A method for producing a metallic interconnector for a fuel cell stack, including an air guiding surface with a first gas distributor structure and a fuel gas guiding surface with a second gas distributor structure, the first gas distributor structure and the second gas distributor structure each formed by grooves and webs, includes providing a sheet metal blank, forming the sheet metal blank by a plastic molding process, the first gas distributor structure and the second gas distributor structure being formed in such a manner that the grooves and webs of the first gas distributor structure are arranged complementary to the grooves and webs of the second gas distributor structure at a predeterminable percentage of area of the air guiding surface and the fuel gas guiding surface of at least 50% and at most 99%.

A separator for a fuel cell includes a metal separator base, crest sections, and a trough sections. Regions surrounded by the respective trough sections and a corresponding electrode layer each constitute a passage that supplies oxidation gas or fuel gas to the electrode layer. A first thin film is placed over the entire surfaces of the crest sections and the trough sections that face the corresponding electrode layer. The first thin film has conductivity and a corrosion resistance higher than that of the separator base. A second thin film having conductivity is placed at least on each of the parts of the first thin film that are placed on top surfaces of the crest sections. The second thin film on the top surface of each crest section has a groove. At least one end of the groove is connected to the passage.

A gasket includes a first separator having a first bead, and a second separator superposed with the first separator and having a second bead formed at a position opposite to the first bead, wherein the first separator further has a first protrusion disposed close to the first bead and protruding from a first separator front surface in the same direction as the protruding direction of the first bead, and the second separator further has a second protrusion disposed close to the second bead, protruding from a second separator rear surface in a direction opposite to the protruding direction of the second bead, and fittable to the first protrusion.

A gasket includes a first separator having a first bead, and a second separator superposed with the first separator and having a second bead formed at a position opposite to the first bead, wherein the first separator further has a first protrusion disposed close to the first bead and protruding from a first separator front surface in the same direction as the protruding direction of the first bead, and the second separator further has a second protrusion disposed close to the second bead, protruding from a second separator rear surface in a direction opposite to the protruding direction of the second bead, and fittable to the first protrusion.

A fuel cell stack includes single cells stacked in a first direction. Each single cell includes a power generating unit, a first separator, and a second separator. The first separator and the second separator hold the power generating unit between the first separator and the second separator. The first separator of each single cell includes first protrusions that protrude toward the second separator of another single cell that is adjacent in the first direction. The first protrusions are in contact with the second separator. Each of the first protrusions includes a top wall portion and two side wall portions. At least one of the two side wall portions includes a step portion having a shape of a step in the first direction.

A method for inspecting a metal separator includes a step of detecting deflection of the metal separator with a height detector, a step of displacing the metal separator or an imaging device in a height direction according to the deflection of the metal separator to keep a distance between the imaging device and an imaging portion of the metal separator constant, and a step of imaging a weld portion with the imaging device.

The present disclosure provides a method of preparing a metal sheet. The method includes extruding a component along an extrusion axis. The component has a wall at least partially defining an interior region. The component includes a metal. The method further includes unfurling the wall to form a sheet precursor. The sheet precursor has a first thickness and a first transverse dimension. The method further includes rolling the sheet precursor along a rolling axis to form the metal sheet. The metal sheet has a second thickness perpendicular to the rolling axis. The second thickness is less than the first thickness. The second transverse dimension is parallel to the rolling axis. The second transverse dimension is greater than the first transverse dimension. In certain aspects, the metal includes lithium and the metal sheet is a lithium metal electrode.

The present disclosure provides methods for forming flow plate and frame assemblies that comprise an anode frame member, a flow plate, and cathode frame member with the flow plate retained between the anode and cathode frame members. The present disclosure also provides for flow plate and frame assemblies, fuel cell stacks containing a plurality of the flow plate and frame assemblies, and fuel cell systems containing the fuel cell stacks. A fluidly connected anode fluid pathway can be provided from an anode fluid inlet, through conduits int eh anode frame member, onto an anode surface of the flow plate, and into anode flow channels.

A power generation cell of a fuel cell stack includes a resin frame equipped MEA and a first metal separator and a second metal separator. In the power generation cell, the relationship of P1>P2>P3 is satisfied, where P1 indicates a first surface pressure applied from a first seal part and a second seal part to a resin frame member, P2 indicates a second surface pressure applied from a first support part and a second support part to the overlap part, and P3 indicates a third surface pressure applied from first flow field forming protrusions and second flow field forming protrusions to the power generation area.

A power generation cell of a fuel cell stack includes a resin frame equipped MEA and a first metal separator and a second metal separator. In the power generation cell, the relationship of P1>P2>P3 is satisfied, where P1 indicates a first surface pressure applied from a first seal part and a second seal part to a resin frame member, P2 indicates a second surface pressure applied from a first support part and a second support part to the overlap part, and P3 indicates a third surface pressure applied from first flow field forming protrusions and second flow field forming protrusions to the power generation area.