Form-in-place fastening for fuel cell assemblies

A method of assembling a fuel cell sub-assembly, comprising:

• providing a first flow field plate comprising a plurality of fastener apertures defined at a plurality of fastening locations;
• providing a second flow field plate comprising a plurality of fastener apertures defined at a plurality of fastening locations;
• providing a membrane electrode assembly situated between the first and second flow field plates and comprising a plurality of fastener apertures defined at a plurality of fastening locations;
• aligning the plurality of fastener apertures of the membrane electrode assembly and the first and second flow field plates to define fastening holes;
• and
• flowing a pre-elastomeric material into the fastening holes to form form-in-place fasteners therein.

A method of accommodating compression within a fuel cell sub-assembly, comprising:

• providing a first flow field plate comprising a plurality of fastener apertures defined at a plurality of fastening locations;
• providing a second flow field plate comprising a plurality of fastener apertures defined at a plurality of fastening locations;
• providing a membrane electrode assembly situated between the first and second flow field plates and comprising a plurality of fastener apertures defined at a plurality of fastening locations, the plurality of fastener apertures of the membrane electrode assembly and the first and second flow field plates defining fastening holes;
• providing a form-in-place fastener comprising an elastomeric material disposed in each of the fastening holes;
• placing the fuel cell sub-assembly in compression;
• and
• accommodating compressive strain by the form-in-place fasteners in response to placing the fuel cell sub-assembly in compression.

A fuel cell sub-assembly, comprising:

• a first flow field plate comprising a plurality of fastener apertures defined at a plurality of fastening locations;
• a second flow field plate comprising a plurality of fastener apertures defined at a plurality of fastening locations;
• a membrane electrode assembly situated between the first and second flow field plates and comprising a plurality of fastener apertures defined at a plurality of fastening locations, the plurality of fastener apertures of the membrane electrode assembly and the first and second flow field plates defining fastening holes;
• and
• means, disposed within the fastening holes, for elastically accommodating compressive strain responsive to placing the fuel cell sub-assembly in compression.