The present invention is concerned with an improved fuel cell stack assembly comprising a metal base plate on which is mounted at least one fuel cell stack and a metal end plate, each stack comprising at least one fuel cell stack layer that comprises at least one fuel cell and at least one electrically insulating compression gasket, wherein a skirt is attached to the base and end plates enclosing the stack and is under tension therebetween so as to maintain a compressive force through the stack, thereby obviating the need for tie-bars.

Systems and methods including a header flange to evenly distribute contact pressure across seals include, in some aspects, a plate including a bead and a flange edge. The bead includes a bead-side and a bead-corner. The flange edge defines an aperture through the plate. The flange edge also includes a first edge-portion proximate the bead-side and a second edge-portion proximate the bead-corner. The bead-side and the first edge-portion define a first edge-distance therebetween. The bead-corner and the second edge-portion define a second edge-distance therebetween. The second edge-distance is greater than the first edge-distance.

Systems and methods including a header flange to evenly distribute contact pressure across seals include, in some aspects, a plate including a bead and a flange edge. The bead includes a bead-side and a bead-corner. The flange edge defines an aperture through the plate. The flange edge also includes a first edge-portion proximate the bead-side and a second edge-portion proximate the bead-corner. The bead-side and the first edge-portion define a first edge-distance therebetween. The bead-corner and the second edge-portion define a second edge-distance therebetween. The second edge-distance is greater than the first edge-distance.

A fuel cell device includes: a cell stack; a case including a cover portion that covers one of side surfaces of the cell stack along a stacking direction; an end plate connected to one end portion of the cover portion in the stacking direction; and a fastening member that extends in parallel with the stacking direction on an opposite side of the cell stack from the cover portion, that includes one end portion in the stacking direction connected to the end plate and another end portion in the stacking direction connected to the case, and that fastens the cell stack, the end plate, and the case to each other. A thermal expansion coefficient of the cover portion is larger than a thermal expansion coefficient of the fastening member.

A fuel cell device includes: a cell stack; a case including a cover portion that covers one of side surfaces of the cell stack along a stacking direction; an end plate connected to one end portion of the cover portion in the stacking direction; and a fastening member that extends in parallel with the stacking direction on an opposite side of the cell stack from the cover portion, that includes one end portion in the stacking direction connected to the end plate and another end portion in the stacking direction connected to the case, and that fastens the cell stack, the end plate, and the case to each other. A thermal expansion coefficient of the cover portion is larger than a thermal expansion coefficient of the fastening member.

A fuel cell stack includes an endplate assembly of a fuel cell system which includes a structural endplate having a first exterior surface and a first interior surface located on an opposite side of the endplate relative to the first exterior surface. An insulator plate has a second exterior surface contacting the first interior surface of the structural endplate and second interior surface on an opposite side of the insulator plate relative to the second exterior surface. A third plate has a third exterior surface contacting the second interior surface and a third interior surface on an opposite side of the third plate relative to the insulator plate. The third interior surface and third exterior surface are substantially flat such that third interior surface and the third exterior surface are about parallel to each other. The second interior surface and the third exterior surface contact each other substantially continuously in a longitudinal direction and a lateral direction such that the second interior surface and the third exterior surface are flat and substantially parallel to each other. The second exterior surface is contoured such that the second exterior surface is not flat and is substantially non-parallel relative to the third interior surface.

A fuel cell assembly has a plurality of fuel cell component elements extending between a pair of end plates to form a stack, and plural reactant gas manifolds mounted externally of and surrounding the stack, in mutual, close sealing relationship to prevent leakage of reactant gas in the manifolds to the environment external to the manifolds. The reactant gas manifolds are configured and positioned to maximize sealing contact with smooth surfaces of the stack and the manifolds. One embodiment is configured for an oxidant reactant manifold to overlie the region where the fuel reactant manifold engages the stack. Another embodiment further subdivides an oxidant reactant manifold to include a liquid flow channel, which liquid flow channel overlies the region where the fuel reactant manifold engages the stack.

A fuel cell assembly has a plurality of fuel cell component elements extending between a pair of end plates to form a stack, and plural reactant gas manifolds mounted externally of and surrounding the stack, in mutual, close sealing relationship to prevent leakage of reactant gas in the manifolds to the environment external to the manifolds. The reactant gas manifolds are configured and positioned to maximize sealing contact with smooth surfaces of the stack and the manifolds. One embodiment is configured for an oxidant reactant manifold to overlie the region where the fuel reactant manifold engages the stack. Another embodiment further subdivides an oxidant reactant manifold to include a liquid flow channel, which liquid flow channel overlies the region where the fuel reactant manifold engages the stack.

There is provided a fuel cell mounting structure including (i) a fuel cell which is configured to be disposed in a vehicle where a drive motor that drives rear wheels is placed in a vehicle rear portion, the fuel cell placed on the vehicle upper side of a suspension member disposed in a vehicle front portion and connected via a plurality of anti-vibration members to the suspension member, and (ii) auxiliaries that are attached to the fuel cell in a state in which the auxiliaries do not contact the suspension member and include at least an air compressor and a pump.

There is provided a fuel cell mounting structure including (i) a fuel cell which is configured to be disposed in a vehicle where a drive motor that drives rear wheels is placed in a vehicle rear portion, the fuel cell placed on the vehicle upper side of a suspension member disposed in a vehicle front portion and connected via a plurality of anti-vibration members to the suspension member, and (ii) auxiliaries that are attached to the fuel cell in a state in which the auxiliaries do not contact the suspension member and include at least an air compressor and a pump.