Raised feed channels to maintain planar bipolar plate alignment

A fuel cell assembly comprising:

• a plurality of bipolar plates that are generally rectangular and planar, stacked relative to each other, and each including at least one seal arranged on an inlet of the bipolar plate, the at least one seal being in contact with at least one seal of an adjacent bipolar plate;
• and
• a diffusion-electrode assembly including a membrane electrode and two gas diffusion layers surrounding the membrane electrode, the diffusion-electrode assembly arranged between adjacent bipolar plates of the plurality of bipolar plates, the membrane electrode including an electrode body and a membrane frame extending away from the electrode body,
• wherein each bipolar plate of the plurality of bipolar plates further includes a raised feed channel spaced apart from at least one seal of the at least one seal and adjacent to the inlet, the raised feed channel protruding away from the bipolar plate in a direction that the at least one seal protrudes away from the bipolar plate, wherein fluid enters the raised feed channel and subsequently flows along channels formed in the bipolar plate in order to engage with one of the two gas diffusion layers, and
• wherein the plurality of bipolar plates are stacked such that the membrane frame is located between adjacent raised feed channels and such that each of the raised feed channels contacts the membrane frame so as to prevent mechanical deformations of the plurality of bipolar plates.

A method of forming a fuel cell, comprising:

• providing a plurality of bipolar plates that are generally rectangular and planar, each bipolar plate including (i) a first outer seal protruding downwardly away from the plate, a first inner seal protruding upwardly away from the plate, and a first raised feed channel protruding upwardly away from the plate, the first outer seal, the first inner seal, and the first raised feed channel arranged on an inlet of the bipolar plate, and (ii) a second inner seal protruding downwardly away from the plate, a second outer seal protruding upwardly away from the plate, and a second raised feed channel protruding downwardly away from the plate, the second outer seal, the second inner seal, and the second raised feed channel arranged on an outlet of the bipolar plate, the inlet being located in a first corner of the plate and the outlet being located in a second corner of the plate diagonally opposite of the first corner;
• providing at least one diffusion-electrode assembly including a membrane electrode and two gas diffusion layers surrounding the membrane electrode, the membrane electrode including an electrode body and a membrane frame extending away from the electrode body;
• arranging a first bipolar plate of the plurality of bipolar plates in a first position;
• arranging a first diffusion-electrode assembly of the at least one diffusion-electrode assembly above the first bipolar plate such that one of the two gas diffusion layers is engaged with the first bipolar plate;
• arranging a second bipolar plate of the plurality of bipolar plates above the first diffusion-electrode assembly such that the other of the two gas diffusion layers is engaged with the second bipolar plate, wherein the second bipolar plate is arranged on the first diffusion-electrode assembly rotated 180 degrees clockwise or counterclockwise relative to the first bipolar plate about a central axis that extends through a central point of the rectangular plate and that is perpendicular to the plate such that the second outer seal, the second inner seal, and the second raised feed channel of the second bipolar plate are aligned with the first outer seal, the first inner seal, and the first raised feed channel of the first bipolar plate, respectively,
• wherein the membrane frame is located between the first and the second raised feed channels such that the first and the second raised feed channels contact the membrane frame so as to prevent mechanical deformations of the first and second bipolar plate.