Manufacture of a fuel cell with liquid electrolyte migration prevention

1. A method of manufacturing a stack of liquid electrolyte fuel cells having a barrier configured to prevent migration of the liquid electrolyte between the fuel cells, the method comprising:

securing the barrier configured to prevent migration of the liquid electrolyte between the fuel cells to a land region of a separator plate assembly of at least one of the fuel cells, wherein the land region extends from an edge of the separator plate assembly toward an adjacent flow channel defined within the separator plate assembly;

securing the barrier adjacent the land region so that a first portion of the barrier extends across at least a portion of the land region and a second portion of the barrier extends outwardly and away from the edge of the separator plate assembly, wherein the first portion of the barrier directly contacts the electrode; and

securing the separator plate assembly adjacent an electrode of the at least one of the fuel cells so that the flow channel is adjacent the electrode and the second portion of the barrier extends outwardly and beyond an edge of the electrode that is aligned with the edge of the separator plate assembly.

2. A method according to claim 1 , wherein the barrier comprises a hydrophobic film which extends away from the edge of the separator plate assembly between about 0.051 and about 2.0 millimeters (about 2 and about 80 mils).

3. A method according to claim 1 , wherein the barrier comprises a hydrophobic film which is between about 0.05 mm and 0.127 mm (about 2 mils and about 5 mils) thick.

4. A method according to claim 1 , wherein the barrier comprises a hydrophobic polymer film that is distinct from the material of the separator plate assembly.

5. A method according to claim 4 , wherein said hydrophobic polymer film is selected from polytetrafluroethylene, fluorinated ethylene propylene and polyfluoroaloxy copolymer resin.

6. A method according to claim 1 , comprising

defining a step within the land region of the separator plate assembly; and

securing the first portion of the barrier within the step and wherein the step and the first portion of the barrier extend all of a distance between the edge of the separator plate assembly and the flow channel.

7. A method according to claim 1 , comprising

defining a step within the land region of the separator plate assembly; and

securing the first portion of the barrier within the step and wherein the step and the first portion of the barrier extend only a portion of a distance between the edge of the separator plate assembly and the flow channel.

8. A method according to claim 1 , comprising bonding the barrier to a step formed in the land region.

9. A method according to claim 8 , comprising bonding the barrier to the step with a fluoroelastomer.

10. A method according to claim 9 , wherein the fluoroelastomer has a fluorine content greater than about 68% by weight.

11. A method according to claim 8 , comprising bonding the barrier to the step during the manufacturing process, prior to assembly of fuel cells into the stack.

12. A method according to claim 1 , comprising bonding the first portion of the barrier to a section of the land region in situ within the stack during initial heating up of the stack.

13. A method according to claim 1 , wherein the barrier comprises a hydrophobic polymer film coated with pressure sensitive adhesive on a surface of the polymer film.

14. A method according to claim 13 , wherein the pressure sensitive adhesive is selected from an acrylic adhesive and a silicone adhesive.

15. A method according to claim 1 , comprising securing a second barrier to a second land region of the separator plate assembly, the second barrier extending from a second edge of the assembly all or a portion of a distance between the second edge and a second flow channel, said second barrier configured to extend away from the second edge of the separator plate assembly in a direction away from the second flow channel.

16. A method according to claim 1 , comprising securing a barrier of hydrophobic polymer film to the land region while compressing the hydrophobic polymer film toward the adjacent land region.

17. A method according to claim 16 , comprising compressing the hydrophobic polymer film toward the adjacent land region by an axial force of at least 345 kPa (50 psi).

18. A method according to claim 1 , wherein the land region includes a step having a depth that is about equal to a thickness of the barrier.

19. A method according to claim 18 , wherein the depth is between about 80% and about 120% of the thickness of the barrier.

20. A method according to claim 1 , comprising aligning the edge of the electrode and the edge of the separator plate assembly to be coplanar.

21. A method of making a stack of liquid electrolyte fuel cells having a barrier configured to prevent migration of the liquid electrolyte between the fuel cells, the method comprising:

situating a plurality of fuel cells adjacent each other, the fuel cells respectively having electrodes;

situating a separator plate between one of the electrodes of one of the fuel cells and an adjacent one of the electrodes of an adjacent one of the fuel cells, the separator plate having outside edges aligned with outside edges of the electrodes; and

securing the barrier configured to prevent migration of the liquid electrolyte between the fuel cells to a land region of the separator plate, the barrier comprising at least one piece of material that is distinct from the material of the separator plate assembly, the barrier having a first portion that extends across at least a portion of the land region and a second portion that extends outwardly beyond and away from the edge of the separator plate, wherein the first portion of the barrier directly contacts at least the portion of the land region and the one of the electrodes of the one of the fuel cells.

22. The method of claim 21 , wherein the first portion of the barrier is received against at least the portion of the land region and the one of the electrodes of the one of the fuel cells.

23. The method of claim 1 , wherein the first portion of the barrier is received against the electrode.