Hybrid bipolar plate for fuel cell

Abstract

A hybrid bipolar plate assembly for a fuel cell includes a formed cathode half plate and a stamped metal anode half plate. The stamped metal anode half plate is unnested with and affixed to the formed cathode half plate. Each of the half plates has a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures. The coolant side of the formed cathode half plate need not correspond with cathode flow channels formed on the opposite reactant side. The coolant side of the stamped metal anode half plate has lands corresponding with anode channels formed on the opposite oxidant side. The lands define a plurality of coolant channels on the coolant side of the stamped metal anode half plate and abut the coolant side of the formed cathode half plate.

Claims

1. A hybrid bipolar plate assembly for a fuel cell, comprising: a formed cathode half plate having a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures, the reactant side having an active area, the active area having a plurality of cathode channels formed therein, wherein each of the plurality of cathode channels includes a first portion, a second portion, and a third portion and the second portion of the cathode channels and the third portion of the cathode channels are bifurcated along a length of the active area, the feed region disposed between the active area and the header and having a plurality of feed channels formed therein and cathode port holes formed therethrough, the feed channels in communication with the cathode channels and the cathode port holes, the coolant side having a coolant distribution area disposed opposite the active area, the coolant distribution area being an entirely uninterrupted, planar surface; and a stamped metal anode half plate unnested with and affixed to the formed cathode half plate, the stamped metal anode half plate having a fuel side and a coolant side, a feed region, and a header with a plurality of header apertures, the fuel side having an active area, the active area having a plurality of anode channels formed therein, the feed region disposed between the active area and the header and having a plurality of feed channels formed therein and anode port holes formed therethrough, the feed channels in communication with the anode channels and the anode port holes, the coolant side having a plurality of lands corresponding with the anode channels, the lands defining a plurality of coolant channels on the coolant side of the stamped metal anode half plate, the plurality of lands abutting the coolant side of the formed cathode half plate.

2. The hybrid bipolar plate assembly of claim 1, wherein the formed cathode half plate has a web thickness of between 0.15 mm and 0.5 mm.

3. The hybrid bipolar plate assembly of claim 2, wherein the coolant side further includes a plurality of coolant tunnels formed in the coolant side.

4. The hybrid bipolar plate assembly of claim 3, wherein the reactant side further comprises a null area, the null area of the reactant side being different from and not corresponding with the coolant distribution area.

5. The hybrid bipolar plate assembly of claim 4, wherein the null area of the reactant side does not contain the plurality of cathode channels.

6. The hybrid bipolar plate assembly of claim 5, wherein the null area of the reactant side is planar.

7. The hybrid bipolar plate assembly of claim 6, wherein the coolant distribution area does not contain the plurality of coolant tunnels.

8. The hybrid bipolar plate assembly of claim 7, wherein the plurality of coolant tunnels only disposed opposite to the null area of the reactant side and are not disposed opposite to the active area of the reactant side.

9. The hybrid bipolar plate assembly of claim 8, wherein the plurality of apertures of the formed cathode half plate includes a first header aperture, a second header, and a third header aperture, and wherein the null area of the reactant side is disposed adjacent to the second header aperture and the third header aperture and is not disposed adjacent to the first header aperture.

10. The hybrid bipolar plate assembly of claim 9, wherein each of the plurality of cathode channels includes a first portion disposed adjacent to the first header aperture and oriented along a first axis, a second portion in communication with the first portion and oriented along a second axis, and a third portion in communication with the second portion and oriented along a third axis, and wherein the second axis is oriented transverse to each of the first axis and the third axis.

11. The hybrid bipolar plate assembly of claim 10, wherein the second axis is oriented orthogonal to each of the first axis and the third axis.

12. The hybrid bipolar plate assembly of claim 11, wherein each of the second header aperture and the third header aperture has an innermost edge disposed adjacent to the null area of the reactant side, and wherein the innermost edge of each of the second header aperture and the third header apertures is oriented along a fourth axis, the fourth axis spaced part from the second axis.

13. The hybrid bipolar plate assembly of claim 12, wherein the plurality of cathode channels includes a first cathode channel that is disposed closest to the second header aperture and the third header aperture, and wherein the null area of the reactant side is bounded by the first axis, the second axis, and the third axis of the first cathode channel, and the fourth axis.

14. The hybrid bipolar plate assembly of claim 13, wherein each of the plurality of coolant tunnels include a first portion and a second portion, the first portion disposed adjacent to the second header aperture and the second portion disposed adjacent to the third header aperture.

15. A hybrid bipolar plate assembly for a fuel cell, comprising: a formed cathode half plate having a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures, the reactant side having an active area and a null portion, the active area having a plurality of cathode channels formed therein, wherein each of the plurality of cathode channels includes a first portion, a second portion, and a third portion and the second portion of the cathode channels and the third portion of the cathode channels are bifurcated along a length of the active area, the feed region disposed between the active area and the header and having a plurality of feed channels formed therein and cathode port holes formed therethrough, the feed channels in communication with the cathode channels and the cathode port holes, the coolant side having a coolant distribution and a plurality of coolant tunnels, the coolant distribution area disposed opposite the active area, the coolant distribution area being an entirely uninterrupted, planar surface, and the plurality of coolant tunnels only disposed opposite to the null area of the reactant side and are not disposed opposite to the active area of the reactant side, and wherein the null area of the reactant side is planar and does not contain the plurality of cathode channels, and being different from and not corresponding with the coolant distribution area, and wherein the formed cathode half plate has a web thickness of between 0.15 mm and 0.5 mm, and wherein the formed cathode half plate is formed from graphite or molded carbon composite; a stamped metal anode half plate unnested with and affixed to the formed cathode half plate, the stamped metal anode half plate having a fuel side and a coolant side, a feed region, and a header with a plurality of header apertures, the fuel side having an active area, the active area having a plurality of anode channels formed therein, the feed region disposed between the active area and the header and having a plurality of feed channels formed therein and anode port holes formed therethrough, the feed channels in communication with the anode channels and the anode port holes, the coolant side having a plurality of lands corresponding with the anode channels, the lands defining a plurality of coolant channels on the coolant side of the stamped metal anode half plate, the plurality of lands abutting the coolant side of the formed cathode half plate, wherein the stamped metal anode half plate has a sealing region with a planar perimeter flange, wherein the plurality of anode channels formed in the stamped metal anode half plate includes a plurality of branched feed channels in the feed region of the stamped metal anode half plate and a plurality of linear flow channels oriented along the active area of the stamped metal anode half plate, wherein the stamped metal anode half plate has a thickness of between 0.25 mm and 0.55 mm, and wherein the stamped metal anode half plate is formed from stainless steel; and a plate seal disposed between and sealing the formed cathode half plate with the stamped metal anode half plate, wherein the plate seal is formed from one of an elastomer, a compressible graphite, and an epoxy material, and is also disposed around a perimeter of each of the formed cathode half plate and the stamped metal anode half plate.

16. The hybrid bipolar plate assembly of claim 15, wherein the plurality of apertures of the formed cathode half plate includes a first header aperture, a second header aperture, and a third header aperture, and wherein the null area of the reactant side is disposed adjacent to the second header aperture and the third header aperture and is not disposed adjacent to the first header aperture.

17. The hybrid bipolar plate assembly of claim 16, wherein each of the plurality of cathode channels includes a first portion disposed adjacent to the first header aperture and oriented along a first axis, a second portion in communication with the first portion and oriented along a second axis, and a third portion in communication with the second portion and oriented along a third axis, and wherein the second axis is oriented transverse to each of the first axis and the third axis.

18. A fuel cell stack comprising: a plurality of membrane electrode assemblies arranged in a stacked configuration, each of the membrane electrode assemblies having a polymer electrolyte membrane with a cathode and an anode; and a hybrid bipolar plate assembly disposed between adjacent membrane electrode assemblies, the hybrid bipolar plate assembly including a formed cathode half plate having a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures, the reactant side having an active area, the active area having a plurality of cathode channels formed therein, wherein each of the plurality of cathode channels includes a first portion, a second portion, and a third portion and the second portion of the cathode channels and the third portion of the cathode channels are bifurcated along a length of the active area, the feed region disposed between the active area and the header and having a plurality of feed channels formed therein and cathode port holes formed therethrough, the feed channels in communication with the cathode channels and the cathode port holes, the coolant side having a coolant distribution area disposed opposite the active area, the coolant distribution area being an entirely uninterrupted, planar surface, and a stamped metal anode half plate unnested with and affixed to the formed cathode half plate, the stamped metal anode half plate having a fuel side and a coolant side, a feed region, and a header with a plurality of header apertures, the fuel side having an active area, the active area having a plurality of anode channels formed therein, the feed region disposed between the active area and the header and having a plurality of feed channels formed therein and anode port holes formed therethrough, the feed channels in communication with the anode channels and the anode port holes, the coolant side having a plurality of lands corresponding with the anode channels, the lands defining a plurality of coolant channels on the coolant side of the stamped metal anode half plate, the plurality of lands abutting the coolant side of the formed cathode half plate.

Description

DRAWINGS

(1) The above, as well as other advantages of the present disclosure, will become readily apparent to those skilled in the art from the following detailed description, particularly when considered in the light of the drawings described herein.

(2) FIG. 1 illustrates a schematic, exploded perspective view of a PEM fuel cell stack, and shows only two cells with a single bipolar plate assembly for purpose of simplicity;

(3) FIG. 2 is a top plan view of a formed cathode half plate for use in the bipolar plate assembly of FIG. 1, and further illustrating a reactant side of the formed cathode half plate;

(4) FIG. 3 is a bottom plan view of the formed cathode half plate shown in FIG. 2, according to one embodiment of the disclosure, and further illustrating a coolant side of the formed cathode half plate with an array of pillars in feed regions of the half plate and an empty pocket between the feed regions of the half plate;

(5) FIG. 4 is a bottom plan view of the formed cathode half plate shown in FIG. 2, according to another embodiment of the disclosure, and further illustrating a coolant side of the formed cathode half plate with coolant channel support ribs between feed regions of the half plate;

(6) FIG. 5 is a top plan view of a stamped metal anode half plate for use in the bipolar plate assembly of FIG. 1;

(7) FIG. 6 is a fragmentary cross-sectional side elevational view of a fuel cell with an assembled bipolar plate assembly and taken along section line T-T of the anode half plate shown in FIG. 5, and with the anode half plate affixed to the cathode half plate shown in FIGS. 2 and 3 and assembled with a membrane electrode assembly (MEA), and further illustrating a long section view of a transition region of the fuel cell;

(8) FIG. 7 is a fragmentary cross-sectional side elevational view of a fuel cell with an assembled bipolar plate assembly and taken along section line E-E of the anode half plate shown in FIG. 5, with the anode half plate affixed to the cathode half plate shown in FIGS. 2 and 3 and assembled with an MEA, and further illustrating an unsupported coolant region of the fuel cell;

(9) FIG. 8 is a fragmentary cross-sectional side elevational view of a fuel cell with an assembled bipolar plate assembly and taken along section line E-E of the anode half plate shown in FIG. 5, with the anode half plate affixed to the cathode half plate shown in FIGS. 2 and 4 and assembled with an MEA, and further illustrating coolant channel support ribs of the fuel cell;

(10) FIG. 9 is a fragmentary cross-sectional side elevational view of a fuel cell with an assembled bipolar plate assembly and taken along section line C-C of the anode half plate shown in FIG. 5, with the anode half plate affixed to the cathode half plate shown in FIGS. 2 and 3 and assembled with an MEA, and further illustrating cathode tunnels of the fuel cell;

(11) FIG. 10 is a fragmentary cross-sectional side elevational view of a fuel cell with an assembled bipolar plate assembly and taken along section line A-A of the anode half plate shown in FIG. 5, the anode half plate affixed to the cathode half plate shown in FIGS. 2 and 3 and assembled with an MEA, and further illustrating anode tunnels of the fuel cell;

(12) FIG. 11 is a fragmentary cross-sectional side elevational view of a fuel cell with an assembled bipolar plate assembly and taken along section line X-X of the anode half plate shown in FIG. 5, the anode half plate affixed to the cathode half plate shown in FIGS. 2 and 3 and assembled with an MEA, and further illustrating coolant tunnels of the fuel cell;

(13) FIG. 12 is a top plan view of a plate seal for use with the fuel cell shown in FIGS. 1-11;

(14) FIG. 13 is a top plan view of a membrane seal for use with the fuel cell shown in FIGS. 1-11;

(15) FIG. 14 is a top plan view of the plate seal shown in FIG. 12 shown overlaid with the elastomeric membrane seal shown in FIG. 13 and a diffusion medium layer of the fuel cell, the plate seal shown without the half plate for purposes of illustrating a relative lateral positioning of the plate seal with the membrane seal;

(16) FIG. 15 is a top plan view of a formed cathode half plate for use in the bipolar plate assembly according to an embodiment of the present disclosure, and further illustrating a reactant side of the formed cathode half plate;

(17) FIG. 16 is an enlarged top plan view of the formed cathode half plate taken at call-out B in FIG. 15, and further illustrating a null portion of the active area;

(18) FIG. 17 is a bottom plan view of the formed cathode half plate shown in FIG. 15, and further illustrating a coolant side of the formed cathode half plate with a plurality of coolant tunnels in feed regions of the half plate and an empty coolant distribution area;

(19) FIG. 18 is a top plan view of a coolant side of a stamped metal anode half plate for use in the bipolar plate, according to an embodiment of the present disclosure;

(20) FIG. 19 is a bottom plan view of a fuel side of the stamped metal anode half plate shown in FIG. 18;

(21) FIG. 20 is a top plan view of the bipolar plate assembly with portions of the stamped metal anode half plate removed to the underlying coolant side of the formed cathode half plate as shown in FIG. 17; and

(22) FIG. 21 is a fragmentary cross-sectional side elevational view of the bipolar plate assembly taken along the section line D-D in FIG. 20.

DETAILED DESCRIPTION

(23) The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should also be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, are not necessary or critical.

(24) For simplicity, only a two-cell stack (i.e. one bipolar plate) is illustrated and described herein with respect to FIG. 1, it being understood that a typical stack will have many more such cells and bipolar plates.

(25) FIG. 1 depicts a two cell PEM fuel cell stack 2 having a pair of membrane-electrode-assemblies (MEAs) 4, 6 separated from each other by an electrically conductive fluid distribution element 8, hereinafter also referred to as bipolar plate assembly 200. The MEAs 4, 6 include a membrane-electrolyte layer having an anode and a cathode with a catalyst on opposite faces of the membrane-electrolyte. The MEAs 4, 6 and bipolar plate assembly 8, 200 are stacked together between end plates 10, 12 and end contact elements 14, 16 under compression. The end contact elements 14,16 and the bipolar plate assembly 8, 200 include working faces 18, 20, 22, 24, respectively, for distributing fuel and oxidant gases (e.g., H.sub.2 and Air or O.sub.2) to the MEAs 4, 6. Nonconductive gaskets 26, 28, 30, 32 provide seals and electrical insulation between the several components of the fuel cell stack 2.

(26) The MEAs 4, 6 are disposed adjacent gas permeable conductive materials known as gas diffusion media 34, 36, 38, 40. The gas diffusion media 34, 36, 38, 40 may include carbon or graphite diffusion paper. The gas diffusion media 34, 36, 38, 40 contact the MEAs 4, 6, with each of the anode and the cathode having an associated one of the diffusion medium layers. The end contact units 14, 16 contacts the gas diffusion media 34, 40 respectively. The bipolar plate assembly 8, 200 contacts the gas diffusion media 36 on the anode face of MEA 4, configured to accept hydrogen-bearing reactant, and also contacts gas diffusion medium 38 on the cathode face of MEA 6, configured to accept oxygen-bearing reactant. Oxygen is supplied to the cathode side of the fuel cell stack 2 from storage tank 46, for example, via an appropriate supply conduit 42. Hydrogen is supplied to the anode side of the fuel cell from a storage tank 48, for example, via an appropriate supply conduit 44. Alternatively, ambient air may be supplied to the cathode side as an oxygen source and hydrogen to the anode from a methanol or gasoline reformer, and the like. Exhaust conduits (not shown) for both the anode and cathode sides of the MEAs 4, 6 are also provided. Additional conduits 50, 52, 54 are provided for supplying liquid coolant to the bipolar plate assembly 8, 200 and end plates 14, 16. Appropriate conduits for exhausting coolant from the bipolar plate assembly 8, 200 and end plates 14, 16 are also provided (not shown).

(27) Referring next to FIGS. 2-14, the bipolar plate assembly 200 is shown in greater detail. The bipolar plate assembly 200 includes a formed cathode half plate 202, for example, as shown in FIGS. 2-4, and a stamped metal anode half plate 204, for example, as shown in FIG. 5. In accordance with the teaching of the present disclosure, the formed cathode half plate 202 and the stamped metal anode half plate 204 are each formed from a different electrically conductive material, and according to different processes before being combined to form the bipolar plate assembly 200.

(28) In particular, the formed cathode half plate 202 is formed from a composite material. The composite material may be suitable for a manufacturing process such as machining, molding, etching, cutting, or carving, as non-limiting examples. Suitable composite materials include, but are not limited to, graphite, graphite foil, conductive particles (e.g. graphite powders) in a polymer matrix, carbon fiber paper and polymer laminates, metal plates, polymer plates with metal cores, conductively coated polymer plates, and combinations thereof, for example.

(29) The stamped metal anode half plate 204 is formed from a metallic material suitable for use in a manufacturing process such as stamping. Suitable metallic materials include, for example, pure metals and metal alloys. The pure metals and metal alloys have sufficient durability and rigidity to function as sheets in the bipolar plate assembly 8 of the fuel cell stack 2. Suitable metals and metal alloys include, but are not limited to, aluminum, titanium, platinum, stainless steel, carbon steel, nickel-based alloys, tantalum, niobium, and alloys and combinations thereof.

(30) Additional design properties considered in selecting a material for the cathode and anode half plates 202, 204 include gas permeability, conductivity, density, thermal conductivity, corrosion resistance, pattern definition, thermal and pattern stability, machinability, joinability, and availability. With these considerations, one of ordinary skill in the art may also select other suitable materials for the formed cathode half plate 202 and the stamped metal anode half plate 204, as desired.

(31) Each of the formed cathode half plate 202 and the stamped metal anode half plate 204 has an optimized thickness, with the stamped metal anode half plate 204 being relatively thinner in thickness relative to the formed cathode half plate 202. For example, the composite cathode half plate 202 may have a thickness of between about 0.3 mm and about 1 mm, more particularly between about 0.5 mm and about 0.75 mm, and most particularly about 0.65 mm. The stamped metal anode half plate 204 may have a thickness of between about 0.25 mm and about 0.55 mm, more particularly between about 0.35 mm and about 0.45 mm, and most particularly about 0.4 mm. One of ordinary skill in the art may also select other suitable thicknesses for the formed cathode plate 202 and the stamped metal anode half plate 204, as desired.

(32) Being made from different materials, with the formed cathode half plate 202 being formed from a composite material not generally conducive to welding or brazing operations, it should be understood that the composite cathode half plate 202 and the stamped metal anode half plate 204 are affixed by other suitable means. Non-limiting examples of suitable means for affixing the half plates 202, 204 may include a compressed plate seal (shown in FIGS. 7-10 and 12 as “302”) disposed between perimeter flanges of each of the half plates 202, 204. A compressed region of compliant graphite of the formed cathode half plate 202 itself, where the formed cathode half plate 202 is formed from graphite, may also be employed to plate seal 302 and affix the half plates 202, 204 to one another. Bonding of the formed cathode half plate 202 with the stamped metal anode half plate 204 may also be accomplished with epoxy in the perimeter flange regions of the half plates 202, 204, for example, as shown in FIGS. 7-10. One of ordinary skill in the art may also select other suitable means for affixing the formed cathode half plate 202 with the stamped metal anode half plate 204 within the scope of the present disclosure.

(33) As shown in FIGS. 2-4, the formed cathode half plate 202 has a reactant side 206 (shown in FIG. 2) and a coolant side 208 (shown in FIGS. 3-4). The formed cathode half plate 202 further has a pair of feed regions 210, 211 and a pair of headers 212, 213 with a plurality of header apertures 214, 215. Although described primarily herewith with respect to a single one of the feed regions 210, a single one of headers 212, and a single set of header apertures 214 on one side of the formed cathode half plate 202, it should be appreciated that descriptions of features from the feed region 210, the header 212, and the header apertures 214 likewise apply to the other feed region 211, the other header 213, and the other header apertures 215 shown in FIGS. 2-4.

(34) With reference to FIG. 2, the reactant side 206 of the formed cathode half plate 202 has an active area 216. The active area 216 having a plurality of cathode channels 218 formed therein. The cathode channels 218 are adapted to distribute the oxidant gases (e.g., air or oxygen) across the active area 216. The cathode channels 218 also define a plurality of lands 220 disposed therebetween.

(35) The feed region 210 of the formed cathode half plate 202 is disposed between the active area 216 and the header 212. The feed region 210 has a plurality of feed channels 222 formed therein. The feed channels 222 also define a plurality of lands 224 disposed therebetween.

(36) The feed region 210 of the formed cathode half plate 202 further has cathode port holes 226 formed therethrough, which are in turn in communication with a one of the header apertures 214 associated with the oxidant gases. The feed channels 222 are in communication with both the cathode channels 218 and the cathode port holes 226. The feed channels 222 are adapted to transport the oxidant gases between the active area 216 and the one of the header apertures 214 associated with the oxidant gases.

(37) It should be appreciated that the cathode port holes 226 provide inlet and outlet passages in the form of tunnels for the fuel gases to flow through the bipolar plate assembly 200. A skilled artisan should understand that various configurations of the cathode channels 218, the feed channels 222, and the cathode port holes 226 may be used within the scope of the present disclosure. It should also be recognized that the present disclosure is not limited to a particular flow field pattern, but has application to bipolar plate assemblies 200 independent of the flow field pattern.

(38) With reference to FIGS. 3-4, the coolant side 208 of the formed cathode half plate 202 has a coolant distribution area 228. The coolant distribution area 228 is disposed opposite the active area 216 of the same formed cathode half plate 202. The coolant side 208 further has support features 230, 232. The support features 230, 232 are disposed opposite at least one of the feed region 210, 211 and the active area 216 of the same formed cathode half plate 202.

(39) In should be understood that at least a portion of the coolant distribution area 228 of the formed cathode half plate 202 is different from, and is not constrained to correspond with, the cathode channels 218 of the active area 216. This is facilitated by the formation of the formed cathode half plate 202 by molding or cutting manufacturing methods, which are different from stamping operations, and which stamping operations are otherwise known to provide lands on one side of the plate corresponding with channels on the other side of the plate, and vice-versa.

(40) Advantageously, the employment of different structure in the coolant distribution area 228 relative to the active area 216 is believed to allow for an optimization or maximization of current density for the bipolar plate assembly 200 of the present disclosure. In particular, desirable current density has been found where the cathode channels 218 are provided with a pitch (where the term “pitch” is defined as a sum of the channel width and the land width) of about 1.5 mm or less. In a most particular embodiment, the cathode channels 218 may have a pitch of about 1 mm.

(41) The very fine pitch for the cathode channels 218 of the present disclosure is believed to provide for superior current densities compared to conventional stamped metal bipolar plates. One of ordinary skill in the art may also select other suitable relative pitches for the cathode channels 218 of the reactant side 206 and the coolant distribution area 228 of the coolant side 208, as desired.

(42) As nonlimiting examples, as shown in FIGS. 3-4, the support features 230 in the feed regions 210, 211 of the formed cathode half plate 202 may include a plurality of pillars 230 or other support structures that permit the passage of coolant flow. The plurality of pillars 230 may extend outwardly from the coolant side of the formed cathode half plate 202. As shown in FIGS. 3-4, the pillars 230 are disposed opposite only the feed regions 210, 211 of the formed cathode half plate 202, and are not otherwise disposed opposite the active area 216 of the formed cathode half plate 202. The pillars 230 may also be spaced apart from one another and arranged in an array or matrix or other patterns that permit the passage of coolant flow. For example, the pillars 230 may be disposed every 3 mm (3 mm×3 mm array with the pillars 230 generally arranged in rows and columns). Similar arrays may be provided with other distributions, for example 1 mm×1 mm arrays, 2 mm×2 mm arrays, and 5 mm×5 mm arrays, for example. It should be understood that other arrangements and distributions of the pillars 230 may be employed by a skilled artisan.

(43) In illustrative embodiments of the present disclosure, each of the plurality of pillars 230 may have an average diameter of less than about 0.2 mm. In further embodiments, the plurality of pillars 230 have an average diameter of less than about 1 mm. In particular embodiments, each of the pillars 230 may have an average diameter of less than about 0.5 mm. Other dimensions for the pillars 230 may also be employed, as desired.

(44) Regardless of arrangement, configuration, or dimensions, it should be appreciated that the pillars 230 are adapted to abut and support the adjacent stamped metal anode half plate 204 that is nested with the formed cathode half plate 202, for example, as shown in FIGS. 6-11. Thus, a height, width, and general shape of each of the pillars 230 may be selected by one skilled in the art depending on the desired nested dimensions of the formed cathode half plate 202 with the stamped metal anode half plate 204. The pillars 230 thereby facilitate a distribution of coolant from an associated one of the header apertures 214 to the coolant distribution area 228, even while the bipolar plate assembly 200 is under compression typical with operation of the fuel cell stack 2.

(45) With reference to FIG. 4, the support features 230, 232 on the coolant side 208 of the formed cathode half plate 202 may also include a plurality of support ribs 232. The support ribs 232 are disposed only in the coolant distribution area 228 opposite the active area 216 of the formed cathode half plate 202. In particular, the support ribs 232 may be spaced apart from, and oriented generally parallel with, one another on the coolant distribution area 228. The support ribs 232 are elongate and may be oriented along a length of the coolant distribution area 228 between the headers 212, 214 of the formed cathode half plate 202. The support ribs 232 may also be substantially linear in shape. However, a skilled artisan may also select other suitable shapes and distributions of the support ribs 232, as desired.

(46) It should be understood that the support ribs 232 on the coolant side 208 of the formed cathode half plate 202 may furthermore allow for the use of thinner metal gauges, such as typical foil gauges, for the stamped metal anode half plate 204 of the present disclosure. In particular, the support ribs 232 may be configured to interact with and support an opposing surface of the stamped metal anode plate 204 as described further herein.

(47) As shown in FIG. 5, the stamped metal anode half plate 204 of the present disclosure is configured to be affixed to the formed cathode half plate 202. The stamped metal anode half plate 204 has a fuel side 234 and a coolant side 236. The stamped metal anode half plate 204 further has a pair of feed regions 238, 239 and a pair of headers 240, 241 with a plurality of header apertures 242, 243. Although described primarily herewith with respect to a single one of the feed regions 238, a single one of headers 240, and a single set of header apertures 242 on one side of the stamped metal anode half plate 204, it should be appreciated that descriptions of features from the feed region 238, the header 240, and the header apertures 242 likewise apply to the other feed region 239, the other header 241, and the other header apertures 243.

(48) Being formed by a stamping operation on a thin metal sheet or foil, it should be understood that the stamped features (e.g., the channels and lands) on the fuel side 234 of the stamped metal anode half plate 204 will have corresponding but opposite features (e.g., lands and channels, respectively) with otherwise the same or similar dimensions on the coolant side 236 of the stamped metal anode half plate 204.

(49) The fuel side 234 of the stamped metal anode half plate 204 has an active area 244. The active area 244 has a plurality of anode channels 246 formed therein. The anode channels 246 are adapted to distribute the fuel gases (e.g., hydrogen) across the active area 244. The anode channels 246 also define a plurality of lands 248 disposed therebetween.

(50) The feed region 238 of the stamped metal anode half plate 204 is disposed between the active area 244 and the header 240. The feed region 238 has a plurality of feed channels 250 formed therein. The feed channels 250 also define a plurality of lands 252 disposed therebetween.

(51) The feed region 238 further has anode port holes 254 formed therethrough, which are in turn in communication with a one of the header apertures 242 associated with the fuel gases. The feed channels 250 are in communication with both the anode channels 246 and the anode port holes 254. The feed channels 250 are adapted to transport the fuel gases between the active area 244 and the one of the header apertures 242 associated with the fuel gases.

(52) It should be appreciated that the anode port holes 254 provide inlet and outlet passages in the form of tunnels for the fuel gases to flow through the bipolar plate assembly 200. A skilled artisan should understand that various configurations of the anode channels 246, the feed channels 250, and the anode port holes 254 may be used within the scope of the present disclosure. It should also be recognized that the present disclosure is not limited to a particular flow field pattern, but has application to bipolar plate assemblies 200 independent of the flow field pattern.

(53) As discussed hereinabove, the coolant side 236 of the stamped metal anode half plate 204 has a plurality of lands 258 corresponding with the anode channels 246. In turn, the lands 258 define a plurality of coolant channels 260 on the coolant side 236 of the stamped metal anode half plate 204. The plurality of lands 258 abut the coolant side 208 of the formed cathode half plate 202 upon assembly, for example, as shown in FIGS. 6-11.

(54) With reference to FIG. 8, where the formed cathode half plate 202 has the support ribs 232 on the coolant side 208, the support ribs 232 may be aligned with every other one of the coolant channels 260 on the coolant side 236 of the stamped metal anode half plate 204. It should be appreciated that the support ribs 232 in such an arrangement provide for sufficient support of the stamped metal anode half plate 204 while also permitting for a sufficient amount of the coolant channels 260 to remain open for transfer of the coolant therethrough. Other arrangements for the support ribs 232, including embodiments without any support ribs 232 and instead just an empty pocket, are also contemplated and considered to be within the scope of the present disclosure.

(55) With renewed reference to FIG. 5, the stamped metal anode half plate 204 a flat or planar perimeter flange 262. The planar perimeter flange 262 defines at least part of a sealing region of the stamped metal anode half plate 204 that is configured to abut and seal with a seal combination 300 of the fuel cell stack 2 including a plate seal 302 and a membrane seal 304, for example, as shown in FIGS. 12-14.

(56) It should further be understood that the plurality of anode channels 246 formed in the stamped metal anode half plate 204 includes a plurality of branched feed channels 264 in the feed region 238 of the stamped metal anode half plate 204. The anode channels 246 may also include a plurality of linear anode channels 266 in the active area 244. The linear anode channels 266 may be oriented along the active area 244 of the stamped metal anode half plate 204. A skilled artisan will appreciate that the linear shape of the anode channels 266 may advantageously facilitate a cooperation of the opposing coolant channels 260 with the support ribs 232 where also linear in shape, as described hereinabove. However, although the anode channels 266 in the active area 244 are shown in FIG. 5 as being linear between the feed regions 238, 239, one of ordinary skill in the art may select other suitable configures for the anode channels 266 in the active area 244 of the stamped metal anode half plate 204, as desired.

(57) With respect to the active areas 216, 244 of the bipolar plate assembly 200, it should be appreciated that at least one of the active areas 216, 244 may be have a coating (not shown). The coating may be adapted to provide corrosion resistance, thermal conductivity, and optimized electrical conductivity and contact resistance, for example. In embodiments where the active areas 216, 244 are coated, the coating may facilitate electrical conductivity.

(58) As nonlimiting example, the coating may include noble metals, metal oxides, carbon and combinations thereof. Suitable noble metals for coatings include gold (Au), silver (Ag), iridium (Ir), ruthenium (Ru), rhodium (Rh), osmium (Os), palladium (Pd) and platinum (Pt), for example. In particular embodiments, the metal employed for the coating of the active areas 216, 244 is gold (Au). Suitable metal oxides for the coating, but are not limited to, hafnium dioxide (HfO.sub.2), zirconium dioxide (ZrO.sub.2), aluminum oxide (Al.sub.2O.sub.3), tin oxide (SnO.sub.2), tantalum pent-oxide (Ta.sub.2O.sub.5), niobium pent-oxide (Nb.sub.2O.sub.5), molybdenum dioxide (MoO.sub.2), iridium dioxide (IrO.sub.2), ruthenium dioxide (RuO.sub.2) and mixtures thereof. The coatings are typically applied using any commercially available process. As nonlimiting examples, the coatings may be applied by one of electroplating, electro-less plating, and physical vapor deposition. It should be understood that other suitable methods for applying the coatings may be used as desired.

(59) In particular embodiments, the coating may be hydrophilic and adapted to facilitate a removal of liquid water from the active areas 216, 244 during operation of the fuel cell stack 2. Suitable hydrophilic coatings may include the noble metal coatings as described herein and as known in the art. As nonlimiting examples, the coating can include at least one Si—O group, at least one polar group and at least one group including a saturated or unsaturated carbon chain. In further embodiments the coating comprises at least one Si—O group and an Si—R group, wherein R includes a saturated or unsaturated carbon chain and the molar ratio of Si—R groups to Si—O groups ranges from 1/8 to 1/2. The coating may also be applied by any means sufficient for applying hydrophilic coatings. Suitable hydrophilic coatings can also include nanoparticles having a size ranging from 1 to 100 nanometers, wherein the nanoparticles comprise a compound comprising a Si—O group, a saturated or unsaturated carbon chain and a polar group. It should be appreciated that other hydrophilic coatings can also be used.

(60) The hydrophilic coatings may be applied by any suitable method including, but not limited to, laminating (such as by hot rolling), brushing, spraying, spreading, coil coating, silk screening, powder coating, and screen printing. Multiple coats of the coating may also be applied as desired.

(61) In operation, and as described further hereinabove with respect to FIG. 1, the hybrid bipolar plate assembly 200 of the present disclosure is employed in the fuel cell stack 2. The fuel cell stack 2 may include a plurality of the MEAs 4, 6 arranged in a stacked configuration. In addition to a plurality of the bipolar plate assembly 200 and the MEAs 4, 6 described hereinabove, the fuel cell stack 2 may further have nonconductive gaskets 28, 30 in the form of a membrane seal 304, for example, as shown in FIGS. 13-14.

(62) In a particular example, shown in FIGS. 12-14, a seal combination 300 of the fuel cell stack 2 may include a plate seal 302. The plate seal 302 is adapted to hermetically seal or affix the formed cathode half plate 202 with the stamped metal anode half plate 204, for example, as shown in FIGS. 6-10. The plate seal 302 may be formed from one of an elastomer, a compressible graphite, and an epoxy material, as non-limiting examples, as also described hereinabove. Other suitable materials and methods for forming the plate seal 302 may also be employed within the scope of the disclosure.

(63) In particular, the plate seal 302 is configured to be disposed around the perimeter of the bipolar plate assembly 200, including bipolar plate headers that are defined by the header apertures header apertures 214, 215, 242, 243. However, as shown in FIG. 12, the plate seal 302 is not disposed adjacent an inboard portion of the header apertures 214, 215, 242, 243 associated with the coolant distribution. It should be appreciated that the absence of the plate seal 302 adjacent the inboard portion these header apertures 214, 215, 242, 243 permits for the distribution of the coolant to the interior coolant distribution area 228 of the bipolar plate assembly 200 in operation.

(64) The seal combination 300 of the fuel cell stack 2 further includes a membrane seal 304, for example, as shown in FIG. 13. The membrane seal 304 is disposed between the bipolar plate 200 and the MEA 4, 6. In particular, the membrane seal 304 is formed from an elastomer and disposed around a perimeter of the bipolar plate assembly 200 and each of the header apertures 214, 215, 242, 243. However, the membrane seal 304 is also configured to be disposed around the header apertures 214, 215, 242, 243 associated with the coolant distribution, as shown in FIG. 13. The membrane seal 304 thereby militates against a leakage of coolant into the active areas of the fuel cell stack 2.

(65) As shown in FIG. 14, it should be appreciated that the membrane seal 304 is generally overlaid with the plate seal 302 when each are present in the fuel cell stack 2, and that the seals 302, 304 together circumscribe one of the diffusion medium layers 36, 38. In addition the diffusion medium layers 36, 38 are of a predetermined size such that a perimeter edge of the one of the diffusion medium layers 36, 38 is laterally spaced apart from each of the membrane seal 304 and the plate seal 302. This advantageously allows spaced for the stamped channels to un-nest in that region between the perimeter edge of the diffusion medium layers 36, 38 and the seal combination 300.

(66) Advantageously, as shown in FIGS. 9-10 and 14, the plate seal 302 may be offset from the membrane seal 304 in an inboard direction in front of at least one of the anode and cathode header apertures 214, 215, 242, 243 by a distance G. The width of the plate seal 302 at this location may also be narrower than the width of a corresponding portion of the membrane seal 304 at this location. For example, the width of the plate seal 302 may be about one-half (½) the width of the membrane seal. This permits for a smaller overall construction of the fuel cell stack 2, while also permitting tunnel flow to at least one of the cathode and anode port holes in operation. Likewise, a width of the plate seal 302 may be narrower in front of the anode header to allow tunnel flow to access the anode ports.

(67) The cooperation of the hybrid bipolar plate assembly 200 with one of the MEAs 4, 6 is further illustrated in FIGS. 6-11, which are cross-sectional views of an exemplary fuel cell stack 2 taken various section lines shown in FIG. 5.

(68) In FIGS. 6-8, the stamped metal anode half plate 204 is illustrated having a flat perimeter in the sealing region. The stamped metal half plate 204 also has the branched feed channels and the straight channels through the active area with an elevation change from the feed region to active area channels to nest into the back of the formed cathode half plate 202. This in turn causes the lands on the coolant side of the stamped metal anode half plate 204 to abut and nest into the coolant side of the formed cathode half plate 202.

(69) In particular, in FIG. 6, a long section view of a transition between the feed region and the active area of the fuel cell stack 2 is shown. In FIG. 7, a cross section view of the fuel cell stack 2 in the active area is shown, where the formed cathode half plate 202 is the embodiment shown in FIG. 3 without the support ribs 232. In FIG. 8, a cross section view of the fuel cell stack 2 in the active area is shown, where the formed cathode half plate 202 is the embodiment shown in FIG. 4 with the support ribs 232.

(70) In FIGS. 9-11, section view of the cathode, anode, and coolant tunnels and associated features for these regions are shown. The tunnels are between the cathode and anode half plates 202, 204 for all three fluids. The cathode has port holes in the formed cathode half plate 202 after the membrane seal into the start of the cathode feed channels. The anode has port holes in the stamped anode half plate 204 after the membrane seal into the start of the anode feed channels. The coolant tunnels continue between the two half plates 202, 204 into the coolant feed region. The bead feature (i.e., the rib on the coolant side 236 of anode half plate 204) along the plate seal 302 can be observed in the cathode and anode tunnel sections shown in FIGS. 9 and 10. The coolant tunnel sections are shown in FIG. 11.

(71) It should be appreciated that the bipolar plate assembly 200 of the present disclosure, having the stamped metal anode half plate 204 nested into the formed cathode half plate 202, advantageously provides tunnel features in the formed cathode half plate 202. As disclosed hereinabove, sealing between the formed cathode half plate 202 and the stamped metal anode half plate 204 is provided by a) a compressed elastomeric plate seal 302, b) a compressed region of compliant graphite of the formed cathode half plate 202 itself, which forms the plate seal 302 and c) bonding of the metal of the stamped metal anode half plate 204 and the formed cathode half plate 202 with epoxy in the same region to form the plate seal 302.

(72) Advantageously, the bipolar plate assembly 200 of the present facilitates a reduced fuel cell thickness compared to fuel cells manufactured with conventional formed bipolar plates. Improved performance with fine pitch cathode channels are obtained, however, with the bipolar plate assembly 200 of the present disclosure. Minimized thermal mass with reduced coolant volume is also obtainable compared to conventional fully stamped metal plates. This can be further reduced with use of the coolant channel support ribs, particularly where compared to conventional nested metal half plates. The bipolar plate assembly 200 also may be manufactured at a reduced cost and mass with thinner metal for the stamped metal anode half plate being enabled by the coolant channel support ribs from the coolant side of the formed cathode half plate.

(73) Referring now to FIGS. 15-21, an unnested bipolar plate assembly 400 is shown. In FIGS. 15-21, like or related structure to that shown in FIGS. 1-14 is identified with the same number in a 400 series for purpose of clarity.

(74) The bipolar plate assembly 400 includes a formed cathode half plate 402, as shown in FIGS. 15-17 and 20-21, and a stamped metal anode half plate 404, for example as shown in FIGS. 18-21. In accordance with the teaching of the present disclosure, the formed cathode half plate 402 and the stamped metal anode half plate 404 are each formed from a different electrically conductive material, and according to different processes before being combined to form the bipolar plate assembly 400.

(75) In particular, the formed cathode half plate 402 is formed from a thin composite material. Desirably, and as described further below, the formed cathode half plate 402 can be one channel depth plus one web thickness than the previously described nested composite/stamped plate (which required two channel depth and one web thickness in the feed region). For example, the formed cathode half plate may have a web thickness of between about 0.15 mm and about 0.5 mm. It should be appreciated that although these dimensions have shown to be useful, different suitable dimensions chosen by a skilled artisan are also within the scope of this disclosure.

(76) As shown in FIGS. 15-17 and 20-21, the formed cathode half plate 402 has a reactant side 406 and a coolant side 408. The formed cathode half plate 402 further has a pair of feed regions 410, 411, and a pair of headers 412, 413, and a plurality of header apertures 414a, 414b, 414c, 415a, 415b, and 415c. It should be appreciated that descriptions of features from feed region 410, the header 412, and the header apertures 414 apply to the other feed regions 411, the other header 413, and the other header apertures 415 shown in FIGS. 15-17 and 20.

(77) With reference to FIG. 15, the reactant side 406 of the formed cathode half plate 402 has an active area 416 and a null area 455. The active area 416 has a plurality of cathode channels 418 formed therein. The plurality of cathode channels 418 define a plurality of lands 420 disposed therebetween.

(78) In some configurations and as shown in FIG. 15-16, each of the plurality of cathode channels 418 may have a first portion 418a, a second portion 418b, and a third portion 418c. Each of the first portions 418a is disposed adjacent to the header aperture 415a and oriented along a first axis 500. Each of the second portions 418b are in communication with the first portions 418a and oriented along a second axis 502. Each of the third portions 418c are in communication with the second portion 418b and oriented along a third axis 504.

(79) With a renewed reference to FIG. 16, the second axis 502 is oriented transverse to the first axis 500 and the third axis 504. In some examples, the second axis 502 is oriented orthogonal to the first axis 500 and the third axis 504. It should be appreciated that a skilled artisan may use different configurations of the plurality of cathode channels to achieve the same result within the scope of this disclosure.

(80) In yet further embodiments, each of the second portions 418b and the third portions 418c of the plurality of cathode channels 418 are bifurcated.

(81) Now referencing FIGS. 15-16, the null area 455 is planar and does not contain any of the plurality of cathode channels 418. The null area 455 may be disposed adjacent to the header apertures 415b, and 415c. Each of the header apertures 415b, and 415c have an innermost edge 468, and 469 disposed adjacent to the null area 455 of the reactant side 406. Each of the innermost edges 468, and 469 are oriented along a fourth axis 506. The null area 455 is bounded by the fourth axis 506 and the first axis 500, the second axis 502, and the third axis 504 of a first cathode channel 470 of the plurality of cathode channels 418.

(82) Referencing back to FIG. 15, the feed region 410 of the formed cathode half plate 402 is disposed between the active area 416 and the header 412. It should be appreciated that due to unnested nature of the bipolar plate assembly 400, the feed region 410 may be located in the active area 416. The feed region 410 has a plurality of feed channels 422 formed therein. The feed channels 422 also define a plurality of lands 424 disposed therebetween. It should be further appreciated that the plurality of feed channels 422 may also be used as the plurality of cathode channels 418, in embodiments in which the feed region 410 is in the active area 416.

(83) While still referencing FIG. 15, the feed region 410 of the formed cathode half plate 402 further has cathode port holes 426 formed therethrough, which are in turn in communication with a one of the headers 414a associated with the oxidant gases. The feed channels 422 are in communication with both the cathode channels 418 and the cathode port holes 426. The feed channels 422 are adapted to transport the oxidant gases between the active area 416 and the one of the header apertures 414a associated with the oxidant gases.

(84) Referring now to FIG. 16, the coolant side 408 of the formed cathode half plate 402 has a coolant distribution area 428 and a plurality of coolant tunnels 456. The coolant distribution area 428 is disposed opposite the active area 416 of the same formed cathode half plate 402 without the coolant tunnels 456. In particular, the coolant distribution area 428 is planar and does not contain the plurality of coolant tunnels 456. The plurality of coolant tunnels 456 are only disposed opposite to the null area 455 of the reactant side 406.

(85) In some embodiments, and as show in FIG. 17, the plurality of coolant tunnels 456 have a first portion 456a and a second portion 456b. The first portion is disposed adjacent to the header aperture 415b. The second portion 456b is disposed adjacent to the header aperture 415c.

(86) Advantageously, having the coolant tunnels 456 only disposed opposite to the null area 455 eliminates the need for excess space between the plurality of cathode channels 418 and the plurality of coolant tunnels 456. Therefore, the formed cathode half plate 402 may be thinner overall.

(87) In addition, the configuration of the plurality of cathode channels 418 and the plurality of coolant tunnels 456 militates against the plate thickness change associated with the nested plate and the need to remove the diffusion medium and provide MEA shim support in the feed regions 410, and 411.

(88) As shown in FIGS. 18-19, the stamped metal anode half plate 404 is configured to be affixed to the formed cathode half plate 402. The stamped metal anode half plate 404 has a fuel side 434 and a coolant side 436. The stamped metal anode half plate 404 further has a pair of feed regions 438, 439 and a pair of headers 440, 441 with a pair of header apertures 442, 443.

(89) It should be appreciated that descriptions of features from the feed regions 438, a single one of the headers 440, and a single set of the header apertures 442 on one side of the stamped metal anode half plate 404 apply to the other feed regions 439, the other header 441, and the other header apertures 443.

(90) Being formed by a stamping operation on a thin metal sheet or foil, it should be understood that the stamped features (e.g. the channels and lands) on the fuel side 434 of the stamped metal anode half plate 403 will have corresponding but opposite features (e.g., lands and channels respectively) with otherwise the same or similar dimensions on the coolant side 436 of the stamped metal anode half plate 404.

(91) With reference to FIG. 17, the fuel side 434 of the stamped anode metal anode half plate 404 has an active area 444. The active area 444 has a plurality of anode channels 446 formed therein. The anode channels 446 are adapted to distribute the fuel gases, such as hydrogen, across the active area 444. It should be understood that the anode channels 446 also define a plurality of lands 448 disposed therebetween.

(92) The feed region 438 of the stamped metal anode half plate 404 is disposed between the active area 444 and the header 440. The feed region 438 has a plurality of feed channels 450 formed therein. The feed channels 450 also define a plurality of lands 452 disposed therebetween.

(93) While still referring to FIG. 17, the feed regions 438 further have anode port holes 454 formed therethrough, which are in communication with one of the header apertures 442 associated with the fuel gases. The feed channels 450 are in communication with both the anode channels 446 and the anode port holes 454. The feed channels 450 are adapted to transport the fuel gases between the active area 444 and the one of the header apertures 442 associated with the fuel gases.

(94) As discussed hereinabove and as shown in FIG. 18, the coolant side 436 of the stamped metal anode half plate 404 has a plurality of lands 458 corresponding with the anode channels 446. In turn, the lands 458 define a plurality of coolant channels 460 on the coolant side 436 of the stamped metal anode half plate 404. The plurality of lands 458 abut the coolant side 408 of the formed cathode half plate 402 upon assembly.

(95) With renewed reference to FIG. 17, the stamped metal anode half plate 404 has a flat or planar perimeter flange 462. The planar flange 462 defines at least part of a sealing region of the stamped metal anode half plate 404 that is configured to abut and seal with the seal combination of the fuel cell stack 2 including a plate seal and a membrane.

(96) It should be understood that the plurality of anode channels 446 formed in the stamped metal anode half plate 404 includes a plurality of branched feed channels 464 in the feed region 438 of the stamped metal anode half plate 404. The anode channels 446 may also include a plurality of linear anode channels 466 in the active area 444. The linear anode channels 466 may be oriented along the active area 444 of the stamped metal anode half plate 404.

(97) As mentioned hereinabove, the formed cathode half plate 402 militates against the plate thickness change associated with the nested plate and the need to remove the diffusion medium and provide MEA shim support in the feed regions.

(98) While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the disclosure, which is further described in the following appended claims.