Manufacturing/assembly of a fuel distributor assembly

1. A fuel distributor assembly for a fuel cell stack, the fuel cell stack including a plurality of fuel cells, the fuel distributor comprising:

an outer shell comprising a sheet, the sheet curved to define a central longitudinal chamber, a first longitudinal edge and a second longitudinal edge, the outer shell having an inner wall surface and an outer wall surface, the first longitudinal edge and the second longitudinal edge defining a longitudinal slot, the first longitudinal edge being bent inwardly towards the longitudinal chamber to form a longitudinal lip; and

an inner shell positioned within the outer shell, the inner shell including a plurality of ribs extending outwardly and contacting the inner wall surface of the outer shell wherein the inner shell, the outer shell, the lip, and the ribs define a plurality of flow channels, the inner shell having a length along which a plurality of apertures are positioned in a partial helical pattern, the inner shell receiving fuel that is provided to the plurality of apertures such that fuel flows within the flow channels and emerges from the slot.

2. The fuel distributor of claim 1 wherein the inner shell is formed from a first shell section and a second shell section, the first shell section attaching to the second shell section to form the inner shell.

3. The fuel distributor of claim 2 wherein the first shell section and the second shell section combine together to form a first seal on a first end of the fuel distributor.

4. The fuel distributor of claim 3 wherein the first shell section includes a first sealing section having O-ring grooves therein and the second shell section includes a second sealing section such that the first sealing section is positioned within the second sealing section to form a second seal on a second end of the fuel distributor.

5. The fuel distributor of claim 3 wherein the first shell section includes a post at a first shell section end and the second shell section defines an opening at a second shell section end, the post being positioned within the opening.

6. The fuel distributor of claim 3 wherein the first shell section has a first edge detail and the second shell section has a second edge detail, the first edge detail mating with the second edge detail when the first shell section is attached to the second shell section.

7. The fuel distributor of claim 6 wherein the first edge detail includes edge protrusions and edge slots and the second edge detail includes edge protrusions and edge slots.

8. The fuel distributor of claim 1 wherein each rib of the plurality of ribs partially extend around the inner shell having a first rib end and a second rib end such that the lip is positioned proximate to the first rib end.

9. The fuel distributor of claim 1 wherein the inner shell has a plurality of notches and the outer shell has a plurality of grooves, the plurality of notches mating with the plurality of grooves when the inner shell is positioned within the outer shell.

10. The fuel distributor of claim 1 wherein the inner shell and the outer shell are each independently plastic.

11. A fuel cell stack assembly comprising the fuel distributor assembly of claim 1 .

12. A fuel distributor assembly for a fuel cell stack, the fuel cell stack including a plurality of fuel cells, the fuel distributor comprising:

an outer shell comprising a sheet, the sheet curved to define a central longitudinal chamber, a first longitudinal edge and a second longitudinal edge, the outer shell having an inner wall surface and an outer wall surface, the first longitudinal edge and the second longitudinal edge defining a longitudinal slot, the first longitudinal edge being bent inwardly towards the longitudinal chamber to form a longitudinal lip; and

an inner shell positioned within the outer shell, the inner shell including a plurality of ribs, a first shell section and a second shell section, the ribs extending outwardly and contacting the inner wall surface of the outer shell, the first shell section attaching to the second shell section to form the inner shell, each rib partially extending around the inner shell and having a first rib end and a second rib end such that the lip is positioned proximate to the first rib end, the inner shell, the outer shell, the lip, and the ribs defining in combination a plurality of flow channels, the inner shell having a length along which a plurality of apertures are positioned in a partial helical pattern, the inner shell receiving fuel which is provided to the plurality of apertures such that fuel flows within the flow channels and emerges from the slot.

13. The fuel distributor of claim 12 wherein the first shell section and the second shell section combine together to form a seal on a wet end.

14. The fuel distributor of claim 13 wherein the first shell section includes a first hoop section and the second shell section includes a second hoop section such that the first hoop section is positioned within the second hoop section to form the seal.

15. The fuel distributor of claim 12 wherein the first shell section includes a first hoop section and the second shell section includes a second hoop section such that the first hoop section is positioned within the second hoop section to form the seal.

16. The fuel distributor of claim 12 wherein the first shell section has a first edge detail and the second shell section has a second edge detail, the first edge detail mating with the second edge detail when the first shell section is attached to the second shell section.

17. The fuel distributor of claim 16 wherein the first edge detail includes edge protrusions and edge slots and the second edge detail includes edge protrusions and edge slots.

18. A fuel cell stack assembly comprising the fuel distributor assembly of claim 12 .

19. A method of forming a fuel distributor, the method comprising:

extrusion molding a first plastic composition to form an outer shell, the outer shell comprising a sheet which defines a central longitudinal chamber, a first longitudinal edge and a second longitudinal edge, the outer shell having an inner wall surface and an outer wall surface, the first longitudinal edge and the second longitudinal edge defining a longitudinal slot, the first longitudinal edge being bent inwardly towards the longitudinal chamber to form a longitudinal lip; and

injection molding a second plastic composition to form a first shell section, the first shell section including a first plurality of rib sections extending outwardly from an outer surface of the first shell section;

injection molding a third plastic composition to form a second shell section, the second shell section including a second plurality of rib sections extending outwardly from an outer surface of the second shell section;

attaching the first shell section to the second shell section to form an inner shell wherein the first plurality of rib sections mate with the second plurality of rib sections to form a plurality of ribs, each rib partially extending around the inner shell and having a first rib end and a second rib end such that the lip is positioned proximate to the first rib end; and

placing the inner shell within the outer shell by sliding the outer shell over the inner shell, the inner shell, the outer shell, the lip, and the ribs defining in combination a plurality of flow channels, the inner shell having a length along which a plurality of apertures are positioned in a partial helical pattern, the inner shell receiving fuel which is provided to the plurality of apertures such that fuel flows within the flow channels and emerges from the slot.

20. The method of claim 19 wherein the inner shell includes a stop that sets relative positioning of the inner shell in the outer shell.