Bipolar plate fabrication

A method for making a current collector plate comprising:

• placing an anti-bonding material onto a first surface of a first sheet of material thereby forming a work area defined by said anti-bonding material and an adjacent non-work area;
• contacting a second sheet of material with said anti-bonding material;
• forming a metallurgical bond between said first and second sheets at said non-work area thereby creating a two-piece bonded plate;
• placing said two-piece bonded plate into a die having a pattern defining at least one flow channel;
• and
• introducing fluid between said two-piece bonded plate to cause at least one of said first and second sheets to project into said die pattern at said work area causing a flow channel to be formed by said pattern of said die.

A method for making a current collector plate comprising:

• providing a first sheet of conductive material;
• providing a second sheet of conductive material;
• placing an anti-bonding material in a desired region over a bonding surface of said first sheet of conductive material, said region of anti-bonding material defining an anti-bonding region along said first sheet, wherein the remaining surface of said bonding surface absent said anti-bonding material defines a bonding area;
• contacting said second sheet of conductive material with said anti-bonding material of said first sheet of conductive material;
• roll bonding said first and second sheets together whereby said first and second sheets form a metallurgical bond therebetween at said bonding area;
• placing said bonded sheets into a die having a pattern defining at least one flow channel;
• and
• injecting fluid between said first and second bonded sheets whereby said anti-bonding area is expanded outwardly into said die pattern thereby forming a flow channel along said desired region.