A fuel cell anode flow field includes at least one flow channel with a cross-sectional area that varies along at least a portion of its length. In some embodiments, the channel width decreases along at least a portion of the channel length according to a natural exponential function. This type of anode flow field can improve performance, reduce fuel consumption and/or reduce detrimental effects such as carbon corrosion and catalyst degradation, thereby improving fuel cell longevity and durability. When operating the fuel cell on either a substantially pure or a dilute fuel stream, this type of anode flow field can provide more uniform current density. These flow channels can be incorporated into reactant flow field plates, fuel cells and fuel cell stacks.

A method for producing a bipolar plate for a fuel cell having a membrane electrode assembly comprises providing a first fuel cell half-plate, which has a circumferential plate edge which has a first media channel offset inwardly from the plate edge and also a first flow field, providing a second fuel cell half-plate, which has a plate edge corresponding to the plate edge of the first fuel cell half-plate, and which has a second media channel offset inwardly from its plate edge and also a second flow field, the second media channel being aligned with the first media channel when the two fuel cell half-plates are stacked one above the other in perfect alignment, and joining the first fuel cell half-plate to the second fuel cell half-plate along a media-channel joint line framing the media channels, wherein a joint-line-free sealing region of the fuel cell half-plates borders the plate edges, on which a seal is fixed or is to be fixed, and the first fuel cell half-plate is joined to the second fuel cell half-plate along an additional frame joint line adjoining the media channel joint line or overlapping same, at least some sections of said additional frame joint line being offset along the plate edges in relation to the sealing region.

One or more methods of designing an FC bipolar plate that enhance the operational performance of FC. A first image analysis is conducted of image data of a fluid flow field structure having one or more dehomogenized microstructures to identify channels having a fluid flow blockage at a channel wall dead-end. The channel wall dead-end of each identified channel is selectively removed in a manner that fluidically connects each identified channel to an adjacent channel. Then, a second image analysis of the image data is conducted in response to selectively removing the channel wall dead-ends to measure a length of each channel wall. Channels walls having a length greater than a threshold channel wall length value are selectively cut, thereby providing reduced fluid flow resistance throughout the FC.

A bipolar plate for a fuel cell, a fuel cell, and a method of designing a bipolar plate for a fuel cell having a hybrid flow field structure that includes a plurality of parallel feed flow channels fluidically connected to an inlet bipolar plate region, a plurality of parallel exit flow channels fluidically connected to an outlet bipolar plate region, and an interwoven pattern formed by a plurality of simplified periodic array flow field structure generated based on flow patterns generated by homogenized anisotropic porous media optimization. The flow field structure enhances fuel cell performance by facilitating lower pressure drop via minimized fluid flow resistance, and removal of accumulated water in the oxygen channel and the gas diffusion layer (GDL) under the ribs of the bipolar plate.

A bipolar plate for a fuel cell, a fuel cell, and a method of designing a bipolar plate for a fuel cell having a hybrid flow field structure that includes a plurality of parallel feed flow channels fluidically connected to an inlet bipolar plate region, a plurality of parallel exit flow channels fluidically connected to an outlet bipolar plate region, and an interwoven pattern formed by a plurality of simplified periodic array flow field structure generated based on flow patterns generated by homogenized anisotropic porous media optimization. The flow field structure enhances fuel cell performance by facilitating lower pressure drop via minimized fluid flow resistance, and removal of accumulated water in the oxygen channel and the gas diffusion layer (GDL) under the ribs of the bipolar plate.

A fuel cell device includes a housing defining an inner space, a runner plate disposed in the inner space, two electrode plates disposed in the inner space such that the runner plate is stacked on and in contact with one of the electrode plates, and a proton exchange membrane clamped between the electrode plates. The runner plate includes a plurality of straight sections arranged in two rows, and a plurality of connecting sections. Each two adjacent straight sections define an opening therebetween. The openings in the two rows are staggered with respect to each other. Each two adjacent connecting sections are connected to and cooperate with a common straight section to define a drain channel communicating with the opening that aligns with the common straight section.

A design of and the process for forming a rigidly bonded metal supported electro-chemical device stack is provided. The electro-chemical device stack can be a solid oxide fuel cell or solid oxide electrolysis stack. The stack comprises multiple planar cells connected in serial by planar metal interconnects. The cells have metal support layers on both anode and cathode sides. The interconnect has gas channels embedded. Thin ceramic electro-chemical active electrodes and electrolyte are sandwiched between the metal support layers. The cells and interconnects are rigidly bonded to form a rigid body stack. The process comprises the steps of a). forming metal supported electro-chemical device cells with metal supports on both anode and cathode sides, b). sealing the peripherals of porous cell layers with an electrically insulating sealing material such as glass. c). bonding the cells and interconnects through commonly used metal-to-metal bonding methods, such as brazing or laser welding.

A design of and the process for forming a rigidly bonded metal supported electro-chemical device stack is provided. The electro-chemical device stack can be a solid oxide fuel cell or solid oxide electrolysis stack. The stack comprises multiple planar cells connected in serial by planar metal interconnects. The cells have metal support layers on both anode and cathode sides. The interconnect has gas channels embedded. Thin ceramic electro-chemical active electrodes and electrolyte are sandwiched between the metal support layers. The cells and interconnects are rigidly bonded to form a rigid body stack. The process comprises the steps of a). forming metal supported electro-chemical device cells with metal supports on both anode and cathode sides, b). sealing the peripherals of porous cell layers with an electrically insulating sealing material such as glass. c). bonding the cells and interconnects through commonly used metal-to-metal bonding methods, such as brazing or laser welding.

Systems and methods are provided for mechanical pretreatment of bipolar plates, for example, for plating electrodes in redox flow batteries. In one example, a method for disrupting surfaces of a bipolar plate may include pressing the bipolar plate between imprint plates, and removing the pressed bipolar plate from the imprint plates prior to use in a redox flow battery. In some examples, the pressed bipolar plate may include negative indentations from at least one of the imprint plates. In some examples, the imprint plates may be patterned meshes, such that the negative indentations may include patterns of asymmetric protrusions. In this way, the bipolar plate may be pretreated via pressing so as to reduce wear to manufacturing equipment (relative to other mechanical pretreatment processes, for example) while maintaining electrochemical performance of the redox flow battery.

The invention relates to a separator plate for an electrochemical system, comprising: at least one first through-opening for conducting a reaction medium through the separator plate; an active region having structures for guiding a reactor medium along a flat side of the separator plate; and a first sealing structure, surrounding the first through-opening, for sealing the first through-opening. The first sealing structure has a first passage for conducting a reaction medium through the first sealing structure, which passage points in a direction facing away from the active region. The invention also relates to a bipolar plate for an electrochemical system, which bipolar plate comprises the described separator plate.