Fuel cell having a modular base active area

1. A method of manufacturing a fuel cell, the method comprising:

calculating a total active area for the fuel cell based on a specification for an application, wherein the specification includes at least one of a fuel cell voltage, a fuel cell current, a fuel cell weight, and a fuel cell volume;

selecting a base active area, wherein the base active area is configured for co-planar arrangement along a single axis;

providing a membrane electrode assembly having the total active area, wherein the total active area comprises a multiple of the base active areas arranged co-planar along at least a single axis; and

placing a pair of bipolar plates adjacent to both sides of the membrane electrode assembly, wherein each bipolar plate is comprised of sections and each section includes common passages, and the number of sections is equal to the number of base active areas forming the total active area of the membrane electrode assembly,

wherein, the total active area comprising the base active areas arranged co-planar in a x-y plane along an x-axis; and

wherein common passages comprise:

at least one first feed passage and at least one second feed passage per base active area;

at least one first discharge passage and at least one second discharge passage per base active area; and

at least one first coolant passage and at least one second coolant passage.

2. The method of manufacturing of claim 1 , wherein a height measured along a y-axis of the total active area is equal to height measured along the y-axis of the base active areas; and

a length measured along the x-axis of the total active area is equal to a multiple of a length measured along the x-axis of base active areas.

3. The method of manufacturing of claim 1 , further comprising at least one tie rod passage, wherein the number of tie rod passages is a multiple of a total number the base active areas forming the total active area.

4. The method of manufacturing of claim 1 , wherein the feed passages and discharge passages are distributed along an upper and lower border region extending along the x-axis of each bipolar plate, and the coolant passages are distributed evenly along a left and a right border region extending along the y-axis of each bipolar plate.

5. The method of manufacturing of claim 1 , wherein the feed passages are sized to supply sufficient quantities of gaseous reactant and discharge passages are sized to discharge sufficient quantities of reactant products to and from the base active area of the membrane electrode assembly to allow for efficient fuel cell performance.

6. The method of manufacturing of claim 1 , wherein each bipolar plate further comprises:

two side sections and at least one inner section;

wherein each of the side sections and the at least one inner section delimits a portion of the total active area substantially equal to one of the base active areas; and

wherein each of the sides sections and the inner section includes a separate first feed passage, second feed passage, first discharge passage, and second discharge passage.

7. The method of manufacturing of claim 6 , wherein each side section is a mirror reflection of the other side section and comprises at least one feed passage, at least one discharge passage, and at least one tie rod passage.

8. The method of manufacturing of claim 7 , wherein each inner section comprises at least one feed passage, at least one discharge passage, and a portion of a tie rod passage.

9. The method of manufacturing of claim 8 , wherein the portion of a tie rod passage is aligned with another portion of a tie rod passage that is part of an adjacent section to form a complete tie rod passage.

10. The method of manufacturing of claim 6 , wherein the total number of the side sections and the at least one inner sections that form each of the bipolar plates is equal to the number of base active areas combined to form the total active area.

11. The method of manufacturing of claim 6 , wherein the side sections and at least one inner section are configured for co-planar attachment parallel to the x-y plane and extending along the x-axis.

12. The method of manufacturing of claim 1 , wherein the fuel cell stack is configured to be compressed by an external compression system.

13. The method of manufacturing of claim 1 , wherein the base active areas arranged co-planar in the x-y plane along an x-axis for a continuous total active area.