PCT No. PCT / US95 / 13325 Sec. 371 Date Sep. 28, 1997 Sec. 102(e) Date Sep. 28, 1997 PCT Filed Oct. 10, 1995 PCT Pub. No. WO96 / 12316 PCT Pub. Date Apr. 25, 1996Fuel
cell stacks comprising stacked separator /
membrane electrode assembly fuel cells in which the separators comprise a series of
thin sheet platelets, having individually configured serpentine micro-channel reactant gas humidification active areas and cooling fields therein. The individual platelets are stacked with coordinate features aligned in contact with adjacent platelets and bonded to form a monolithic separator. Post-bonding
processing includes
passivation, such as
nitriding. Preferred
platelet material is 4-25 mil Ti, in which the features, serpentine channels, tabs, lands, vias, manifolds and holes, are formed by chemical and
laser etching,
cutting, pressing or
embossing, with combinations of depth and through
etching preferred. The
platelet manufacturing process is continuous and fast. By employing CAD based
platelet design and
photolithography, rapid change in
feature design can accommodate a wide range of thermal management and humidification techniques. One hundred H2-O2 / PEM fuel
cell stacks of this IFMT platelet design will exhibit outputs on the order of 0.75 kW / kg, some 3-6 times greater than the current
graphite plate PEM stacks.