The present disclosure provides methods for forming flow plate and frame assemblies that comprise an anode frame member, a flow plate, and a 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 in the anode frame member, onto an anode surface of the flow plate, and into anode flow channels.

A method for bonding a solid electrolyte layer and electrodes used a fuel cell includes: laminating the solid electrolyte layer and the electrodes so that the electrodes sandwich the solid electrolyte layer therebetween; applying a first voltage of a first polarity between the electrodes sandwiching the solid electrolyte layer; and applying a second voltage of a second polarity that is the reverse of the first polarity between the electrodes sandwiching the solid electrolyte layer.

A fuel-cell single cell has a membrane electrode assembly sandwiched between a pair of separators, and a sealing member that seals a gas channel formed between the membrane electrode assembly and the separators. An uneven portion is formed in a part of the membrane electrode assembly where the sealing member is disposed. A sealing member sump to trap the sealing member is provided at a side exposed to reactant gas pressure and a holder part for the sealing member are provided within a part of the separators where the sealing member is disposed. The uneven portion is opposed to the holder part.

A fuel-cell single cell has a membrane electrode assembly sandwiched between a pair of separators, and a sealing member that seals a gas channel formed between the membrane electrode assembly and the separators. An uneven portion is formed in a part of the membrane electrode assembly where the sealing member is disposed. A sealing member sump to trap the sealing member is provided at a side exposed to reactant gas pressure and a holder part for the sealing member are provided within a part of the separators where the sealing member is disposed. The uneven portion is opposed to the holder part.

A fuel cell is formed by laminating a plurality of cells. Each cell includes a membrane electrode assembly and two separators, which hold the membrane electrode assembly in between. Each separator includes a base member made of a metal material. A first layer is provided on the surface of the base member. The first layer includes a resin film and conductive particles that have greater hardness than the oxide film of the base member. Between the separators that are adjacent to each other, the first layers are in contact with each other.

A fuel cell is formed by laminating a plurality of cells. Each cell includes a membrane electrode assembly and two separators, which hold the membrane electrode assembly in between. Each separator includes a base member made of a metal material. A first layer is provided on the surface of the base member. The first layer includes a resin film and conductive particles that have greater hardness than the oxide film of the base member. Between the separators that are adjacent to each other, the first layers are in contact with each other.

A fuel cell assembly includes a pair of corrugated bipolar plates. Each of the plates is defined by peak portions and sidewalls connecting the peak portions. The plates are fitted and nested within each other such that the sidewalls are in direct contact. Some of the sidewalls include a stepped shoulder portion such that each of the some of the sidewalls and the peak portions adjacent thereto form a stair-step profile and define a flow channel having a depth greater than a width.

A fuel cell assembly includes a pair of corrugated bipolar plates. Each of the plates is defined by peak portions and sidewalls connecting the peak portions. The plates are fitted and nested within each other such that the sidewalls are in direct contact. Some of the sidewalls include a stepped shoulder portion such that each of the some of the sidewalls and the peak portions adjacent thereto form a stair-step profile and define a flow channel having a depth greater than a width.

A metal plate stamping method is provided for cutting a metal plate, on which a bulging portion is formed through stamping, at a cutting area that is defined in a portion other than the bulging portion. The method includes forming a bead on the opposite side of the cutting area from the bulging portion and crushing the bead prior to the cutting of the metal plate.

A metal plate stamping method is provided for cutting a metal plate, on which a bulging portion is formed through stamping, at a cutting area that is defined in a portion other than the bulging portion. The method includes forming a bead on the opposite side of the cutting area from the bulging portion and crushing the bead prior to the cutting of the metal plate.