FORMED PLATE ASSEMBLY FOR PEM FUEL CELL

1 . A bipolar plate assembly for a fuel cell, comprising:

a unipolar cathode plate; and

a unipolar anode plate joined with the cathode plate, wherein at least one of the cathode plate and the anode plate is formed having a first thickness of a low electrical resistance, high corrosion resistance material by a vapor deposition process.

2 . The bipolar plate assembly of claim 1 , wherein the low electrical resistance, high corrosion resistance material is a high nickel content alloy.

3 . The bipolar plate assembly of claim 2 , wherein the high nickel content alloy contains at least fifty percent nickel.

4 . The bipolar plate assembly of claim 3 , wherein the high nickel content alloy contains at least eighty percent nickel.

5 . The bipolar plate assembly of claim 1 , wherein the low electrical resistance, high corrosion resistance material is carbon.

6 . The bipolar plate assembly of claim 1 , wherein at least a portion of an active area of the anode plate matingly engages at least a portion of an active area of the cathode plate to provide electrical conductivity therebetween.

7 . The bipolar plate assembly of claim 1 , wherein the first thickness is between 5 and 100 microns.

8 . The bipolar plate assembly of claim 1 , wherein a first perimeter of the cathode plate is integrally joined with a second perimeter of the anode plate to form a substantially hermetic seal therebetween.

9 . The bipolar plate assembly of claim 1 , wherein at least one of the anode plate and the cathode plate is entirely formed of the first thickness.

10 . The bipolar plate assembly of claim 1 , wherein the first thickness includes a first layer of low contact resistance, high corrosion resistance material forming a reactant interface and a second layer of low contact resistant, high corrosion resistance material forming a coolant surface.

11 . The bipolar plate assembly of claim 10 , wherein the first thickness further includes a support layer between the first and second layers.

12 . The bipolar plate assembly of claim 11 , wherein the first and second layers are formed of a high nickel content alloy.

13 . A fuel cell stack comprising:

a plurality of membrane electrode assemblies arranged in a stacked configuration, each of the plurality of membrane electrode assemblies having a cathode and an anode; and

a bipolar plate assembly disposed between adjacent membrane electrode assemblies, the bipolar plate assembly including a unipolar cathode plate joined to a unipolar anode plate, wherein at least one of the cathode plate and the anode plate is formed having a first thickness of a low electrical resistance, high corrosion resistance material by a vapor deposition process.

14 . The fuel cell stack of claim 13 , wherein at least a portion of an active area of the anode plate matingly engages at least a portion of an active area of the cathode plate to provide electrical conductivity therebetween.

15 . The bipolar plate assembly of claim 13 , wherein the first thickness is between 5 and 100 microns.

16 . The fuel cell stack of claim 13 , wherein a first perimeter of the cathode plate is joined with a second perimeter of the anode plate to form a substantially hermetic seal therebetween.

17 . The bipolar plate assembly of claim 16 , wherein the substantially hermetic seal is formed by one of welding, laser welding, brazing and soldering.

18 . A method for producing a bipolar plate assembly for a fuel cell stack, the method comprising the steps of:

providing a first substrate surface external surface corresponding to a desired cathode plate flow field pattern;

providing a second substrate external surface corresponding to a desired anode plate flow field pattern;

applying a first predetermined thickness of a low contact resistance, high corrosion resistance material to the first and second external surfaces with a vapor deposition process to form a cathode plate on the first external surface and an anode plate on the second external surface;

removing the substrate; and

joining a first perimeter of the cathode plate with a second perimeter of the anode plate to form a substantially hermetic seal therebetween.

19 . The method of claim 18 , wherein the first predetermined thickness is between about 10 and 100 micrometers.

20 . The method of claim 18 , further comprising the step of:

assembling the cathode plate to the anode plate prior to the joining step so that at least a portion of an active area of the anode plate matingly engages at least a portion of an active area of the cathode plate to provide electrical conductivity therebetween.