Bulk metallic glass interconnect for high power density fuel cell

A fuel cell layer of a multi-layer fuel cell, comprising:

• a cathode;
• an anode;
• an electrolyte disposed between the anode and the cathode;
• a support layer disposed at the anode opposite the electrolyte;
• a separator plate disposed at the support layer opposite the anode, the separator plate configured to contact the cathode of an adjacent fuel cell layer, the separator plate defining a plurality of anode flow channels configured to deliver a fuel therethrough and a plurality of cathode flow channels configured to deliver an air flow therethrough;
• wherein the separator plate is formed from a bulk metallic glass material;
• wherein the plurality of anode flow channels at least partially overlap the plurality of cathode flow channels in the stacking axis direction of the plurality of fuel cell layers;
• wherein the separator plate includes a plurality of curved portions separated by flat support portions, with the support portions interfacing with the support layer and curved portions contacting the cathode of the adjacent fuel cell layer, each curved portion including a first curved surface and a second curved surface spaced apart from the first curved surface along the stacking axis.

A method of assembling a multi-layer fuel cell, comprising:

• assembling a plurality of fuel cell layers, each fuel cell layer including:
• a cathode;
• an anode;
• an electrolyte disposed between the anode and the cathode;
• a support layer disposed at the anode opposite the electrolyte;
• a separator plate disposed at the support layer opposite the anode, the separator plate configured to contact the cathode of an adjacent fuel cell layer, the separator plate defining a plurality of anode flow channels configured to deliver a fuel therethrough and a plurality of cathode flow channels configured to deliver an air flow therethrough;
• wherein the separator plate is formed from a bulk metallic glass material;
• wherein the plurality of anode flow channels at least partially overlap and the plurality of cathode flow channels in the stacking axis direction of the plurality of fuel cell layers;
• arranging the plurality of fuel cell layers along a stacking axis;
• heating the separator plate to a temperature greater than a glass transition temperature of the bulk metallic glass material;
• applying a compressive load to the plurality of fuel cell layers;
• and
• allowing the bulk metallic glass material to thermoplastically flow thereby increasing a contact area of the separator plate to the cathode of the adjacent fuel cell layer;
• wherein the separator plate includes a plurality of curved portions separated by flat support portions, with the support portions interfacing with the support layer and curved portions contacting the cathode of the adjacent fuel cell layer, each curved portion including a first curved surface and a second curved surface spaced apart from the first curved surface along the stacking axis.