Insert-molded, externally manifolded, sealed membrane based electrochemical cell stacks

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

a) providing at least one fuel cell including:

i) a membrane electrode assembly;

ii) a reductant flow field disposed proximate a first side of the membrane electrode assembly, the reductant flow field including a reductant flow channel extending to a periphery of the fuel cell;

iii) an oxidant flow field disposed proximate a second side of the membrane electrode assembly, the oxidant flow field including an oxidant flow channel extending to the periphery of the fuel cell;

b) molding a plenum housing about the periphery of the fuel cell, the plenum housing at least partially defining:

i) a reductant manifold in fluid communication with the reductant flow channel, the reductant manifold and the reductant flow channel cooperating to form a reductant plenum; and

ii) an oxidant manifold in fluid communication with the oxidant flow channel, the oxidant manifold and the oxidant flow channel cooperating to form an oxidant plenum, wherein at least one of the reductant and oxidant manifolds includes a portion of sealant having a negative impression of a manifold insert defining a volume at least partially bounded by the sealant.

2. The method of claim 1 , wherein the fuel cell further includes a coolant plate in thermal communication with the membrane electrode assembly, the coolant plate including a coolant flow channel extending to the periphery of the fuel cell and the molding step includes forming a coolant manifold in fluid communication with the coolant flow channel, the coolant manifold and the coolant flow channel cooperating to form a coolant plenum.

3. The method of claim 2 , wherein the molding step defines an interior surface of at least one of the (i) oxidant manifold, (ii) reductant manifold and (iii) coolant manifold in cooperation with a portion of the periphery of the fuel cell.

4. The method of claim 3 , wherein the portion of the periphery of the fuel cell includes at least one of (i) an edge of the membrane electrode assembly and (ii) an edge of a plate.

5. The method of claim 1 , further comprising integrally forming the reductant flow field and oxidant flow field into a separator plate, the separator plate being chosen from the group consisting of (i) a bipolar plate and (ii) a cooling plate.

6. The method of claim 1 , wherein the reductant flow field includes a second reductant flow channel extending to a periphery of the fuel cell and the oxidant flow field includes a second oxidant flow channel extending to the periphery of the fuel cell and the molding step further includes:

a) forming a second reductant manifold in fluid communication with the second reductant flow channel, the second reductant manifold and the second reductant flow channel cooperating to form a second reductant plenum; and

b) forming a second oxidant manifold in fluid communication with the second oxidant flow channel, the second oxidant manifold and the second oxidant flow channel cooperating to form a second oxidant plenum.

7. The method of claim 2 , wherein the coolant plate includes a second coolant flow channel extending to the periphery of the fuel cell and the molding step further includes:

a) forming a second coolant manifold in fluid communication with the second coolant flow channel, the second coolant manifold and the second coolant flow channel cooperating to form a second coolant plenum.

8. The method of claim 1 , further comprising positioning a first end plate at a first end of the at least one fuel cell and positioning a second end plate at a second end of the at least one fuel cell.

9. The method of claim 8 , further comprising inserting at least one removable runner mold into at least one of the oxidant flow channel and reductant flow channel to prevent molding compound from entering the channel and to define a flow passage.

10. The method of claim 9 , further comprising molding material about the fuel cell and the runner mold to form the flow passage.

11. The method of claim 1 , further comprising positioning a mold against the fuel cell, the removable mold having a shape that defines the volume of at least one of the oxidant manifold and reductant manifold.

12. The method of claim 11 , further comprising molding material about the fuel cell and the mold.

13. The method of claim 5 , further comprising forming a contoured surface in the edge of each separator plate proximate a port of a flow channel at the periphery of the fuel cell, the contoured surface being adapted and configured to mate with a removable manifold mold.

14. The method of claim 13 , further comprising positioning a manifold mold against the contoured portion.

15. The method of claim 14 , further comprising molding material around the fuel cell and mold to define the manifold.

16. The method of claim 15 , further comprising removing the mold.

17. The method of claim 1 , further comprising integrally forming a tubular insert into the plenum housing proximate an end of one of the manifolds, the tubular insert being made from a material that is compatible with the material of the plenum housing, wherein the tubular insert forms a portion of a fluid flow path including the manifold to which it is attached.

18. The method of claim 17 , further comprising fitting an end plate of the fuel cell stack over the tubular insert such that the tubular insert protrudes through a port of the end plate of the fuel cell stack.

19. The method of claim 1 , wherein material introduced during the molding step is introduced by a technique selected from the group consisting of: (i) pressure assisted resin transfer, (ii) vacuum assisted resin transfer, (iii) injection molding, and combinations thereof.

20. The method of claim 19 , wherein the material is introduced under a pressure differential of between about +15 psi and about −15 psi.