H Power Corporation

Reginald G Spear, Jr

Rex Hodge

H Harry Mueggenburg

William A Hayes

Jerrold E Franklin

David E Janke

H Harry Mueggenberg

Fuel cell platelet separators having coordinate features

Improved fuel cell stacks constructed from a plurality of cells, each comprising a series of interrelated mono and bipolar collector plates (BSPs), which in turn are built up by lamination of a core of related non-conductiveplastic orceramic platelets sandwiched between conductive microscreen platelets of metal or conductive ceramic or plastic, with an electrode membrane (EMA) between adjacent BSPs. The platelets, both metal and plastic of the composite BSPs, are produced from sheet material with through and depth features formed by etching, pressing, stamping, casting, embossing and the like. Adjacent plates, each with correspondingly relieved features form serpentine channels within the resultant monolithic platelet/cell stack for integrated fluid and thermal management. The plastic platelets are particularly useful for PEM fuel cells employing H.sub.2 and Air/O.sub.2 as fuel. The platelets are easily made by printing (embossing) processes, and dies made by photolithographic etching for rapid redesign. Each BSP can be individually tailored to each type of membrane, fuel, and intra-cell location within the stack. As materials are cheap and easy to manufacture and assemble, lightweight fuel cells of very high power density are realizable. Industrial applicability includes both stationary and vehicular power supplies, in both micro and macro sizes.

Plastic platelet fuel cells employing integrated fluid management

Fuel cell stacks comprising stacked separator/membrane electrode assembly cells in which the separators comprise a series of stacked thin sheet platelets having individually configured serpentine micro-channel reactant gas humidification, active area and cooling fields therein. The individual platelets are stacked with coordinate features precisely aligned in contact with adjacent platelets and bonded to form a monolithic separator. Post bonding processing includes passivation, such as nitriding. Preferred platelet material is 4-25 mil Ti in which the features, serpentine channels, tabs, lands, vias, manifolds and holes, are formed by chemical or laser etching, cutting, pressing or embossing, with combinations of depth and through-etching being preferred. The platelet manufacturing process is continuous and fast. By employing CAD based platelet design and photolithography, rapid change in feature design to accommodate a wide range of thermal management and humidification techniques. 100 cell H.sub.2 --O.sub.2 /Air PEM fuel cell stacks of this IFMT platelet design will exhibit outputs on the order of 0.75 kW/kg, some 3-6 times greater than current graphite plate PEM stacks.

Fuel cells employing integrated fluid management platelet technology

Fuel cell stacks comprising stacked separator/membrane electrode assembly cells in which the separators comprise a series of stacked thin sheet platelets having individually configured serpentine micro-channel reactant gas humidification, active area and cooling fields therein. The individual platelets are stacked with coordinate features precisely aligned in contact with adjacent platelets and bonded to form a monolithic separator. Post bonding processing includes passivation, such as nitriding. Preferred platelet material is 4-25 mil Ti in which the features, serpentine channels, tabs, lands, vias, manifolds and holes, are formed by chemical or laser etching, cutting, pressing or embossing, with combinations of depth and through-etching being preferred. The platelet manufacturing process is continuous and fast. By employing CAD based platelet design and photolithography, rapid change in feature design to accommodate a wide range of thermal management and humidification techniques. 100 cell H.sub.2 -O.sub.2 /Air PEM fuel cell stacks of this IFMT platelet design will exhibit outputs on the order of 0.75 kW/kg, some 3-6 times greater than current graphite plate PEM stacks.

Metal platelet fuel cells production and operation methods

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Sacramento, CA, United States of America

Reginald G Spear, Jr