Method of manufacturing a fuel cell stack

A method for assembling a fuel cell stack, the method comprising the steps of:

• providing a batch of fuel cells, each fuel cell in the batch of fuel cells having an active area thickness and a tolerance for the active area thickness;
• measuring an active area thickness for each fuel cell in the batch of fuel cells and sorting each fuel cell into one of a first group, a second group, and a third group;
• assembling a first plurality of fuel cells from any one of the first, second and third groups onto a first end plate until at least one of the first, second and third groups is depleted;
• assembling a second plurality of fuel cells to the first plurality of fuel cells until a target number of fuel cells is achieved, the second plurality of fuel cells being formed from any one of the first, second and third groups of fuel cells;
• and
• affixing a second end plate to the first plurality of fuel cells and the first end plate thereby creating a fuel cell stack.

A method for assembling a fuel cell stack, the method comprising the steps of:

• providing a batch of fuel cells, each fuel cell in the batch of fuel cells having an active area thickness and a tolerance for the active thickness;
• measuring an active area thickness for each fuel cell in the batch of fuel cells and sorting each fuel cell into one of a first group, a second group, and a third group;
• randomly assembling a first plurality of fuel cells from any one or more of the first, second and third groups onto a first end plate until at least 50 percent of a target fuel cell number is achieved;
• selectively assembling a second plurality of fuel cells to the first plurality of fuel cells until 100 percent of the target number of fuel cells is achieved and a target height is achieved, the second plurality of fuel cells being formed from one or more fuel cells from each the first, second and third groups of fuel cells;
• and
• affixing a second end plate to the first plurality of fuel cells and the first end plate thereby creating a fuel cell stack.