Plastic frame assembly and bipolar plate with through-flow fuel feed

Abstract

The present disclosure provides methods for forming flow plate and frame assemblies that comprise an anode frame member, a flow plate, and cathode frame member with the flow plate retained between the anode and cathode frame members. The present disclosure also provides for flow plate and frame assemblies, fuel cell stacks containing a plurality of the flow plate and frame assemblies, and fuel cell systems containing the fuel cell stacks. A fluidly connected anode fluid pathway can be provided from an anode fluid inlet, through conduits int eh anode frame member, onto an anode surface of the flow plate, and into anode flow channels.

1 . A flow plate and frame assembly comprising:
 an anode frame member comprising an outer surface, an inner surface, and an anode frame opening;
 a cathode frame member comprising an outer surface, an inner surface, and a cathode frame opening; 
 a flow plate comprising an anode surface and a cathode surface; 
 wherein the cathode frame member and anode frame member engage with each other along their respective inner surfaces via a gasket, and retain and surround the flow plate in between the inner surfaces with a portion of the anode surface in contact with the anode frame member inner surface and a portion of the cathode surface in contact with the cathode frame member inner surface; and, 
 wherein the flow plate comprises an integral coolant flow path cooperating with the flow plate, and wherein the flow plate further comprises an open coolant fluid delivery edge configured to provide for coolant fluid flow out of the integral coolant flow path volume and onto the cathode surface. 
   
     
     
         2 . The flow plate and frame assembly of  claim 1 , wherein the anode surface of the flow plate has a plurality of anode flow channels and the cathode surface of the flow plate has a plurality of cathode flow channels. 
     
     
         3 . The flow plate and frame assembly of  claim 2 , wherein:
 the anode frame member comprises one or more anode fluid inlets, one or more coolant fluid inlets, one or more cathode fluid inlets, one or more anode exhaust outlets, and one or more cathode exhaust outlets;
 the cathode frame member comprises one or more anode fluid inlets, one or more coolant fluid inlets, one or more cathode fluid inlets, one or more anode exhaust outlets, and one or more cathode exhaust outlets; and, 
 each anode fluid inlet, coolant fluid inlet, cathode fluid inlet, anode exhaust outlet, and cathode exhaust outlet in the anode frame member is aligned with a corresponding anode fluid inlet, coolant fluid inlet, cathode fluid inlet, anode exhaust outlet, and cathode exhaust outlet in the cathode frame member. 
   
     
     
         4 . The flow plate and frame assembly of  claim 3 , wherein:
 the anode frame member, cathode frame member, and flow plate are configured to provide a fluidly connected anode fluid pathway;
 the anode fluid pathway comprises one or more anode fluid inlets, a portion of the outer surface defined by an anode fluid flow region, one or more anode fluid conduits pass through the anode frame member and connect outer surface to inner surface, a volume between the anode frame member inner surface and flow plate anode surface, and one or more anode flow channels; and, 
 the anode fluid flow region is defined by a stepped down edge and fluid distributing protrusions. 
   
     
     
         5 . The flow plate and frame assembly of  claim 4 , wherein:
 the anode frame member, cathode frame member, and flow plate are configured to provide a fluidly connected cathode fluid pathway;   the cathode fluid pathway comprises one or more cathode fluid inlets, a first portion of the inner surface of the cathode frame member, a volume between inner surface and cathode surface of the flow plate, and one or more cathode flow channels; and   the first portion is disposed between the cathode fluid inlets and the cathode frame member opening.   
     
     
         6 . The flow plate and frame assembly of  claim 5 , wherein:
 the anode frame member, cathode frame member, and flow plate are configured to provide a fluidly connected coolant fluid pathway;   the coolant fluid pathway comprises one or more coolant fluid inlets, a coolant fluid flow region, a portion of the cathode plate inner surface, a coolant manifold hole, a coolant flowpath volume entry conduit formed in portion, the integral coolant flowpath volume, open coolant fluid delivery edge, and one or more cathode flow channels; and,   the coolant fluid flow region is defined by a stepped down edge.   
     
     
         7 . The flow plate and frame assembly of any one of  claims 1 , wherein the anode frame member, the cathode frame member, or both comprise two distinct materials. 
     
     
         8 . The flow plate and frame assembly of  claim 7 , wherein the two distinct materials comprise a rigid frame element made from a hard plastic material and select regions of a compressible sealing material. 
     
     
         9 . The flow plate and frame assembly of  claim 8  further comprising a membrane electrode assembly. 
     
     
         10 . A flow plate and frame assembly comprising:
 an anode frame member comprising an outer surface, an inner surface, and an anode frame opening;   a cathode frame member comprising an outer surface, an inner surface, and a cathode frame opening;   a flow plate comprising an anode surface and a cathode surface;   wherein the cathode frame member and anode frame member engage with each other along their respective inner surfaces, and retain and surround an entire perimeter of the flow plate in between the inner surfaces with a portion of the anode surface in contact with the anode frame member inner surface;   a portion of the cathode surface in contact with the cathode frame member inner surface; and,   one or more gaskets are interposed between the respective inner surface.   
     
     
         11 . The flow plate and frame assembly of  claim 10 , wherein the anode surface comprises a plurality of anode flow channels and the cathode surface comprises a plurality of cathode flow channels. 
     
     
         12 . The flow plate and frame assembly of  claim 11 , wherein:
 the flow plate comprises an integral coolant flowpath volume formed by a fluid flow plate configured over a portion of the cathode surface of the flow plate; and,   the flow plate further comprises an open coolant fluid delivery edge configured to provide for coolant fluid flow out of the integral coolant flow path volume and onto the cathode surface.   
     
     
         13 . The flow plate and frame assembly of  claim 12 , wherein:
 the anode frame member, cathode frame member, and flow plate are configured to provide a fluidly connected anode fluid pathway;   the anode fluid pathway comprises one or more anode fluid inlets, a portion of the outer surface defined by an anode fluid flow region, one or more anode fluid conduits pass through the anode frame member and connect outer surface to inner surface, a volume between the anode frame member inner surface and flow plate anode surface, and one or more anode flow channels; and,   the anode fluid flow region is defined by a stepped down edge and fluid distributing protrusions.   
     
     
         14 . The flow plate and frame assembly of  claim 12 , wherein:
 the anode frame member, cathode frame member, and flow plate are configured to provide a fluidly connected coolant fluid pathway;   the coolant fluid pathway comprises one or more coolant fluid inlets, a coolant fluid flow region, a portion of the cathode plate inner surface, a coolant manifold hole, a coolant flow path volume entry conduit formed in portion, the integral coolant flowpath volume, open coolant fluid delivery edge, and one or more cathode flow channels; and,   the coolant fluid flow region is defined by a stepped down edge.   
     
     
         15 . The flow plate and frame assembly of  claim 10 , wherein the anode frame member, the cathode frame member, or both comprise two distinct materials. 
     
     
         16 . A method of assembling a flow plate and frame assembly comprising:
 forming an anode frame member having an outer surface, an inner surface, and an anode frame opening;   forming a cathode frame member having an outer surface, an inner surface, and a cathode frame opening;   forming a flow plate having an anode surface and a cathode surface;   disposing the flow plate onto the cathode frame member with the cathode surface of the flow plate in contact with the inner surface of the cathode frame member;   disposing the anode frame member onto the flow plate and cathode frame member with the inner surface of the anode frame member in contact with the inner surface of the cathode frame member and the anode surface of the flow plate, wherein the formed flow plate comprises an integral coolant flowpath volume formed by one of a gasket and a welded edge of the flow plate, with a portion of the flow plate over the cathode surface of the flow plate; and,   wherein the formed flow plate further comprises an open coolant fluid delivery edge configured to provide for coolant fluid flow out of the integral coolant flowpath volume and onto the cathode surface.   
     
     
         17 . The method of assembling a flow plate and frame assembly of  claim 16 , wherein the forming of the cathode frame member, the anode frame member, or both includes at least one gasket. 
     
     
         18 . The method of  claim 17 , the method further comprising a step of retaining the anode frame member and cathode frame member together.