sealingly joined in each said seal areas; and said separator plate fabricated of a material selected from the group consisting of stainless steel, graphite and graphite/plastic composite.

Claim 35

A subassembly according to claim 31, wherein said sealingly joined comprises welding.

Claim 36

A subassembly according to claim 31, wherein said separator plate is about 0.005 to about 0.050 inch thick and said wet seals are about 0.25 to about 0.75 inches wide in the flattened portions of the wet seal structures.

Claim 37

A subassembly according to claim 31, wherein a current collector is between at least one of said anode and said cathode and said separator plate.

Claim 38

A subassembly according to claim 34, wherein said current collector extends to the edge region of said fuel cell stack.