Bipolar plate alignment system and method of using same

Abstract

A bipolar plate alignment system includes a bipolar plate, a gasket seal, and an adhesive film. The bipolar plate is formed to include a sealing groove and a plate alignment feature extending outwardly from a perimeter of the bipolar plate. The gasket seal is sized for placement within the seal groove and is formed to include a seal alignment feature extending outwardly from a perimeter of the gasket seal.

Description

Cross - Reference to Related Applications

[0001] Under 35 U.S.C. § 119(e) and any other applicable laws or regulations, this non - provisional application claims the benefit and priority of U.S. Provisional Patent Application Serial No. 63 / 610,946, filed on December 15, 2023, the entire content of which is hereby incorporated by reference in its entirety. Technical Field

[0002] This disclosure relates to a bipolar plate alignment system and a method of aligning a gasket seal with a bipolar plate using the bipolar plate alignment system. Summary of the Invention

[0003] To meet these and other needs, embodiments of the present disclosure are included herein.

[0004] In one aspect described herein, a bipolar plate alignment system includes a bipolar plate, a gasket seal, and an adhesive film. The bipolar plate is formed to include a seal groove defined in a first side of the bipolar plate and a plurality of plate alignment features extending outward from a perimeter of the bipolar plate. Each of the plurality of plate alignment features is formed to include a hole extending therethrough. The gasket seal is sized to be placed within the seal groove of the bipolar plate to seal reactants within an active area of the bipolar plate. The gasket seal is formed to include a plurality of seal alignment features extending outward from a perimeter of the gasket seal. Each of the plurality of seal alignment features is formed to include a hole extending therethrough. The adhesive film is coupled to the gasket seal and the seal groove. The adhesive film is formed to include a plurality of film alignment features extending outward from a perimeter of the adhesive film. Each of the plurality of film alignment features is formed to include a hole extending therethrough. The holes formed in each of the plurality of plate alignment features are aligned with the corresponding holes formed in each of the plurality of seal alignment features and with the corresponding holes formed in each of the plurality of film alignment features such that the gasket seal is correctly aligned within the seal groove of the bipolar plate.

[0005] In some embodiments, the adhesive film can be adhered to a bottom side of the gasket seal to position the adhesive film between the seal groove of the bipolar plate and the gasket seal. In some embodiments, each of the plurality of film alignment features can be aligned with a corresponding one of the plurality of seal alignment features and a corresponding one of the plurality of plate alignment features. In some embodiments, the perimeter of the bipolar plate can be defined by a first side, a second side opposite the first side, a third side extending between and connecting the first side and the second side, and a fourth side opposite the third side and extending between and connecting the first side and the second side.

[0006] In some embodiments, the perimeter of the gasket seal can be defined by a first side of the perimeter of the gasket seal, a second side opposite the first side of the perimeter of the gasket seal, a third side extending between and interconnecting the first side of the perimeter of the gasket seal and the second side of the perimeter of the gasket seal, and a fourth side opposite the third side of the perimeter of the gasket seal and extending between and interconnecting the first side of the perimeter of the gasket seal and the second side of the perimeter of the gasket seal.

[0007] In some embodiments, the plurality of plate alignment features can include a first plate alignment feature extending outward from a first side of the perimeter of the bipolar plate, a second plate alignment feature extending outward from a second side of the perimeter of the bipolar plate, a third plate alignment feature extending outward from a third side of the perimeter of the bipolar plate, and a fourth plate alignment feature extending outward from a fourth side of the perimeter of the bipolar plate. In some embodiments, the plurality of seal alignment features can include a first seal alignment feature extending outward from a first side of the perimeter of the gasket seal, a second seal alignment feature extending outward from a second side of the perimeter of the gasket seal, a third seal alignment feature extending outward from a third side of the perimeter of the gasket seal, and a fourth seal alignment feature extending outward from a fourth side of the perimeter of the gasket seal.

[0008] In some embodiments, the perimeter of the adhesive film can be defined by a first side of the perimeter of the adhesive film, a second side opposite the first side of the perimeter of the adhesive film, a third side extending between and interconnecting the first side of the perimeter of the adhesive film and the second side of the perimeter of the adhesive film, and a fourth side opposite the third side of the perimeter of the adhesive film and extending between and interconnecting the first side of the perimeter of the adhesive film and the second side of the perimeter of the adhesive film.

[0009] In some embodiments, the plurality of film alignment features can include a first film alignment feature extending outward from a first side of the perimeter of the adhesive film, a second film alignment feature extending outward from a second side of the perimeter of the adhesive film, a third film alignment feature extending outward from a third side of the perimeter of the adhesive film, and a fourth film alignment feature extending outward from a fourth side of the perimeter of the adhesive film.

[0010] In some embodiments, the first plate alignment feature can be aligned with the first seal alignment feature and the first film alignment feature, the second plate alignment feature can be aligned with the second seal alignment feature and the second film alignment feature, the third plate alignment feature can be aligned with the third seal alignment feature and the third film alignment feature, and the fourth plate alignment feature can be aligned with the fourth seal alignment feature and the fourth film alignment feature.

[0011] In some embodiments, the bipolar plate alignment system may further include a plurality of alignment pins. In some embodiments, each alignment pin of the plurality of alignment pins may be configured to extend through a corresponding hole formed in one of the plurality of plate alignment features, a corresponding hole formed in one of the plurality of seal alignment features, and a corresponding hole formed in one of the plurality of membrane alignment features.

[0012] In another aspect described herein, the bipolar plate alignment system includes a bipolar plate, a gasket seal, and a plurality of alignment pins. The bipolar plate is formed to include a seal groove defined in a first side of the bipolar plate and a plurality of plate alignment features extending outward from a perimeter of the bipolar plate. Each of the plurality of plate alignment features is formed to include a hole extending therethrough. The gasket seal is sized to be placed within the seal groove of the bipolar plate to seal reactants within an active area of the bipolar plate. The gasket seal is formed to include a plurality of seal alignment features extending outward from a perimeter of the gasket seal. Each of the plurality of seal alignment features is formed to include a hole extending therethrough. Each of the plurality of alignment pins is configured to extend through a corresponding hole formed in one of the plurality of plate alignment features and a corresponding hole formed in one of the plurality of seal alignment features. The gasket seal is disposed on the bipolar plate such that a hole formed in each of the plurality of plate alignment features is aligned with a corresponding hole formed in each of the plurality of seal alignment features such that each of the plurality of alignment pins extends through the corresponding holes of the plurality of plate alignment features and the corresponding holes of the plurality of seal alignment features to align the gasket seal within the seal groove.

[0013] In some embodiments, the bipolar plate alignment system may further include an adhesive film attached to a bottom side of the gasket seal. In some embodiments, the adhesive film may be formed to include a plurality of membrane alignment features extending outward from a perimeter of the adhesive film. In some embodiments, each of the plurality of membrane alignment features may be formed to include a hole extending therethrough.

[0014] In some embodiments, a hole formed in each of the plurality of membrane alignment features may be aligned with a corresponding hole formed in each of the plurality of seal alignment features and a corresponding hole formed in each of the plurality of plate alignment features. In some embodiments, each of the plurality of membrane alignment features may be aligned with a corresponding one of the plurality of seal alignment features and a corresponding one of the plurality of plate alignment features.

[0015] In some embodiments, the perimeter of the bipolar plate may be defined by a first side, a second side opposite the first side, a third side extending between and connecting the first and second sides, and a fourth side opposite the third side and extending between and connecting the first and second sides. In some embodiments, the perimeter of the gasket seal may be defined by a first side of the perimeter of the gasket seal, a second side opposite the first side of the perimeter of the gasket seal, a third side extending between and connecting the first and second sides of the perimeter of the gasket seal, and a fourth side opposite the third side of the perimeter of the gasket seal and extending between and connecting the first and second sides of the perimeter of the gasket seal.

[0016] In some embodiments, the plurality of plate alignment features may include a first plate alignment feature extending outward from the first side of the perimeter of the bipolar plate, a second plate alignment feature extending outward from the second side of the perimeter of the bipolar plate, a third plate alignment feature extending outward from the third side of the perimeter of the bipolar plate, and a fourth plate alignment feature extending outward from the fourth side of the perimeter of the bipolar plate. In some embodiments, the plurality of plate alignment features may further include a fifth plate alignment feature extending outward from the first side of the perimeter of the bipolar plate and spaced apart from the first plate alignment feature and a sixth plate alignment feature extending outward from the second side of the perimeter of the bipolar plate and spaced apart from the second plate alignment feature.

[0017] In some embodiments, the plurality of seal alignment features may include a first seal alignment feature extending outward from the first side of the perimeter of the gasket seal, a second seal alignment feature extending outward from the second side of the perimeter of the gasket seal, a third seal alignment feature extending outward from the third side of the perimeter of the gasket seal, and a fourth seal alignment feature extending outward from the fourth side of the perimeter of the gasket seal. In some embodiments, the first plate alignment feature may be aligned with the first seal alignment feature, the second plate alignment feature may be aligned with the second seal alignment feature, the third plate alignment feature may be aligned with the third seal alignment feature, and the fourth plate alignment feature may be aligned with the fourth seal alignment feature. Description of the Drawings

[0018] Figure 1A is a schematic diagram of an exemplary fuel cell system that includes an air delivery system, a hydrogen delivery system, and a fuel cell module that includes a plurality of fuel cells in a stack;

[0019] Figure 1B is a cross-sectional view of an exemplary fuel cell system that includes an air delivery system, a plurality of hydrogen delivery systems, and a plurality of fuel cell modules, each module including a plurality of fuel cell stacks;

[0020] Figure 1C is Figure 1APerspective view of an exemplary repeating unit of a fuel cell stack of a fuel cell system;

[0021] Figure 1D is Figure 1C Cross-sectional view of an exemplary repeating unit of a fuel cell stack;

[0022] Figure 2A Perspective view of an electrolytic cell stack according to the present disclosure;

[0023] Figure 2B is configured to use Figure 2A Schematic diagram of an electrolysis system of an electrolytic cell stack;

[0024] Figure 2C is Figure 2B Schematic diagram of an additional part of the electrolysis system;

[0025] Figure 3 Perspective view of a bipolar plate alignment system including a bipolar plate, a gasket seal, and an adhesive film;

[0026] Figure 4 is Figure 3 Perspective view of the bipolar plate of the bipolar plate alignment system, showing that the bipolar plate is formed to include a sealing groove for accommodating the gasket seal and the adhesive film therein and a plurality of plate alignment features extending outward from the periphery of the bipolar plate, and each of the plurality of plate alignment features is formed to include a hole extending therethrough;

[0027] Figure 5 is Figure 3 Perspective view of the gasket seal of the bipolar plate alignment system, the gasket seal being formed to include a plurality of seal alignment features extending outward from the periphery of the gasket seal, and each of the plurality of seal alignment features is formed to include a hole extending therethrough;

[0028] Figure 6 is Figure 3 Perspective view of the adhesive film of the bipolar plate alignment system, the adhesive film being formed to include a plurality of film alignment features extending outward from the periphery of the adhesive film, and each of the plurality of film alignment features is formed to include a hole extending therethrough;

[0029] Figure 7 Perspective view of the adhesive film attached to the bottom side of the gasket seal; and

[0030] Figure 8 Exploded view of the bipolar plate alignment system, showing that the bipolar plate alignment system further includes a plurality of alignment pins extending through the holes of each of the plurality of plate alignment features, and the gasket seal and the adhesive film are aligned with the bipolar plate through the plurality of plate alignment pins. Detailed Description

[0031] As is well known, fuel cell systems can efficiently utilize fuel to generate direct current electrical energy, thereby powering mobile applications such as vehicles, trains, buses, and trucks. Electrolyzer systems are known for efficiently using water and electrical energy to produce hydrogen and oxygen. Typical fuel cell systems and electrolyzer systems include bipolar plates that evenly distribute reactants to the active areas of the cells of the fuel cell system or electrolyzer system. Typical fuel cell systems and electrolyzer systems also include gasket seals that seal the reactants within the active area. It may be advantageous to ensure that the gasket seal is aligned with the bipolar plate so that proper sealing occurs.

[0032] The present disclosure relates to a bipolar plate alignment system for gasket seals and bipolar plates and methods of using the same. For example, the gasket seal and the bipolar plate are each formed with alignment features that may assist in the proper alignment of the gasket seal relative to the bipolar plate.

[0033] As Figure 1A shown, a fuel cell system 10 typically includes one or more fuel cell stacks 12 or fuel cell modules 14 that are connected to a balance of plant (BOP) 16 that includes various components to support electrochemical conversion, power generation, and / or power distribution, and thereby help meet modern industrial and commercial needs in an environmentally friendly manner. As Figure 1B and Figure 1C shown, the fuel cell system 10 may include a fuel cell stack 12 that includes a plurality of single cell fuel cells 20. Each fuel cell stack 12 may accommodate a plurality of fuel cells 20 assembled in series and / or in parallel. The fuel cell system 10 may include one or more fuel cell modules 14, as Figure 1A and Figure 1B shown. In some embodiments, the fuel cell system 10 may include one or more fuel cell stacks 12.

[0034] Each fuel cell module 14 may include a plurality of fuel cell stacks 12 and / or a plurality of fuel cells 20. The fuel cell module 14 may also include an appropriate combination of associated structural elements, mechanical systems, hardware, firmware, and / or software for supporting the function and operation of the fuel cell module 14. Such items include, but are not limited to, piping, sensors, regulators, current collectors, seals, and insulators.

[0035] The fuel cells 20 in the fuel cell stack 12 can be stacked together to multiply and increase the voltage output of a single fuel cell stack 12. The number of fuel cell stacks 12 in the fuel cell system 10 can vary depending on the amount of power required to operate the fuel cell system 10 and meet the electrical demands of any load. The number of fuel cells 20 in the fuel cell stack 12 can vary depending on the amount of power required to operate the fuel cell system 10, including the fuel cell stack 12.

[0036] The number of fuel cells 20 in each fuel cell stack 12 or fuel cell system 10 can be any number. For example, the number of fuel cells 20 in each fuel cell stack 12 can range from about 100 fuel cells to about 1000 fuel cells, including any specific number or range of numbers of the fuel cells 20 contained therein (e.g., about 200 to about 800). In an embodiment, the fuel cell system 10 can include from about 20 to about 1000 fuel cell stacks 12, including any specific number or range of numbers of the fuel cell stacks 12 contained therein (e.g., about 200 to about 800). The fuel cells 20 in the fuel cell stack 12 within the fuel cell module 14 can be oriented in any direction to optimize the operating efficiency and function of the fuel cell system 10.

[0037] The fuel cells 20 in the fuel cell stack 12 can be any type of fuel cell 20. The fuel cell 20 can be a polymer electrolyte membrane or proton exchange membrane (PEM) fuel cell, an anion exchange membrane fuel cell (AEMFC), an alkaline fuel cell (AFC), a molten carbonate fuel cell (MCFC), a direct methanol fuel cell (DMFC), a regenerative fuel cell (RFC), a phosphoric acid fuel cell (PAFC), or a solid oxide fuel cell (SOFC). In an exemplary embodiment, the fuel cell 20 can be a polymer electrolyte membrane or proton exchange membrane (PEM) fuel cell or a solid oxide fuel cell (SOFC).

[0038] In Figure 1C the illustrated embodiment, the fuel cell stack 12 includes a plurality of proton exchange membrane (PEM) fuel cells 20. Each fuel cell 20 includes a single membrane electrode assembly (MEA) 22 and gas diffusion layers (GDLs) 24, 26 on one or both sides of the membrane electrode assembly (MEA) 22 (see Figure 1C ). The fuel cell 20 also includes bipolar plates (BPPs) 28, 30 on the outer sides of the respective gas diffusion layers (GDLs) 24, 26, as Figure 1C illustrated. The above components, particularly the bipolar plate 30, the gas diffusion layer (GDL) 26, the membrane electrode assembly (MEA) 22, and the gas diffusion layer (GDL) 24, each include a single repeating unit 50.

[0039] The bipolar plates (BPPs) 28, 30 are responsible for transporting reactants, such as fuel 32 (e.g., hydrogen) or oxidant 34 (e.g., oxygen, air), as well as coolant 36 (e.g., coolant and / or water) in the fuel cell 20. The bipolar plates (BPPs) 28, 30 can evenly distribute the reactants 32, 34 to the active area 40 of each fuel cell 20 through the oxidant flow field 42 and / or fuel flow field 44 formed on the outer surfaces of the bipolar plates (BPPs) 28, 30. When the stack 12 is viewed from a top-down angle, the active area 40 is located at the center of the membrane electrode assembly (MEA) 22, gas diffusion layers (GDLs) 24, 26, and bipolar plates (BPPs) 28, 30. An electrochemical reaction occurs in the active area 40 to generate the electricity produced by the fuel cell 20.

[0040] The bipolar plates (BPPs) 28, 30 can each be formed to have reaction flow fields 42, 44 formed on opposite outer surfaces of the bipolar plates (BPPs) 28, 30, and be formed to have a coolant flow field 52 located within the bipolar plates (BPPs) 28, 30, as Figure 1D shown. For example, the bipolar plates (BPPs) 28, 30 may include a fuel flow field 44 for transferring fuel 32 on one side of the plates 28, 30 to interact with the gas diffusion layer (GDL) 26. The bipolar plates (BPPs) 28, 30 also include an oxidant flow field 42 for transferring oxidant 34 on a second, opposite side of the plates 28, 30 to interact with the gas diffusion layer (GDL) 24.

[0041] As Figure 1D shown, the bipolar plates (BPPs) 28, 30 may also include coolant flow fields 52 formed within the plates (BPPs) 28, 30, which are typically centered between the opposite outer surfaces of the plates (BPPs) 28, 30. The coolant flow fields 52 facilitate the flow of coolant 36 through the bipolar plates (BPPs) 28, 30 to regulate the temperature of the plate (BPP) 28, 30 materials and reactants. The bipolar plates (BPPs) 28, 30 are compressed against the adjacent gas diffusion layers (GDLs) 24, 26 to isolate and / or seal one or more reactants 32, 34 within their respective channels 44, 42, thereby maintaining electrical conductivity, which is necessary for the robust operation of the fuel cell 20 (see Figure 1C and Figure 1D ).

[0042] The fuel cell system 10 described herein can be used in stationary and / or immovable power systems, such as industrial applications and power plants. The fuel cell system 10 can also be implemented in combination with an air delivery system 18. In addition, the fuel cell system 10 can also be implemented in combination with a hydrogen delivery system and / or a hydrogen source 19, such as a pressurized tank, including a gaseous pressurized tank, a cryogenic liquid storage tank, a chemical storage, a physical storage, a fixed storage, an electrolysis system or an electrolyzer. In one embodiment, the fuel cell system 10 is connected and / or attached to the hydrogen delivery system and / or the hydrogen source 19 in series or parallel, such as one or more hydrogen delivery systems and / or hydrogen sources 19 in the BOP 16 (see Figure 1A ). In another embodiment, the fuel cell system 10 is not connected and / or attached to the hydrogen delivery system and / or the hydrogen source 19 in series or parallel.

[0043] In some embodiments, the fuel cell system 10 can include an on / off valve 10XV1, a pressure transducer 10PT1, a mechanical regulator 10REG, and a venturi 10VEN, which are arranged to communicate functionally with each other and are located downstream of the hydrogen delivery system and / or the hydrogen source 19, as Figure 1A shown. The pressure transducer 10PT1 can be arranged between the on / off valve 10XV1 and the mechanical regulator 10REG. In some embodiments, a proportional control valve can be used instead of the mechanical regulator 10REG. In some embodiments, a second pressure transducer 10PT2 is arranged downstream of the venturi 10VEN, and the venturi is located downstream of the mechanical regulator 10REG.

[0044] In some embodiments, the fuel cell system 10 can further include a recirculation pump 10REC, which is downstream of the stack 12 and operably connected to the venturi 10VEN, as Figure 1A shown. The fuel cell system 10 can further include an on / off valve 10XV2 located downstream of the fuel cell stack 12 and a pressure transfer valve 10PSV, as Figure 1A shown.

[0045] The fuel cell system 10 can also be included in mobile applications. In an exemplary embodiment, the fuel cell system 10 is in a vehicle and / or a powertrain 100. The vehicle 100 including the fuel cell system 10 can be an automobile, a pass-through vehicle, a bus, a truck, a train, a locomotive, an aircraft, a light vehicle, a medium vehicle, or a heavy vehicle. The types of vehicles 100 can also include, but are not limited to: commercial vehicles and engines, trains, trolleybuses, trams, airplanes, buses, ships, vessels, and other known vehicles, as well as other mechanical and / or manufacturing equipment, facilities, etc.

[0046] The vehicle and / or powertrain 100 can be used on roads, highways, railways, air routes, and / or waterways. The vehicle 100 can be used in applications including but not limited to off-road transportation, cars, and / or mining equipment. For example, an exemplary embodiment of the mining equipment vehicle 100 is a mining truck or a haul truck.

[0047] As Figure 2A and Figure 2B shown, the electrolysis system 110 is generally configured to produce hydrogen and oxygen using water and electricity. The electrolysis system 110 typically includes one or more electrolytic cell batteries 180 that chemically produce substantially pure hydrogen 113 and oxygen 115 from deionized water 130 using electricity. The power source for the electrolysis system 110 generally comes from an electrical or power generation system, including renewable energy systems for producing green hydrogen, such as wind energy, solar energy, hydropower, and geothermal sources. In turn, the pure hydrogen produced by the electrolysis system 110 is typically used as a fuel or energy source for those same power generation systems, such as fuel cell systems. Alternatively, the pure hydrogen produced by the electrolysis system 110 can be stored for later use.

[0048] A typical electrolytic cell battery 180 or electrolytic cell includes multiple components that are compressed and bundled to form a single component; multiple electrolytic cell batteries 180 can be stacked on top of each other, together with bipolar plates (BPPs) 184, 185 therebetween, to form an electrolytic cell stack (e.g., Figure 2B the electrolytic cell stacks 111, 112 in ). Each electrolytic cell stack 111, 112 can accommodate multiple electrolytic cell batteries 180 connected in series and / or in parallel. In the electrolysis system 110, the number of electrolytic cell stacks 111, 112 can vary depending on the amount of power required to meet the power demand of any load (e.g., a fuel cell stack). In the electrolytic cell stacks 111, 112, the number of electrolytic cell batteries 180 can vary depending on the amount of power required for the operation of the electrolysis system 110 (including the electrolytic cell stacks 111, 112).

[0049] The electrolytic cell 180 includes a multi-component membrane electrode assembly (MEA) 181 having an electrolyte 181E, an anode 181A, and a cathode 181C. Generally, the anode 181A, cathode 181C, and electrolyte 181E of the membrane electrode assembly (MEA) 181 are configured in a multi-layer arrangement to activate an electrochemical reaction through the contact of water with one or more gas diffusion layers 182, 183, thereby generating hydrogen and / or oxygen. The gas diffusion layers (GDLs) 182, 183, which may also be referred to as porous transport layers (PTLs), are typically located on one or both sides of the MEA 181. Bipolar plates (BPPs) 184, 185 are typically located on both sides of the GDLs and separate the individual electrolytic cells 180 of the electrolytic cell stacks 111, 112 from each other. A bipolar plate 185, the adjacent gas diffusion layers 182, 183, and the MEA 181 can form a repeating unit 188.

[0050] As Figure 2B and Figure 2C shown, the exemplary electrolysis system 110 can include two electrolytic cell stacks 111, 112 and a fluid circuit 110FC that includes Figure 2B and 2C various fluid channels as shown, which are configured to convey, inject, and discharge fluids and other components to and from the electrolysis system 110. Those skilled in the art will understand that the electrolysis system 110 can use one or more of the various components within the fluid circuit 110FC and more or fewer than two electrolytic cell stacks 111, 112. For example, the electrolysis system 110 can include one electrolytic cell stack 111, and in other examples, the electrolysis system 110 can include three or more electrolytic cell stacks.

[0051] One or more types of electrolytic cell stacks 111, 112 can be included in the electrolysis system 110. In the illustrated embodiment, the cell stacks 111, 112 can use polymer electrolyte membrane (PEM) electrolytic cells 180. The PEM electrolytic cells 180 typically operate at a temperature of about 4°C to about 150°C, including any specific temperature or temperature range therein. The PEM electrolytic cells 180 typically also operate at a pressure of about 100 bar or lower, but pressures up to about 1000 bar are also possible (including any specific pressure or pressure range therein) because this reduces the total energy requirement of the system. The standard electrochemical reaction for hydrogen generation that occurs in the PEM electrolytic cell 180 is as follows. · Anode: 2H2O → O2 + 4H + + 4e – · Cathode: 4H + + 4e – → 2H2 ·Overall: 2H2O (liquid) → 2H2 + O2

[0052] Additionally, a solid oxide electrolyzer cell 180 can also be used in the electrolysis system 110. The solid oxide electrolyzer cell 180 will operate at a temperature of about 500 °C to about 1000 °C, including any specific temperature or temperature range contained therein. The standard electrochemical reaction for hydrogen production occurring in the solid oxide electrolyzer cell 180 is as follows. ·Anode: 2O 2- → O2 + 4e – ·Cathode: 2H2O → 4e – + 2H2 + 2O 2- ·Overall: 2H2O (liquid) → 2H2 + O2

[0053] Furthermore, an AEM electrolyzer cell 180 using an alkaline medium can also be used. An exemplary AEM electrolyzer cell 180 is an alkaline electrolyzer cell 180. The alkaline electrolyzer cell 180 uses an aqueous solution as the electrolyte, such as potassium hydroxide (KOH) and / or sodium hydroxide (NaOH) solution. The alkaline electrolyzer cell 180 typically operates at a working temperature of about 0 °C to about 150 °C, including any specific temperature or temperature range contained therein. The alkaline electrolyzer cell 180 typically operates within a pressure range of about 1 bar to about 100 bar, including any specific pressure or pressure range contained therein. The typical electrochemical reaction for hydrogen production occurring in the alkaline electrolyzer cell 180 is as follows. ·Anode: 4OH - → O2 + 2H2O + 4e – ·Cathode: 4H2O + 4e – → 2H2 + 4OH - ·Overall: 2H2O 2H2 + O2

[0054] As Figure 2B shown, the electrolyzer cell stacks 111, 112 include one or more electrolyzer cells 180 that chemically produce substantially pure hydrogen and oxygen from water using electricity. In turn, the pure hydrogen produced by the electrolyzer can be used as fuel or an energy source. As Figure 2B shown, the electrolyzer cell stacks 111, 112 output the produced hydrogen along the fluid connection pipeline 113 to the hydrogen separator 116, and also output the produced oxygen along the fluid connection pipeline 115 to the oxygen separator 114.

[0055] The hydrogen separator 116 can be configured to output pure hydrogen and also discharge the additional output fluid to the hydrogen discharge tank 120, which then outputs the fluid to the deionized water discharge pipe 121. The oxygen separator 114 can output the fluid to the oxygen discharge tank 124, which in turn outputs the fluid to the deionized water discharge pipe 125. Those skilled in the art should understand that some of the fluid inputs and outputs can be pure water or other fluids, such as coolant or by-products of the chemical reactions of the electrolyzer cell stacks 111, 112. For example, oxygen and hydrogen can flow from the cell stacks 111, 112 to their respective separators 114, 116. The system 110 can also include a rectifier 132 configured to convert the electricity 133 flowing to the cell stacks 111, 112 from alternating current (AC) to direct current (DC).

[0056] The deionized water discharge pipes 121, 125 output to a deionized water tank 140 respectively, which is part of a polishing circuit 136 in the fluid circuit 110FC, as Figure 2C shown. When ion-containing water interacts with the internal components of the electrolyzer cell stacks 111, 112, it can damage the electrolyzer cell stacks 111, 112. Figure 2C Shown in more detail, the polishing circuit 136 is configured to deionize water so that it can be used for the cell stacks 111, 112 without damaging them.

[0057] In the illustrated embodiment, the deionized water tank 140 outputs fluid, particularly water, to the deionized water polishing pump 144. The deionized water polishing pump 144 in turn outputs the water to the water polishing heat exchanger 146 for polishing and treatment. Subsequently, the water flows to the deionized water resin tank 148.

[0058] Coolant is directed through the electrolysis system 110, particularly through the deionized water heat exchanger 172 fluidly connected to the oxygen separator 114. The coolant used to cool the water flow can also subsequently be fed via the coolant input pipe 127 into the water polishing heat exchanger 146 for polishing. Then, the coolant is fed back to the deionized water heat exchanger 172 to cool the water therein.

[0059] After the water is output from the deionized water polishing heat exchanger 146 and then enters the deionized water resin tank 148, a portion of the water can be fed into the deionized water high-pressure supply pump 160. Another portion of the water can be fed into the deionized water pressure control valve 152, as Figure 2C shown. The portion of the water fed into the deionized water pressure control valve 152 flows through the recirculation fluid connection pipe 154, which allows the water to flow back to the deionized water tank 140 for continued polishing.

[0060] In some embodiments, the electrolysis system 110 may be supplemented with a deionized water skid for polishing the water stream to flush out the ions in the water at a faster rate. Then, this portion of the water fed into the deionized water high-pressure supply pump 160 is output to the deionized water supply pipe 164, then flows into the oxygen separator 114 for recirculation, and is ultimately reused in the electrolyzer cell stacks 111, 112. Then, this process can be repeated continuously.

[0061] The electrolysis system 110 described herein can be used in stationary and / or non-mobile power systems, such as industrial applications and power plants. The electrolysis system 110 can also be implemented in combination with other electrolysis systems 110.

[0062] This electrolysis system 110 can be included in mobile applications. The electrolysis system 110 can be located in a vehicle or powertrain 100. The vehicle or powertrain 100 including the electrolysis system 110 can be an automobile, a commuter vehicle, a bus, a truck, a train, a locomotive, an aircraft, a light vehicle, a medium vehicle, or a heavy vehicle.

[0063] The present disclosure provides a bipolar plate alignment system 210, as Figure 3 shown. The bipolar plate alignment system 210 includes a bipolar plate 212, a gasket seal 214, and an adhesive film 216, as Figures 3 to 6 shown. In some embodiments, the bipolar plate 212 is used in the fuel cell stack 12 (i.e., the bipolar plate 212 can be the bipolar plates (BPP) 28, 30 as described above). In some embodiments, the bipolar plate 212 is used in the electrolyzer cell stacks 111, 112 (i.e., the bipolar plate 212 can be the bipolar plates (BPP) 184, 185 as described above).

[0064] The bipolar plate 212 separates the cells within the stacks 12, 111, 112, such as the fuel cells 20 or the electrolyzer cells 180. The bipolar plate 212 conducts and collects current between the cells 20, 180, distributes the reactants, and provides mechanical support for the cells 20, 180.

[0065] The bipolar plate 212 is formed to include a plurality of manifold openings 222, seal grooves 223, and / or an active area 218 having a flow field 220, as Figure 4 shown. The seal grooves 223 are defined in the first side 215 of the bipolar plate 212 and are sized to accommodate the gasket seal 214 and the adhesive film 216 therein. The active area 218 and the flow field 220 can be the same as the active area 40 and the flow fields 42, 44, 52 described above. The active area 218 is disposed within the seal grooves 223 such that when the gasket seal 214 is located in the seal grooves 223, the reactants within the flow field 220 of the active area 218 are sealed.

[0066] The bipolar plate 212 is also formed to include a plurality of plate alignment features 224, such as Figure 4 shown. In some embodiments, the plurality of plate alignment features 224 are integrally formed as part of the bipolar plate 212. For example, each of the plurality of plate alignment features 224 is formed as a flange portion, a protruding portion, a projecting portion, a hanging portion, and / or an extending portion.

[0067] The plurality of plate alignment features 224 extend outward from the perimeter 226 of the bipolar plate 212, such as Figure 4 shown. Each of the plurality of plate alignment features 224 is spaced apart from each other around the perimeter 226. For example, the bipolar plate 212 includes ten plate alignment features 224. The number of plate alignment features 224 can be any number. For example, the number of plate alignment features 224 can range from about one (1) plate alignment feature 224 to about twenty (20) plate alignment features 224, including any specific number or range of numbers of plate alignment features 224 contained therein.

[0068] For example, the perimeter 226 of the bipolar plate 212 is defined by four sides of the bipolar plate 212: a first side 212A, a second side 212B opposite the first side 212A, a third side 212C, and a fourth side 212D opposite the third side 212C, such as Figure 4 shown. The first side 212A and the second side 212B are spaced apart from each other and parallel to each other. The third side 212C extends between and connects the terminals of the first side 212A and the second side 212B. The third side 212C is spaced apart from and parallel to the fourth side 212D. The fourth side 212D extends between and connects the terminals of the first side 212A and the second side 212B, and is opposite the third side 212C.

[0069] Each of the four sides (i.e., the first side 212A, the second side 212B, the third side 212C, and the fourth side 212D) of the perimeter 226 of the bipolar plate 212 can include the same or different numbers of plate alignment features 224. For example, in the Figure 4 illustrative plate, two sides of the plate (e.g., the third side 212C and the fourth side 212D) each include two plate alignment features 224. The two plate alignment features 224 are spaced apart from each other. The other two sides of the bipolar plate 212 (e.g., the first side 212A and the second side 212B) each include three plate alignment features 224. The three plate alignment features 224 are spaced apart from each other.

[0070] In some embodiments, the plurality of plate alignment features 224 consists of one plate alignment feature 224, and one plate alignment feature 224 extends from the first side 212A of the bipolar plate 212. In some embodiments, the plurality of plate alignment features 224 includes at least two plate alignment features 224, and one of the two plate alignment features 224 extends from the first side 212A of the bipolar plate 212, and the other of the two plate alignment features 224 extends from the second side 212B of the bipolar plate 212. In some embodiments, the plurality of plate alignment features 224 includes at least two plate alignment features 224, and one of the two plate alignment features 224 extends from the first side 212A of the bipolar plate 212, and the other of the two plate alignment features 224 extends from the third side 212C of the bipolar plate 212. In some embodiments, the plurality of plate alignment features 224 includes at least four plate alignment features 224, and one of the plate alignment features 224 extends from each of the four sides 212A, 212B, 212C, 212D of the bipolar plate 212.

[0071] For example, in some embodiments, the plurality of plate alignment features 224 includes a first plate alignment feature 224A extending outward from the first side 212A of the perimeter 226 of the bipolar plate 212, a second plate alignment feature 224B extending outward from the second side 212B of the perimeter 226 of the bipolar plate 212, a third plate alignment feature 224C extending outward from the third side 212C of the perimeter 226 of the bipolar plate 212, and a fourth plate alignment feature 224D extending outward from the fourth side 212D of the perimeter 226 of the bipolar plate 212. In some embodiments, the plurality of plate alignment features 224 further includes a fifth plate alignment feature 224E extending outward from the first side 212A of the perimeter 226 of the bipolar plate 212 and spaced apart from the first plate alignment feature 224A, and a sixth plate alignment feature 224F extending outward from the second side 212B of the perimeter 226 of the bipolar plate 212 and spaced apart from the second plate alignment feature 224B.

[0072] In some embodiments, each of the plurality of plate alignment features 224 has a semi - lunar shape or a semi - circular shape. However, each of the plurality of plate alignment features 224 can have any suitable shape.

[0073] Each of the plurality of plate alignment features 224 is formed to include a hole 227 extending therethrough, as Figure 4 shown. Each hole 227 of each plate alignment feature 224 is configured to couple with one or more other alignment features and / or alignment pins 236, as described in more detail below.

[0074] The gasket seal 214 is adapted to fit into a seal groove 223 formed in the bipolar plate 212, asFigure 3 and Figure 8 as shown. The gasket seal 214 prevents the reactants from leaking from the active area 218 into other parts of the stacks 12, 111, 112. In addition, the gasket seal 214 prevents cracking of the electrode substrates, provides electrical insulation between the components of the stacks 12, 111, 112, prevents the membrane electrode assembly (MEA) 22, 18 from swelling and / or provides mechanical support when the cells 20, 180 are compressed. The gasket seal 214 matches the shape of the sealing groove 223 formed in the bipolar plate 212 such that the gasket seal 214 can be firmly inserted into the sealing groove 223.

[0075] The gasket seal 214 is formed to include a plurality of seal alignment features 228 extending outward from the perimeter 229 of the gasket seal 214, as Figure 5 shown. In some embodiments, the plurality of seal alignment features 228 are integrally formed as part of the gasket seal 214. Each of the plurality of seal alignment features 228 is spaced apart from each other around the perimeter 229 of the gasket seal 214. For example, each of the plurality of seal alignment features 228 is formed as a flange portion, a protrusion, a projection, a hanging portion, and / or an extension portion.

[0076] For example, the perimeter 229 of the gasket seal 214 is defined by four sides of the gasket seal 214: a first side 214A, a second side 214B opposite the first side 214A, a third side 214C, and a fourth side 214D opposite the third side 214C, as Figure 5 shown. The first side 214A and the second side 214B are spaced apart from each other and parallel to each other. The third side 214C extends between and connects the terminals of the first side 214A and the second side 214B. The third side 214C is spaced apart from the fourth side 214D. The fourth side 214D extends between and connects the terminals of the first side 214A and the second side 214B and is opposite the third side 214C.

[0077] Each of the four sides (i.e., the first side 214A, the second side 214B, the third side 214C, and the fourth side 214D) of the perimeter 229 of the gasket seal 214 may include the same or different numbers of seal alignment features 228. For example, in the Figure 5 illustrative gasket seal 214, two of the sides of the gasket seal 214 (e.g., the third side 214C and the fourth side 214D) each include two seal alignment features 228. The two seal alignment features 228 are spaced apart from each other. The other two sides of the gasket seal 214 (e.g., the first side 214A and the second side 214B) each include three seal alignment features 228. The three seal alignment features 228 are spaced apart from each other.

[0078] In some embodiments, the plurality of seal alignment features 228 consists of one seal alignment feature 228, and one seal alignment feature 228 extends from the first side 214A of the gasket seal 214. In some embodiments, the plurality of seal alignment features 228 includes at least two seal alignment features 228, and one of the two seal alignment features 228 extends from the first side 214A of the gasket seal 214, and the other of the two seal alignment features 228 extends from the second side 214B of the gasket seal 214. In some embodiments, the plurality of seal alignment features 228 includes at least two seal alignment features 228, and one of the two seal alignment features 228 extends from the first side 214A of the gasket seal 214, and the other of the two seal alignment features 228 extends from the third side 214C of the gasket seal 214. In some embodiments, the plurality of seal alignment features 228 includes at least four seal alignment features 228, and one of the seal alignment features 228 extends from each of the four sides 214A, 214B, 214C, 214D of the gasket seal 214.

[0079] For example, in some embodiments, the plurality of seal alignment features 228 includes a first seal alignment feature 228A extending outward from the first side 214A of the perimeter 229 of the gasket seal 214, a second seal alignment feature 228B extending outward from the second side 214B of the perimeter 229 of the gasket seal 214, a third seal alignment feature 228C extending outward from the third side 214C of the perimeter 229 of the gasket seal 214, and a fourth seal alignment feature 228D extending outward from the fourth side 214D of the perimeter 229 of the gasket seal 214. In some embodiments, the plurality of seal alignment features 228 further includes a fifth seal alignment feature 228E extending outward from the first side 214A of the perimeter 229 of the gasket seal 214 and spaced apart from the first seal alignment feature 228A, and a sixth seal alignment feature 228F extending outward from the second side 214B of the perimeter 229 of the gasket seal 214 and spaced apart from the second seal alignment feature 228B.

[0080] In some embodiments, each of the seal alignment features 228 of the plurality of seal alignment features 228 has a semi - moon shape or a semi - circular shape. However, each of the seal alignment features 228 of the plurality of seal alignment features 228 can have any suitable shape.

[0081] For example, the plurality of seal alignment features 228 includes ten seal alignment features 228. The number of seal alignment features 228 can be any number. For example, the number of seal alignment features 228 can range from about one (1) seal alignment feature 228 to about twenty (20) seal alignment features 228, including any specific number or range of numbers of seal alignment features 228 contained therein. In an exemplary embodiment, the number of the plurality of seal alignment features 228 is equal to the number of the plurality of plate alignment features 224, and the positioning of the plurality of plate alignment features 224 is the same as the positioning of the plurality of seal alignment features 228, such that the plate alignment features 224 and the seal alignment features 228 are aligned with each other.

[0082] Each seal alignment feature of the plurality of seal alignment features 228 is formed to include a hole 230 extending therethrough, as Figure 5 shown. Each hole 230 of each seal alignment feature 228 is configured to be coupled to one or more other alignment features (such as corresponding plate alignment features 224), corresponding holes 227, and / or alignment pins 236, as described in more detail below. Each hole 230 of the plurality of seal alignment features 228 is aligned with a corresponding hole 227 of the plurality of plate alignment features 224.

[0083] In some embodiments, the gasket seal 214 is formed of a rubber-based material. In some embodiments, the gasket seal 214 is formed of a fluororubber material based on fluorocarbons. In some embodiments, the gasket seal 214 is formed of an ethylene propylene diene monomer material.

[0084] The adhesive film 216 is coupled to the gasket seal 214 and the seal groove 223, as Figure 8 prompted. In some embodiments, the adhesive film 216 adheres to and / or attaches to the bottom side of the gasket seal 214, as Figure 7 shown. The adhesive film 216 matches the shapes of the gasket seal 214 and the seal groove 223. The adhesive film 216 is formed to include a plurality of film alignment features 232 extending outward from a perimeter 233 of the adhesive film 216, as Figure 6 shown. Each of the plurality of film alignment features 232 is spaced apart from each other around the perimeter 233 of the adhesive film 216. For example, each of the plurality of film alignment features 232 is formed as a flange portion, a protruding portion, a protruding part, a hanging portion, and / or an extending portion.

[0085] For example, the perimeter 233 of the adhesive film 216 is defined by four sides of the adhesive film 216: a first side 216A, a second side 216B opposite the first side 216A, a third side 216C, and a fourth side 216D opposite the third side 216C, as Figure 6As shown. The first side 216A and the second side 216B are spaced apart from each other and parallel to each other. The third side 216C extends between and connects the terminals of the first side 216A and the second side 216B. The third side 216C is spaced apart from the fourth side 216D. The fourth side 216D extends between and connects the terminals of the first side 216A and the second side 216B, and is opposite to the third side 216C.

[0086] Each of the four sides (i.e., the first side 216A, the second side 216B, the third side 216C, and the fourth side 216D) of the perimeter 233 of the adhesive film 216 may include the same or different numbers of film alignment features 232. For example, in Figure 6 the illustrative adhesive film 216 shown, two sides (e.g., the third side 216C and the fourth side 216D) of the adhesive film 216 each include two film alignment features 232. The two film alignment features 232 are spaced apart from each other. The other two sides (e.g., the first side 216A and the second side 216B) of the adhesive film 216 each include three film alignment features 232. The three film alignment features 232 are spaced apart from each other.

[0087] In some embodiments, the plurality of film alignment features 232 consists of one film alignment feature 232, and one film alignment feature 232 extends from the first side 216A of the adhesive film 216. In some embodiments, the plurality of film alignment features 232 includes at least two film alignment features 232, and one of the two film alignment features 232 extends from the first side 216A of the adhesive film 216, and the other of the two film alignment features 232 extends from the second side 216B of the adhesive film 216. In some embodiments, the plurality of film alignment features 232 includes at least two film alignment features 232, and one of the two film alignment features 232 extends from the first side 216A of the adhesive film 216, and the other of the two film alignment features 232 extends from the third side 216C of the adhesive film 216. In some embodiments, the plurality of film alignment features 232 includes at least four film alignment features 232, and one of the film alignment features 232 extends from each of the four sides 216A, 216B, 216C, 216D of the adhesive film 216.

[0088] For example, in some embodiments, the plurality of film alignment features 232 includes a first film alignment feature 232A extending outward from a first side 216A of the perimeter 233 of the adhesive film 216, a second film alignment feature 232B extending outward from a second side 216B of the perimeter 233 of the adhesive film 216, a third film alignment feature 232C extending outward from a third side 216C of the perimeter 233 of the adhesive film 216, and a fourth film alignment feature 232D extending outward from a fourth side 216D of the perimeter 233 of the adhesive film 216. In some embodiments, the plurality of film alignment features 232 further includes a fifth film alignment feature 232E extending outward from the first side 216A of the perimeter 233 of the adhesive film 216 and spaced apart from the first film alignment feature 232A, and a sixth film alignment feature 232F extending outward from the second side 216B of the perimeter 233 of the adhesive film 216 and spaced apart from the second film alignment feature 232B.

[0089] In such embodiments, the first plate alignment feature 224A is aligned with the first seal alignment feature 228A and the first film alignment feature 232A, the second plate alignment feature 224B is aligned with the second seal alignment feature 228B and the second film alignment feature 232B, the third plate alignment feature 224C is aligned with the third seal alignment feature 228C and the third film alignment feature 232C, and the fourth plate alignment feature 224D is aligned with the fourth seal alignment feature 228D and the fourth film alignment feature 232D.

[0090] In some embodiments, each film alignment feature of the plurality of film alignment features 232 has a semi - lunar shape or a semi - circular shape. However, each film alignment feature of the plurality of film alignment features 232 can have any suitable shape.

[0091] By way of example, the plurality of film alignment features 232 includes ten film alignment features 232. The number of film alignment features 232 can be any number. For example, the number of film alignment features 232 can range from about one (1) film alignment feature 232 to about twenty (20) film alignment features 232, including any specific number or range of numbers of film alignment features 232 contained therein. In an exemplary embodiment, the number of the plurality of film alignment features 232 is equal to the number of the plurality of seal alignment features 228 and the number of the plurality of plate alignment features 224, and the positioning of the plurality of film alignment features 232 is the same as the positioning of the plurality of seal alignment features 228 and the positioning of the plurality of plate alignment features 224, such that the plate alignment features 224, the seal alignment features 228, and the film alignment features 232 are aligned with each other.

[0092] Each film alignment feature of the plurality of film alignment features 232 is formed to include a hole 234 extending therethrough, as Figure 6As shown. Each hole 234 of each membrane alignment feature 232 is configured to couple with one or more other alignment features (such as corresponding plate alignment feature 224), corresponding holes 227, corresponding seal alignment feature 228, corresponding holes 230, and / or alignment pins 236, as described in more detail below. Each hole 234 of the plurality of membrane alignment features 232 is aligned with the corresponding hole 230 of the plurality of seal alignment features 228 and with the corresponding hole 227 of the plurality of plate alignment features 224.

[0093] The gasket seal 214 and the adhesive film 216 are inserted and / or positioned in the seal groove 223 formed in the bipolar plate 212 such that the adhesive film 216 is located between the seal groove 223 and the gasket seal 214, as Figure 8 shown. The adhesive film 216 helps attach, couple, and / or adhere the gasket seal 214 to the bipolar plate 212 by adhering to each of the gasket seal 214 and the seal groove 223 of the bipolar plate 212.

[0094] As shown previously, the plate alignment feature 224, the seal alignment feature 228, and the membrane alignment feature 232 are all aligned with each other, while the bipolar plate 212, the gasket seal 214, and the adhesive film 216 are stacked on top of each other, as Figure 3 shown. Thus, the holes 227, 230, 234 formed in each of the plate alignment feature 224, the seal alignment feature 228, and the membrane alignment feature 232 are aligned with each other to form a single multi-layer hole 240, as Figure 3 shown.

[0095] The bipolar plate alignment system 210 further includes a plurality of alignment pins 236, as Figure 3 and Figure 8 shown. The alignment pins 236 extend through the overlapping holes 227, 230, 234 (i.e., the multi-layer hole 240) formed in each of the plate alignment feature 224, the seal alignment feature 228, and the membrane alignment feature 232. The alignment pins 236 ensure that the adhesive film 216 and the gasket seal 214 are correctly aligned on or with the bipolar plate 212 such that the gasket seal 214 is correctly aligned with and inserted into the seal groove 223.

[0096] For example, the bipolar plate alignment system 210 includes ten alignment pins 236. In some embodiments, the number of alignment pins 236 can be any number. For example, the number of alignment pins 236 can range from about one (1) alignment pin 236 to about twenty (20) alignment pins 236, including any specific number or range of numbers of alignment pins 236 contained therein.

[0097] In an exemplary embodiment, the number of the plurality of alignment pins 236 is equal to the number of the multi-layer holes 240. In other words, the number of the plurality of alignment pins 236 is equal to the number of the plurality of membrane alignment features 232, the number of the plurality of seal alignment features 228, and / or the number of the plurality of plate alignment features 224. In other words, in some embodiments, the bipolar plate alignment system 210 includes an alignment pin 236 for each multi-layer hole 240.

[0098] The bipolar plate alignment system 210 facilitates manufacturing (i.e., attaching, adhering, and / or coupling the gasket seal 214 to the bipolar plate 212). The alignment features 224, 228, 232 enable continuous production of the bipolar plate alignment system 210 in a fully automated manner with little to no human interaction and / or involvement.

[0099] In some conventional systems, in addition to a machine (such as a robotic arm) that helps align the gasket seal with the bipolar plate, a human operator and / or an imaging device (i.e., a camera) may also be included. In some conventional systems, the gasket seal is directly molded onto a pre-treated bipolar plate. The pre-treatment of the bipolar plate includes cleaning the seal groove with isopropyl alcohol, spraying the non-seal groove portion of the bipolar plate with Teflon, applying glue to the seal groove, and pre-heating the bipolar plate. Then, the pre-heated bipolar plate is moved into an injection molding machine to inject the gasket seal. After the gasket seal is molded onto the bipolar plate, the bipolar plate and the gasket seal combination are cured. After curing, the bipolar plate is moved to a hot table to cut off any excess flash of the gasket seal on the bipolar plate, and then the bipolar plate is moved for post-curing. Overall, the conventional process requires a long cycle time, heavy machinery, and high labor requirements.

[0100] Therefore, the bipolar plate alignment system 210 can simplify the manufacturing process without direct injection molding. For example, the gasket seal 214 is positioned on a roll of adhesive film 216. Then, the adhesive film 216 is coupled and / or adhered to the gasket seal 214, for example, by a mechanical press, a hot press, a cold press, or any other suitable method. Then, the adhesive film 216 can be cut using a rolling die to match the shape of the gasket seal 214, and any excess adhesive film 216 can be removed after cutting. Then, the adhesive film 216 and the gasket seal 214 can be attached to the bipolar plate 212 with the aid of the plurality of alignment pins 236.

[0101] For example, the bipolar plate 212 can be located on a platform, where the plurality of alignment pins 236 extend through the holes 227 of the plurality of plate alignment features 224, as Figure 8As shown. The combination of the adhesive film 216 and the gasket seal 214 can be located on top of the bipolar plate 212 such that a plurality of alignment pins 236 extend through holes 230, 234 in the seal alignment features 228 and the film alignment features 232. The bipolar plate alignment system 210 enables reduced cycle times, reduced labor requirements, and reduced reject rates during production. During manufacturing, a plurality of alignment pins 236 can be inserted into each of the holes 227 of the plurality of plate alignment features 224 of the bipolar plate 212. Then, the gasket seal 214 can be placed on the bipolar plate 212 by a robotic arm or an operator by moving the gasket seal 214 (to which the adhesive film 216 is attached to its bottom side) until the gasket seal 214 is properly aligned with the bipolar plate 212 such that the plurality of alignment pins 236 extend through corresponding holes 234 of the plurality of seal alignment features 228 of the gasket seal 214 and corresponding holes 232 of the plurality of film alignment features 232 of the adhesive film 216. A vacuum can be arranged below the bipolar plate 212, and the vacuum applies suction to force the gasket seal 214 into the seal groove 223 and ensure a tight seal between the seal groove 223 and the gasket seal 214.

[0102] The present system and method enable fully automatic and / or hands-free coupling of the alignment features 224, 228, 232 and the alignment pins 236, which also aligns the gasket seal 214 with the bipolar plate 212 without the interaction or involvement of an operator and / or an imaging device to ensure proper alignment. Accordingly, the present system and method are beneficial and advantageous because their efficiency and cost-effectiveness are superior to traditional methods of manually and / or automatically aligning bipolar plates and gasket seals that do not use alignment features.

[0103] It should be understood that the bipolar plate 212 is similar on both sides of the bipolar plate 212. The first side 215 of the bipolar plate 212 is shown and described herein. However, the opposite second side 217 of the bipolar plate 212 is similarly formed to define a seal groove. As described above, another gasket seal and another adhesive film are located within the seal groove on the second side 217 of the bipolar plate 212.

[0104] The following aspects of the present invention are contemplated and non-limiting:

[0105] A first aspect of the present invention relates to a bipolar plate alignment system. The bipolar plate alignment system includes a bipolar plate, a gasket seal, and an adhesive film. The bipolar plate is formed to include a seal groove defined in a first side of the bipolar plate and a plurality of plate alignment features extending outwardly from a perimeter of the bipolar plate. Each of the plurality of plate alignment features is formed to include a hole extending therethrough. The gasket seal is sized to be placed within the seal groove of the bipolar plate to seal reactants within an active area of the bipolar plate. The gasket seal is formed to include a plurality of seal alignment features extending outwardly from a perimeter of the gasket seal. Each of the plurality of seal alignment features is formed to include a hole extending therethrough. The adhesive film is coupled to the gasket seal and the seal groove. The adhesive film is formed to include a plurality of film alignment features extending outwardly from a perimeter of the adhesive film. Each of the plurality of film alignment features is formed to include a hole extending therethrough. The holes formed in each of the plurality of plate alignment features are aligned with corresponding holes formed in each of the plurality of seal alignment features and with corresponding holes formed in each of the plurality of film alignment features such that the gasket seal is correctly aligned within the seal groove of the bipolar plate.

[0106] A second aspect of the present invention relates to a bipolar plate alignment system. The bipolar plate alignment system includes a bipolar plate, a gasket seal, and a plurality of alignment pins. The bipolar plate is formed to include a seal groove defined in a first side of the bipolar plate and a plurality of plate alignment features extending outwardly from a perimeter of the bipolar plate. Each of the plurality of plate alignment features is formed to include a hole extending therethrough. The gasket seal is sized to be placed within the seal groove of the bipolar plate to seal reactants within an active area of the bipolar plate. The gasket seal is formed to include a plurality of seal alignment features extending outwardly from a perimeter of the gasket seal. Each of the plurality of seal alignment features is formed to include a hole extending therethrough. Each of the plurality of alignment pins is configured to extend through a corresponding hole formed in one of the plurality of plate alignment features and a corresponding hole formed in one of the plurality of seal alignment features. The gasket seal is disposed on the bipolar plate such that the holes formed in each of the plurality of plate alignment features are aligned with corresponding holes formed in each of the plurality of seal alignment features such that each of the plurality of alignment pins extends through the corresponding holes of the plurality of plate alignment features and the corresponding holes of the plurality of seal alignment features to align the gasket seal within the seal groove.

[0107] In the first aspect of the present invention, the adhesive film can be adhered to a bottom side of the gasket seal to position the adhesive film between the seal groove of the bipolar plate and the gasket seal. In the first aspect of the present invention, each of the plurality of film alignment features can be aligned with a corresponding one of the plurality of seal alignment features and a corresponding one of the plurality of plate alignment features.

[0108] In a first aspect of the present invention, the perimeter of the bipolar plate may be defined by a first side, a second side opposite the first side, a third side extending between and interconnecting the first side and the second side, and a fourth side opposite the third side and extending between and interconnecting the first side and the second side. In a first aspect of the present invention, the perimeter of the gasket seal may be defined by a first side of the perimeter of the gasket seal, a second side opposite the first side of the perimeter of the gasket seal, a third side extending between and interconnecting the first side of the perimeter of the gasket seal and the second side of the perimeter of the gasket seal, and a fourth side opposite the third side of the perimeter of the gasket seal and extending between and interconnecting the first side of the perimeter of the gasket seal and the second side of the perimeter of the gasket seal.

[0109] In a first aspect of the present invention, the plurality of seal alignment features may include a first seal alignment feature extending outwardly from the first side of the perimeter of the gasket seal, a second seal alignment feature extending outwardly from the second side of the perimeter of the gasket seal, a third seal alignment feature extending outwardly from the third side of the perimeter of the gasket seal, and a fourth seal alignment feature extending outwardly from the fourth side of the perimeter of the gasket seal.

[0110] In a first aspect of the present invention, the plurality of plate alignment features may include a first plate alignment feature extending outwardly from the first side of the perimeter of the bipolar plate, a second plate alignment feature extending outwardly from the second side of the perimeter of the bipolar plate, a third plate alignment feature extending outwardly from the third side of the perimeter of the bipolar plate, and a fourth plate alignment feature extending outwardly from the fourth side of the perimeter of the bipolar plate.

[0111] In a first aspect of the present invention, the perimeter of the adhesive film may be defined by a first side of the perimeter of the adhesive film, a second side opposite the first side of the perimeter of the adhesive film, a third side extending between and interconnecting the first side of the perimeter of the adhesive film and the second side of the perimeter of the adhesive film, and a fourth side opposite the third side of the perimeter of the adhesive film and extending between and interconnecting the first side of the perimeter of the adhesive film and the second side of the perimeter of the adhesive film. In a first aspect of the present invention, the plurality of film alignment features may include a first film alignment feature extending outwardly from the first side of the perimeter of the adhesive film, a second film alignment feature extending outwardly from the second side of the perimeter of the adhesive film, a third film alignment feature extending outwardly from the third side of the perimeter of the adhesive film, and a fourth film alignment feature extending outwardly from the fourth side of the perimeter of the adhesive film.

[0112] In a first aspect of the present invention, a first plate alignment feature may be aligned with a first seal alignment feature and a first membrane alignment feature, a second plate alignment feature may be aligned with a second seal alignment feature and a second membrane alignment feature, a third plate alignment feature may be aligned with a third seal alignment feature and a third membrane alignment feature, and a fourth plate alignment feature may be aligned with a fourth seal alignment feature and a fourth membrane alignment feature. In a first aspect of the present invention, the bipolar plate alignment system may further include a plurality of alignment pins.

[0113] In a first aspect of the present invention, the plurality of plate alignment features may further include a fifth plate alignment feature extending outward from a first side of the perimeter of the bipolar plate and spaced apart from the first plate alignment feature, and a sixth plate alignment feature extending outward from a second side of the perimeter of the bipolar plate and spaced apart from the second plate alignment feature. In a first aspect of the present invention, the plurality of seal alignment features may further include a fifth seal alignment feature extending outward from a first side of the perimeter of the gasket seal and spaced apart from the first seal alignment feature, and a sixth seal alignment feature extending outward from a second side of the perimeter of the gasket seal and spaced apart from the second seal alignment feature.

[0114] In a first aspect of the present invention, the plurality of membrane alignment features may further include a fifth membrane alignment feature extending outward from a first side of the perimeter of the adhesive membrane and spaced apart from the first membrane alignment feature, and a sixth membrane alignment feature extending outward from a second side of the perimeter of the adhesive membrane and spaced apart from the second membrane alignment feature. In a first aspect of the present invention, the plurality of plate alignment features may further include a fifth plate alignment feature extending outward from a first side of the perimeter of the bipolar plate and spaced apart from the first plate alignment feature, and a sixth plate alignment feature extending outward from a second side of the perimeter of the bipolar plate and spaced apart from the second plate alignment feature.

[0115] In a first aspect of the present invention, the bipolar plate alignment system may further include a plurality of alignment pins. In a first aspect of the present invention, each alignment pin of the plurality of alignment pins may be configured to extend through a corresponding hole formed in one of the plurality of plate alignment features, a corresponding hole formed in one of the plurality of seal alignment features, and a corresponding hole formed in one of the plurality of membrane alignment features. In a first aspect of the present invention, each of the plurality of membrane alignment features may be aligned with a corresponding one of the plurality of seal alignment features and a corresponding one of the plurality of plate alignment features.

[0116] In a first aspect of the present invention, each alignment pin of the plurality of alignment pins may be configured to extend through a corresponding hole formed in one of the plurality of plate alignment features, a corresponding hole formed in one of the plurality of seal alignment features, and a corresponding hole formed in one of the plurality of membrane alignment features.

[0117] In a second aspect of the present invention, the bipolar plate alignment system may further include an adhesive film attached to the bottom side of the gasket seal. In a second aspect of the present invention, the adhesive film may be formed to include a plurality of film alignment features extending outward from the perimeter of the adhesive film.

[0118] In a second aspect of the present invention, each of the plurality of film alignment features may be formed to include a hole extending therethrough. In a second aspect of the present invention, the holes formed in each of the plurality of film alignment features may be aligned with the corresponding holes formed in each of the plurality of seal alignment features and the corresponding holes formed in each of the plurality of plate alignment features. In a second aspect of the present invention, each of the plurality of film alignment features may be aligned with a corresponding one of the plurality of seal alignment features and a corresponding one of the plurality of plate alignment features.

[0119] In a second aspect of the present invention, the perimeter of the bipolar plate may be defined by a first side, a second side opposite the first side, a third side extending between and connecting the first side and the second side, and a fourth side opposite the third side and extending between and connecting the first side and the second side.

[0120] In a second aspect of the present invention, the perimeter of the gasket seal may be defined by a first side of the perimeter of the gasket seal, a second side opposite the first side of the perimeter of the gasket seal, a third side extending between and connecting the first side of the perimeter of the gasket seal and the second side of the perimeter of the gasket seal, and a fourth side opposite the third side of the perimeter of the gasket seal and extending between and connecting the first side of the perimeter of the gasket seal and the second side of the perimeter of the gasket seal.

[0121] In a second aspect of the present invention, the plurality of plate alignment features may include a first plate alignment feature extending outward from the first side of the perimeter of the bipolar plate, a second plate alignment feature extending outward from the second side of the perimeter of the bipolar plate, a third plate alignment feature extending outward from the third side of the perimeter of the bipolar plate, and a fourth plate alignment feature extending outward from the fourth side of the perimeter of the bipolar plate. In a second aspect of the present invention, the plurality of plate alignment features may further include a fifth plate alignment feature extending outward from the first side of the perimeter of the bipolar plate and spaced apart from the first plate alignment feature and a sixth plate alignment feature extending outward from the second side of the perimeter of the bipolar plate and spaced apart from the second plate alignment feature.

[0122] In a second aspect of the present invention, the plurality of seal alignment features may include a first seal alignment feature extending outwardly from a first side of the perimeter of the gasket seal, a second seal alignment feature extending outwardly from a second side of the perimeter of the gasket seal, a third seal alignment feature extending outwardly from a third side of the perimeter of the gasket seal, and a fourth seal alignment feature extending outwardly from a fourth side of the perimeter of the gasket seal. In a second aspect of the present invention, a first plate alignment feature may be aligned with the first seal alignment feature, a second plate alignment feature may be aligned with the second seal alignment feature, a third plate alignment feature may be aligned with the third seal alignment feature, and a fourth plate alignment feature may be aligned with the fourth seal alignment feature.

[0123] Features illustrated or described in connection with one exemplary embodiment may be combined with any other features or elements of any other embodiment described herein. Such modifications and variations are intended to be included within the scope of the present disclosure. Additionally, those skilled in the art will recognize that terms well known in the art may be used interchangeably herein.

[0124] The description of the above embodiments is detailed enough for those skilled in the art to practice what is claimed, and it should be understood that logical, mechanical, and electrical changes may be made without departing from the spirit and scope of the claims. Thus, the detailed description should not be construed as having a limiting meaning.

[0125] As used herein, an element or step recited in the singular and preceded by the word "a" or "an" should be understood as not excluding the plural of said element or step, unless expressly stated to the contrary. Additionally, a reference to "one embodiment" of the subject matter described herein does not mean an interpretation that excludes the existence of additional embodiments that also incorporate the recited features. A specified numerical range of units, measurements, and / or values includes, consists essentially of, or consists of: all numerical values, units, measurements, and / or ranges including these ranges and / or endpoints or within these ranges and / or endpoints, whether or not such numerical values, units, measurements, and / or ranges are expressly recited in the present disclosure.

[0126] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. As used herein, the terms "first," "second," "third," etc. do not denote any order or importance, but rather are used to distinguish one element from another. The term "or" means inclusive and means any one or all of the listed items. Additionally, the terms "connected" and "coupled" are not limited to physical or mechanical connection or coupling and may also include direct or indirect electrical connection or coupling.

[0127] In addition, unless stated to the contrary explicitly, embodiments of an element or elements having a particular attribute with "comprising", "including", or "having" may include additional such elements that do not have that attribute. The terms "comprising" or "including" refer to a composition, compound, formulation, or method that includes but does not exclude additional elements, components, and / or method steps. The term "comprising" also refers to embodiments of a composition, compound, formulation, or method in the present disclosure that include but do not exclude additional elements, components, and / or method steps.

[0128] The phrase "consisting of" or "consists of" refers to a mixture, composition, formulation, or method that excludes the presence of any additional elements, components, or method steps. The phrase "consisting of" refers to a compound, composition, formulation, or method in the present disclosure that excludes the presence of any additional elements, components, or method steps.

[0129] The phrase "consisting essentially of" or "consists essentially of" refers to a composition, compound, formulation, or method that includes additional elements, components, or method steps that do not materially affect the characteristics of the composition, compound, formulation, or method. The phrase "consisting essentially of" also refers to embodiments of a composition, compound, formulation, or method in the present disclosure that include additional elements, components, or method steps that do not materially affect the characteristics of the composition, compound, formulation, or method.

[0130] As used throughout the specification and claims, approximate language may be used to modify any quantitative representation that admits of variation without resulting in a change in the basic function associated therewith. Thus, a value modified by one or more terms, such as "about" and "substantially", is not limited to the precise value specified. In some instances, the approximate language may correspond to the precision of the instrument used to measure the value. Throughout this specification and the claims, range limitations may be combined and / or interchanged. Such ranges have been recognized and include all the subranges subsumed therein unless the context or language indicates otherwise.

[0131] As used herein, the terms "may" and "may be" denote a possibility of occurring in a series of circumstances; having a particular property, characteristic, or function; and / or qualifying another verb by expressing one or more abilities or possibilities associated with the qualifying verb. Thus, the use of "may" and "may be" indicates that the modified term is clearly appropriate, capable, or suitable for the indicated ability, function, or usage, while considering that in some cases, the modified term may sometimes be inappropriate, incapable, or unsuitable.

[0132] It should be understood that the above description is illustrative and not restrictive. For example, the above embodiments (and / or aspects thereof) may be used alone, together, or in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the subject matter described herein without departing from its scope. Although the dimensions and types of the materials described herein are intended to define the parameters of the disclosed subject matter, they are by no means restrictive but are exemplary embodiments. After reviewing the above description, many other embodiments will be apparent to those skilled in the art. Accordingly, the scope of the subject matter described herein should be determined with reference to the appended claims and the full scope of equivalents to which such claims are entitled.

[0133] This written description uses examples to disclose several embodiments of the subject matter described herein (including the best mode), and also enables those of ordinary skill in the art to practice the embodiments of the disclosed subject matter, including manufacturing and using devices or systems and performing methods. The patentable scope of the subject matter described herein is defined by the claims and may include other examples that occur to those of ordinary skill in the art. If such other examples have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not materially different from the literal language of the claims, then these other examples are intended to be within the scope of the claims.

[0134] Although only certain features of the invention have been illustrated and described herein, many modifications and variations will occur to those skilled in the art. Accordingly, it should be understood that the appended claims are intended to cover all such modifications and variations that fall within the true spirit of the invention.

Claims

1. A bipolar plate alignment system, the bipolar plate alignment system comprising: a bipolar plate formed to include a seal groove defined in a first side of the bipolar plate and a plurality of plate alignment features extending outwardly from a perimeter of the bipolar plate, each of the plurality of plate alignment features being formed to include a hole extending therethrough, a gasket seal sized to be placed within the seal groove of the bipolar plate to seal reactants within an active area of ​​the bipolar plate, the gasket seal being formed to include a plurality of seal alignment features extending outwardly from a perimeter of the gasket seal, each of the plurality of seal alignment features being formed to include an aperture extending therethrough, and an adhesive film coupled to the gasket seal and the seal groove, the adhesive film being formed to include a plurality of film alignment features extending outwardly from a periphery of the adhesive film, each of the plurality of film alignment features being formed to include an aperture extending therethrough, wherein the hole formed in each of the plurality of plate alignment features is aligned with a corresponding hole formed in each of the plurality of seal alignment features, and is aligned with a corresponding hole formed in each of the plurality of membrane alignment features, such that the gasket seal is properly aligned within the seal groove of the bipolar plate.

2. The bipolar plate alignment system according to claim 1, wherein: The adhesive film is adhered to the bottom side of the gasket seal to position the adhesive film between the seal groove of the bipolar plate and the gasket seal.

3. The bipolar plate alignment system according to claim 1, wherein: Each of the plurality of film alignment features is aligned with a corresponding one of the plurality of seal alignment features and a corresponding one of the plurality of plate alignment features.

4. The bipolar plate alignment system according to claim 1, wherein: The perimeter of the bipolar plate is defined by a first side, a second side opposite to the first side, a third side extending between and interconnecting the first and second sides, and a fourth side opposite to the third side and extending between and interconnecting the first and second sides, and wherein the perimeter of the gasket seal is defined by a first side of the perimeter of the gasket seal, a second side opposite to the first side of the perimeter of the gasket seal, a third side extending between and interconnecting the first and second sides of the perimeter of the gasket seal, and a fourth side opposite to the third side of the perimeter of the gasket seal and extending between and interconnecting the first and second sides of the perimeter of the gasket seal.

5. The bipolar plate alignment system according to claim 4, wherein: The plurality of plate alignment features include a first plate alignment feature extending outward from the first side of the periphery of the bipolar plate, a second plate alignment feature extending outward from the second side of the periphery of the bipolar plate, a third plate alignment feature extending outward from the third side of the periphery of the bipolar plate, and a fourth plate alignment feature extending outward from the fourth side of the periphery of the bipolar plate.

6. The bipolar plate alignment system according to claim 5, wherein: The multiple sealing alignment features include a first sealing alignment feature extending outward from the first side of the periphery of the gasket seal, a second sealing alignment feature extending outward from the second side of the periphery of the gasket seal, a third sealing alignment feature extending outward from the third side of the periphery of the gasket seal, and a fourth sealing alignment feature extending outward from the fourth side of the periphery of the gasket seal.

7. The bipolar plate alignment system according to claim 6, wherein: The periphery of the adhesive film is defined by a first side of the periphery of the adhesive film, a second side opposite to the first side of the periphery of the adhesive film, a third side extending between and connecting the first side of the periphery of the adhesive film and the second side of the periphery of the adhesive film, and a fourth side opposite to the third side of the periphery of the adhesive film and extending between and connecting the first side of the periphery of the adhesive film and the second side of the periphery of the adhesive film.

8. The bipolar plate alignment system according to claim 7, wherein: The plurality of film alignment features include a first film alignment feature extending outward from the first side of the periphery of the adhesive film, a second film alignment feature extending outward from the second side of the periphery of the adhesive film, a third film alignment feature extending outward from the third side of the periphery of the adhesive film, and a fourth film alignment feature extending outward from the fourth side of the periphery of the adhesive film.

9. The bipolar plate alignment system according to claim 8, wherein: The first plate alignment feature is aligned with the first seal alignment feature and the first film alignment feature, the second plate alignment feature is aligned with the second seal alignment feature and the second film alignment feature, the third plate alignment feature is aligned with the third seal alignment feature and the third film alignment feature, and the fourth plate alignment feature is aligned with the fourth seal alignment feature and the fourth film alignment feature.

10. The bipolar plate alignment system of claim 1 , further comprising a plurality of alignment pins, each of the plurality of alignment pins being configured to extend through a corresponding hole formed in one of the plurality of plate alignment features, a corresponding hole formed in one of the plurality of seal alignment features, and a corresponding hole formed in one of the plurality of membrane alignment features.

11. The bipolar plate alignment system according to claim 10, wherein: The plurality of seal alignment features also include a fifth seal alignment feature extending outwardly from the first side of the periphery of the gasket seal and spaced apart from the first seal alignment feature and a sixth seal alignment feature extending outwardly from the second side of the periphery of the gasket seal and spaced apart from the second seal alignment feature.

12. The bipolar plate alignment system of claim 11, wherein: The plurality of film alignment features also include a fifth film alignment feature extending outward from the first side of the periphery of the adhesive film and spaced apart from the first film alignment feature and a sixth film alignment feature extending outward from the second side of the periphery of the adhesive film and spaced apart from the second film alignment feature.

13. The bipolar plate alignment system according to claim 5, wherein: The plurality of plate alignment features also include a fifth plate alignment feature extending outwardly from the first side of the perimeter of the bipolar plate and spaced apart from the first plate alignment feature and a sixth plate alignment feature extending outwardly from the second side of the perimeter of the bipolar plate and spaced apart from the second plate alignment feature.

14. The bipolar plate alignment system of claim 1 , further comprising a plurality of alignment pins, each of the plurality of alignment pins being configured to extend through a corresponding hole formed in one of the plurality of plate alignment features, a corresponding hole formed in one of the plurality of seal alignment features, and a corresponding hole formed in one of the plurality of membrane alignment features.

15. The bipolar plate alignment system of claim 1, wherein: Each of the plurality of film alignment features is aligned with a corresponding one of the plurality of seal alignment features and a corresponding one of the plurality of plate alignment features.

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