Fuel cell microseal and a method of manufacture thereof

Abstract

A microseal for a metal bead seal joint includes a substantially horizontal surface, first and second substantially vertical surfaces disposed on opposite ends of the substantially horizontal surface, and a contoured surface operatively configured to adhere to a portion of a metal bead. The contoured surface may be disposed opposite the substantially horizontal surface and may be integral to the first and second substantially vertical surfaces. The substantially horizontal surface may be operatively configured to substantially maintain its horizontal surface orientation in both a compression state and a non-compression state.

What is claimed is: 
     
         1 . A microseal for a metal bead seal joint, the microseal comprising:
 a substantially horizontal surface;   a first substantially vertical surface disposed at a first end of the substantially horizontal surface and a second substantially vertical surface disposed at a second end of the substantially horizontal surface; and   a contoured surface disposed opposite the substantially horizontal surface, the contoured surface being integral to the first and second substantially vertical surfaces and being operatively configured to adhere to a portion of a metal bead.   
     
     
         2 . The microseal for a metal bead seal joint as defined in  claim 1  wherein the substantially horizontal surface is operatively configured to maintain a substantially flat surface orientation when subjected to a vertical load. 
     
     
         3 . The microseal for a metal bead seal joint as defined in  claim 1  wherein the contoured surface and the substantially horizontal surface define a microseal thickness. 
     
     
         4 . The microseal for a metal bead seal joint as defined in  claim 2  wherein an entire surface area of the contoured surface is operatively configured to flex together with a metal bead. 
     
     
         5 . The microseal for a metal bead seal joint as defined in  claim 3  wherein the microseal thickness is greater at an edge region than the microseal thickness at a center region, the edge region being proximate to each of the first and the second substantially vertical surfaces and the center region being disposed between the edge region for the first substantially vertical wall and the edge region for the second substantially vertical wall. 
     
     
         6 . The microseal for a metal bead seal joint as defined in  claim 3  wherein the microseal thickness varies along a width of the substantially horizontal surface. 
     
     
         7 . A metal bead seal joint for a fuel cell plate, the metal bead seal joint comprising:
 a first metal bead having a first microseal; and   a second metal bead having a second microseal compressed against at least a portion of the first microseal and the first metal bead.   
     
     
         8 . The metal bead seal joint for a fuel cell plate as defined in  claim 7  wherein each of the first and second microseals further comprise
 a substantially horizontal surface; 
 a first substantially vertical surface disposed at a first end of the substantially horizontal surface and a second substantially vertical surface disposed at a second end of the substantially horizontal surface; and 
 a contoured surface disposed opposite the substantially horizontal surface, the contoured surface being integral to the first and second substantially vertical surfaces. 
 
     
     
         9 . The metal bead seal joint for a fuel cell plate as defined in  claim 8  wherein each of the first substantially horizontal surfaces are operatively configured to maintain a substantially flat orientation in a compression state as well as a non-compression state. 
     
     
         10 . The metal bead seal joint for a fuel cell plate as defined in  claim 9  wherein each of the first and second substantially vertical surfaces and the contoured surface are operatively configured to have a surface orientation which changes between the compression and non-compression states. 
     
     
         11 . The metal bead seal joint for a fuel cell plate as defined in  claim 8  wherein each of the contoured surface and the substantially horizontal surface for each of the first and second microseals define a microseal thickness. 
     
     
         12 . The metal bead seal joint for a fuel cell plate as defined in  claim 10  wherein each contoured surface is operatively configured to adhere to at least a portion of one of the first and second metal beads, and each contoured surface is operatively configured to flex as the first and second metal beads flex under compression. 
     
     
         13 . The metal bead seal joint for a fuel cell plate as defined in  claim 11  wherein each microseal is operatively configured to have a microseal thickness which varies along a width of the microseal prior to compression. 
     
     
         14 . A method for manufacturing a microseal, the method comprising the steps of:
 applying a first application of a microseal material to a metal bead wherein the microseal material is in a viscous state;   forming a substantially horizontal surface in the microseal material; and   curing the microseal material.   
     
     
         15 . The method for manufacturing a microseal as defined in  claim 14 , further comprising the steps of:
 partially curing the first application of the microseal material;   applying a compression load across a width of the microseal material during the curing process;   removing the compression load; and   fully curing the first application of the microseal material thereby forming a microseal.   
     
     
         16 . The method for manufacturing a microseal as defined in  claim 14 , further comprising the step of:
 applying a second application of the microseal material to the metal bead adjacent to the first application of the microseal material wherein the microseal material from the first and second applications is in a viscous state.   
     
     
         17 . The method for manufacturing a microseal as defined in  claim 16  wherein the first and second applications of microseal material are operatively configured to flow toward one another thereby forming the substantially horizontal surface.