Electrochemical fuel cell comprised of a series of conductive compression gaskets and method of manufacture

1. An electrochemical fuel cell stack comprising at least one fuel cell assembly, wherein said fuel cell assembly comprises:

A. An anode separator comprising at least one fuel inlet and at least one means for fuel distribution from said fuel inlet to the anode;

B. A cathode separator comprising at least one oxidant inlet and at least one means for oxidant distribution from said oxidant inlet to the cathode;

C. A heat transfer separator interposed between said anode and cathode separators comprising at least one heat transfer fluid inlet, at least one means for heat transfer fluid distribution from said heat transfer fluid inlet to a heat transfer zone within the heat transfer separator, at least one heat transfer fluid outlet and at least one means for beat transfer fluid distribution from said heat transfer zone to said heat transfer fluid outlet; and

D. A membrane electrode assembly comprising a proton exchange membrane interposed between said anode and said cathode, said membrane electrode assembly interposed between said anode separator and said cathode separator; wherein said anode, catnode, and heat transfer separators each comprise a specific series of electrically conductive compression gaskets possessing inter-related fluid distribution channel and manifold features that, once said separators are consolidated, compose said fluid manifolding and means of distribution.

2. The electrochemical fuel cell stack of claim 1 , wherein the mode of embodiment of said fuel cell assembly further comprises countercurrent heat transfer separators to enable countercurrent heat transfer fluid flow within said fuel cell stack.

3. The electrochemical fuel cell stack of claim 1 , wherein said fuel cell assembly further comprises a chemically benign structural frame, either externally situated on the distal face(s) of a given fuel cell separator or internally situated within a given fuel cell separator.

4. The electrochemical fuel cell stack of claim 3 , wherein said chemically benign structural frame is comprised of ester and polyester resins.

5. The electrochemical fuel cell stack of claim 1 , wherein said fuel cell assembly further comprises an electrically conductive mesh to prevent the displacement of the membrane into said fluid manifolding and distribution means.

6. The electrochemical fuel cell stack of claim 1 , wherein said conductive compression gaskets are comprised of a material selected from the group consisting of electrically conductive elastomers, electrically conductive elastomer media, electrically conductive compressive thermoplastic media, graphite, expanded graphite, exfoliated graphite and flexible graphite.

7. The electrochemical fuel cell stack of claim 1 , wherein said fuel cell assembly additionally comprises a chemically benign sealant.

8. The electrochemical fuel cell stack of claim 7 , wherein said sealant is a water-based polymer emulsion.

9. The electrochemical fuel cell stack of claim 7 , wherein said sealant diffuses and coalesces with the conductive compression gasket material to augment sealing.

10. The electrochemical fuel cell stack of claim 1 , wherein said fuel cell assembly further comprises a load-activated polymer sealant.

11. The electrochemical fuel cell stack of claim 10 , wherein said load-activated polymer sealant further comprises a thermoplastic component enabling a thermal cycle that facilitates repeated sealing of said fuel cell assembly components.

12. The electrochemical fuel cell stack of claim 10 , wherein said load-activated polymer sealant is applied to said electrically conductive compression gaskets by a process which comprises a step involving either hand spraying, mechanical spraying, automated spraying, dipping, screen printing, or dry-laminating.

13. The electrochemical fuel cell of claim 1 , wherein said electrochemical fuel cell is manufactured by a process comprising the step of forming said electrically conductive compression gaskets from electrically conductive compressive material by means of cutting, shearing, punching, ablating, male-female die cutting, and/or stamping.

14. The process of claim 13 , wherein said step of forming said gaskets further comprises imparting features into said gaskets, wherein said features are for the purpose of providing fluid distribution through said gaskets.

15. The electrochemical fuel cell of claim 1 , wherein said electrochemical fuel cell is manufactured by a process which comprises the steps of:

A. treating said electrically conductive compression gaskets with a chemically benign sealant, by means of a process that may be executed by such methods as hand spraying, mechanical spraying, automated spraying, dipping, screen printing or dry-laminating;

B. collating said electrically conductive compression gaskets into said specific series intended to embody the desired fuel cell separator by means of a process that may be executed by such methods as hand sorting, mechanical sorting or automated sorting; and

C. sealing said sealant-treated electrically conductive compression gaskets together into a fuel cell separator by means of thermal compression.

16. The electrochemical fuel cell of claim 3 , wherein said electrochemical fuel cell is manufactured by a process comprising the step of treating said chemically benign structural frame with a load-activated polymer sealant.

17. The electrochemical fuel cell of claim 1 , wherein said electrochemical fuel cell is manufactured by a process comprising the step of compressing said electrically conductive compression gaskets under a mechanical load into a state wherein said electrically conductive compression gaskets effect a fuel cell separator that maintains sufficient structural integrity, electrical and thermal conductivity, material obduracy, and fluid impermeability.

18. The electrochemical fuel cell of claim 1 , wherein said electrochemical fuel cell is designed in part by obviating a critical region of lateral load transmission of a given species of electrically conductive compression gasket material, whereby the fuel cell separator and fuel cell stack demonstrate sufficient structural integrity, electrical and thermal conductivity, material obduracy, and fluid impermeability.