Integrated plate and cell sealing

1. A bipolar plate assembly comprising:

a first frame member including a first side and a second side, the first side having a first side protuberance;

a second frame member including a first side and a second side, the second side having a second side recess;

a bipolar plate including an anode plate and a cathode plate, a portion of the anode plate and a portion of the cathode plate disposed between the first frame member and the second frame member;

a membrane electrode assembly including a proton exchange membrane disposed between an anode catalyst layer and a cathode catalyst layer, the membrane electrode assembly disposed adjacent one of the anode plate and the cathode plate of the bipolar plate;

wherein the first side protuberance of the first frame member deforms the portion of the anode plate and the portion of the cathode plate into the second side recess of the second frame member, thereby forming a seal therebetween.

2. The bipolar plate assembly of claim 1 , wherein the first frame member includes a second side recess and the second frame member includes a first side protuberance.

3. The bipolar plate assembly of claim 2 , wherein the first frame member includes a first side recess and the second frame member includes a second side protuberance.

4. The bipolar plate assembly of claim 3 , wherein the first frame member includes a second side protuberance and the second frame member includes a first side recess.

5. The bipolar plate assembly of claim 4 , wherein the first frame member and the second frame member have substantially a same structure.

6. The bipolar plate assembly of claim 1 , wherein

the first frame member includes a first side recess;

the second frame member includes second side protuberance; and

wherein the second side protuberance of the second frame member deforms the portion of the anode plate and the portion of the cathode plate into the first side recess of the first frame member, thereby forming another seal therebetween.

7. The bipolar plate assembly of claim 1 , wherein the first frame member and the second frame member comprise plastic and are electrically nonconductive.

8. The bipolar plate assembly of claim 1 , wherein the first side protuberance of the first frame member is deformed in forming the seal.

9. The bipolar plate assembly of claim 1 , wherein the first side protuberance of the first frame member has one of a substantially trigonal cross-section and a substantially frustoconical cross-section.

10. The bipolar plate assembly of claim 1 , wherein each of the first frame member and the second frame member includes:

a plurality of edges, each edge substantially congruent with an edge of the bipolar plate assembly;

an anode header;

a cathode header; and

a coolant header.

11. The bipolar plate assembly of claim 1 , wherein each of the first frame member and the second frame member is substantially congruent with a perimeter of the bipolar plate assembly, substantially circumscribes the membrane electrode assembly, and the anode catalyst layer and the cathode catalyst layer are disposed within an open interior portion thereof.

12. The bipolar plate assembly of claim 1 , wherein:

the portion of the anode plate and the portion of the cathode plate disposed between the first frame member and the second frame member are at an edge of the bipolar plate assembly;

a portion of the proton exchange membrane is disposed between the first frame member and the second frame member at the edge of the bipolar plate assembly; and

the first side protuberance of the first frame member contacts and deforms the portion of the proton exchange membrane, which contacts and deforms the portion of the anode plate, which contacts and deforms the portion of the cathode plate into the second side recess of the second frame member, thereby forming the seal therebetween.

13. The bipolar plate assembly of claim 12 , wherein:

wherein the first frame member includes a second side protuberance and a third frame member includes a first side recess; and

the second side protuberance of the first frame member contacts and deforms a portion of a second cathode plate, which contacts and deforms a portion of a second anode plate into the first side recess of the third frame member, thereby forming a seal therebetween.

14. The bipolar plate assembly of claim 1 , wherein:

the portion of the anode plate and the portion of the cathode plate disposed between the first frame member and the second frame member are at an anode header of the bipolar plate assembly;

the first side protuberance of the first frame member contacts and deforms the portion of the anode plate, which contacts and deforms the portion of the cathode plate into the second side recess of the second frame member, thereby forming the seal therebetween; and

the first frame member including an anode channel fluidly coupling the anode header and an anode flow field positioned between the anode plate and the anode catalyst layer.

15. The bipolar plate assembly of claim 14 , wherein:

a portion of the proton exchange membrane is disposed between the first frame member and a third frame member at the anode header of the bipolar plate assembly;

wherein the first frame member includes a second side protuberance and a third frame member includes a first side recess; and

the second side protuberance of the first frame member contacts and deforms the portion of the proton exchange membrane, which contacts and deforms a portion of a second cathode plate, which contacts and deforms a portion of a second anode plate into the first side recess of the third frame member, thereby forming a seal therebetween.

16. The bipolar plate assembly of claim 1 , wherein:

the portion of the anode plate and the portion of the cathode plate disposed between the first frame member and the second frame member are at a cathode header of the bipolar plate assembly;

a portion of the proton exchange membrane is disposed between the first frame member and the second frame member at the cathode header of the bipolar plate assembly;

the first side protuberance of the first frame member contacts and deforms the portion of the proton exchange membrane, which contacts and deforms the portion of the anode plate, which contacts and deforms the portion of the cathode plate into the second side recess of the second frame member, thereby forming the seal therebetween; and

the first frame member including a cathode channel fluidly coupling the cathode header and a cathode flow field positioned between the cathode plate and the cathode catalyst layer.

17. The bipolar plate assembly of claim 16 , wherein:

the first frame member includes a second side protuberance and a third frame member includes a first side recess;

the second side protuberance of the first frame member contacts and deforms a portion of a second cathode plate, which contacts and deforms a portion of a second anode plate into the first side recess of the third frame member, thereby forming a seal therebetween.

18. The bipolar plate assembly of claim 1 , wherein:

the portion of the anode plate and the portion of the cathode plate disposed between the first frame member and the second frame member are at a coolant header of the bipolar plate assembly;

a portion of the proton exchange membrane is disposed between the first frame member and the second frame member at the coolant header of the bipolar plate assembly;

the first side protuberance of the first frame member contacts and deforms the portion of the cathode plate, which contacts and deforms the portion of the proton exchange membrane, which contacts and deforms the portion of the anode plate into the second side recess of the second frame member, thereby forming the seal therebetween;

the first frame member including a first coolant channel fluidly coupling the coolant header and a first coolant flow field, the first coolant flow field in thermal communication with the cathode plate; and

the second frame member including a second coolant channel fluidly coupling the coolant header and a second coolant flow field, the second coolant flow field in thermal communication with the anode plate.

19. A bipolar plate assembly comprising:

a first frame member including a first side and a second side, the first side having a first side protuberance and a first side recess;

a second frame member including a first side and a second side, the second side having a second side recess and a second side protuberance;

a bipolar plate including an anode plate and a cathode plate, a portion of the cathode plate disposed between the first frame member and the second frame member;

a membrane electrode assembly including a proton exchange membrane disposed between an anode catalyst layer and a cathode catalyst layer, the membrane electrode assembly disposed adjacent one of the anode plate and the cathode plate of the bipolar plate, a portion of the proton exchange membrane disposed between the first frame member and the second frame member,

wherein the first side protuberance of the first frame member contacts and deforms the portion of the proton exchange membrane, which contacts and deforms the portion of the cathode plate into the second side recess of the second frame member, thereby forming a seal therebetween,

wherein the second side protuberance of the second frame member contacts and deforms the portion of the cathode plate, which contacts and deforms the portion of the proton exchange membrane into the first side recess of the first frame member, thereby forming the another seal therebetween, and

wherein the first frame member includes a fluid channel fluidly coupling an fluid header and an fluid flow field positioned between one of the anode plate and the cathode plate and one of the anode catalyst layer and the cathode catalyst layer, wherein the cathode plate includes an aperture between the seal and the another seal that cooperates with the cathode channel in fluidly coupling the cathode header and the cathode flow field.

20. A method of assembling a bipolar plate assembly, the method comprising:

providing a bipolar plate assembly according to claim 1 ; and

deforming the portion of the anode plate and the portion of the cathode plate into the second side recess of the second frame member with the first side protuberance of the first frame member, thereby forming the seal therebetween.