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Metal platelet fuel cells production and operation methods
| Details |
Inventors: Spear, Reginald G.; Mueggenburg, H. Harry; Hodge, Rex;
Assignee: H Power Corp. (Belleville, NJ)
Primary Examiner: Skapars; Anthonty
Assistant Examiner:
Attorney, Agent or Firm: Oblon, Spivak, McClelland, Maier & Neustadt P.C.
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. |
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DETAILED DESCRIPTION We claim: 1.
A method for producing fuel cell separator assemblies comprising the steps of: a) forming in thin sheet stock a plurality of different individual platelets with coordinate features selected from micro-channels, vias and manifolds, said features together forming at least one active area field for oxidant or fuel consumption in contact with a membrane electrode assembly; b) stacking said platelets with said individual platelet features in precise alignment with corresponding features of a matingly adjacent platelet to provide continuous circulation paths for said oxidant or fuel; and c) bonding said aligned platelets to form a monolithic separator having internal microchannels and access manifolds thereto.
2.
A method as in claim 1 wherein said sheet stock is metal and said forming step includes the step of etch forming said features by a combination of depth etching and through etching.
3.
A method as in claim 2 wherein said through etching comprises depth etching selected areas from both sides of said sheet stock to depths greater than 50% of the sheet thickness.
4.
A method as in claim 3 wherein said metal is selected from Ti, Al, Cu, W, Niobium, stainless steel, and alloys, laminates, platings and composites thereof.
5.
A method as in claim 2 wherein said forming step includes resist coating said sheet metal platelets to define features thereon.
6.
A method as in claim 2 which includes the step of passivating said separator after bonding.
7.
A method as in claim 6 wherein said bonding includes diffusion bonding under heat and pressure, said metal is Ti, and said passivating includes exposure to Nitrogen at an elevated temperature.
8.
A method as in claim 5 wherein said resist coating is applied by at least one of direct transfer or photolithographic processing.
9.
A method of designing fuel cell separator assemblies comprising the steps of: a) developing a plurality of individual platelet drawings as plan views of platelet faces having features selected from at least one of metering orifices, channels, vias and manifolds to provide integrated fluid management of fuel, oxidant, humidification and temperature; and b) generating photo-tooling masks artwork for said platelets faces from said platelet drawings so that said features are coordinated from platelet to platelet to form a functional separator upon properly aligned stacking of said platelets in proper sequence and bonding them together
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Fuel Cells 
