Preventing migration of liquid electrolyte out of a fuel cell

1. A stack of fuel cells for generating electrical current from streams of hydrogen-containing reducing fluid and oxygen-containing oxidant reactant, comprising:

a plurality of cathode electrodes;

a plurality of anode electrodes;

a plurality of matrix plates holding a liquid acid electrolyte, each matrix plate being between one of the cathode electrodes and one of the anode electrodes;

a plurality of separator plate assemblies, each separator plate assembly having a separator plate secured in contact with and between one of the cathode electrodes and one of the anode electrodes, each separator plate defining a first flow field adjacent a first contact surface of the separator plate, the first flow field including at least one first flow channel extending inwardly from the first contact surface of the separator plate, the first flow channel being configured to direct a corresponding one of the streams adjacent a selected one of the electrodes, each separator plate having outside edges that are perpendicular to the first contact surface, the outside edges of the separator plates being aligned with outside edges of the cathode electrodes and outside edges of the anode electrodes, each separator plate comprising a land region extending along the first contact surface between the at least one first flow channel and an adjacent one of the edges of the separator plate, the land region extending parallel to the at least one flow channel; and

an acid migration barrier to inhibit acid migration, the barrier comprising a film that is distinct from the material of the separator plate, the barrier being secured to the land region of the separator plate and extending away from and outwardly beyond the adjacent one of the outside edges of the separator plate and the outside edge of an adjacent one of the electrodes in a direction away from the at least one first flow channel,

wherein each matrix plate is between the one of the cathode electrodes and the one of the anode electrodes without any acid migration barrier between the matrix plate and said electrodes.

2. A stack of fuel cells according to claim 1 , wherein the barrier extends away from the adjacent one of the outside edges between about 0.051 mm and about 2.0 mm (about 2 mils and about 80 mils).

3. A stack of fuel cells according to claim 1 , wherein the barrier has a thickness between about 0.051 mm and about 0.127 mm (about 2 and 5 mils).

4. A stack of fuel cells according to claim 1 , wherein the barrier is a hydrophobic polymer film.

5. A stack of fuel cells according to claim 4 , wherein the barrier comprises at least one of polytetrafluroethylene, fluorinated ethylene propylene and polyfluoroaloxy co-polymer resin.

6. A stack of fuel cells according to claim 1 , wherein

a step is defined within the land region; and

the barrier is secured to the step.

7. A stack of fuel cells according to claim 6 , wherein a depth of the step inwardly of the first contact surface is about equal to a thickness of the barrier.

8. A stack of fuel cells according to claim 6 , wherein the step and the barrier extend all of the distance of the land region between the adjacent one of the edges and the at least one flow channel.

9. A stack of fuel cells according to claim 6 , wherein the step and the barrier extend only a portion of a distance between the adjacent one of the edges and the at least one flow channel.

10. A stack of fuel cells according to claim 1 , wherein the land region is flush with the contact surface.

11. A stack of fuel cells according to claim 1 , wherein the land region is recessed beneath the contact surface.

12. A stack of fuel cells according to claim 1 , wherein the film of the barrier is bonded to the land region.

13. A stack of fuel cells according to claim 12 , comprising a fluoroelastomer bonding the film to the land region.

14. A stack of fuel cells according to claim 13 , wherein the fluoroelastomer has a fluorine content greater than about 68% by weight.

15. A stack of fuel cells according to claim 1 , wherein

the barrier has a first thickness;

the adjacent one of the edges has a second thickness; and

the second thickness is greater than the first thickness.

16. A stack of fuel cells according to claim 1 , comprising a plurality of the barriers and wherein the plurality of barriers are secured only to land regions adjacent ones of said flow channels which direct the oxygen-containing oxidant reactant.

17. A stack of fuel cells according to claim 1 , comprising a plurality of the barriers and wherein the plurality of barriers are secured only to land regions adjacent ones of said flow channels which direct the hydrogen-containing reducing fluid.

18. A stack of fuel cells according to claim 1 , wherein the plurality of barriers are secured only in land regions adjacent edges of said separator plates through which the oxygen-containing oxidant reactant enters the at least one flow channel.

19. A stack of fuel cells according to claim 1 , comprising a plurality of barriers and wherein the plurality of barriers are secured to land regions adjacent edges of said separator plates through which the oxygen-containing oxidant reactant enters the at least one flow channel, and to land regions adjacent edges of said separator plates through which the oxygen-containing oxidant reactant exits the at least one flow channel.

20. A stack of fuel cells according to claim 1 wherein

each separator plate comprises a second flow field adjacent a second contact surface opposite from said first contact surface and adjacent one of said electrodes other than the selected electrode, the second flow field including at least one second flow channel extending inwardly from the second contact surface;

a second land region extending along the second contact surface between the at least one second flow channel and a second adjacent one of the edges of the separator plate, and extending parallel to the at least one second flow channel; and

a second barrier to acid migration, the second barrier comprising a second film that is distinct from the separator plate, the second film being secured to the second land region of the separator plate and extending away and outwardly from the second adjacent one of the edges of the separator plate in a direction away from the second flow channel.

21. A stack of fuel cells according to claim 1 , wherein the outside edges of the electrodes and the outside edges of the separator plates are generally coplanar.

22. A method comprising:

prohibiting migration of a liquid acid electrolyte between a plurality of fuel cells in a stack using a plurality of acid migration barriers to inhibit acid migration, the fuel cells including a cathode electrode and an anode electrode secured adjacent opposed planar surfaces of a matrix for holding some of the liquid acid electrolyte, the stack including a plurality of separator plate assemblies respectively secured in contact with the cathode electrode of one of the cells and the anode electrode of an adjacent cell, the separator plate assemblies respectively defining a first flow field adjacent a first contact surface of the separator plate assembly, the first flow field including at least one flow channel extending inwardly from the first contact surface to direct a reactant stream adjacent a selected one of the electrodes, a land region extending along the first contact surface between the at least one flow channel and an adjacent edge of the separator plate assembly, the land region extending parallel to the at least one flow channel;

the acid migration barriers respectively being secured partially against the land region and partially extending away from and outwardly beyond the adjacent edge of the separator plate assembly and a laterally outside edge of an adjacent one of the electrodes

there is no acid migration barrier between any one of the matrix plates and the cathode electrode secured adjacent the planar surface of the matrix; and

there is no acid migration barrier between any one of the matrix plates and the anode secured adjacent the planar surface of the matrix.

23. A method according to claim 22 , wherein the barriers respectively extend away from the adjacent edge of the separator plate between about 0.127 mm and about 2.0 mm (about 2 mils and about 80 mils).

24. A method according to claim 22 , wherein the barriers respectively comprise a film that is between about 0.051 mm and 0.127 mm (about 2 mils and about 5 mils).

25. A method according to claim 22 , wherein

a step within the land region extends from the adjacent edge all or a portion of a distance between the adjacent edge and the flow channel; and

the barriers are respectively secured partially within the step.

26. A method according to claim 25 , wherein the step has a depth that is about equal to a thickness of the barrier.

27. A method according to claim 22 , wherein each barrier comprises a hydrophobic polymer film distinct from a material of the separator plate.

28. A method according to claim 27 , wherein said polymer film is selected from polytetrafluroethylene, fluorinated ethylene propylene and polyfluoroaloxy copolymer resin.

29. A method according to claim 22 , wherein the barrier is bonded to a step within the land region.

30. A method according to claim 29 , wherein the barrier is bonded to the step with a fluoroelastomer.

31. A method according to claim 30 , wherein the fluoroelastomer has a fluorine content greater than about 68% by weight.

32. A method according to claim 22 , wherein

each separator plate assembly defines a second flow field adjacent a second contact surface opposite from said first contact surface, the second flow field including at least one second flow channel extending inwardly from the second contact surface to direct another one of the reactant streams adjacent one of said electrodes other than the selected electrode;

a second step within a second land region extends from a second adjacent edge all or a portion of a distance between the second adjacent edge and the second flow channel; and

respective ones of the barriers to acid migration are secured within the second step and extend away from and outward of the second adjacent edge of the separator plate assembly in a direction away from the second flow channel.

33. A method according to claim 22 , wherein said liquid acid electrolyte is selected from phosphoric acid and fluoroborate acid.

34. A stack of fuel cells according to claim 1 , wherein said matrices contain a liquid acid electrolyte selected from phosphoric acid and fluoroborate acid.