Fluid flow plate for a fuel cell

1. A bipolar plate for an electrochemical fuel cell assembly, comprising:

a first corrugated plate having a plurality of first fluid flow channels extending thereacross between first inlet and outlet ports;

A second corrugated plate having a second plurality of fluid flow channels extending thereacross between second inlet and outlet ports;

a first gasket forming a fluid seal around a periphery of the first and second corrugated plates;

first inlet and outlet ports and forming the first inlet and outlet manifolds,

a third plurality of fluid flow channels extending between third inlet and outlet ports at opposing ends of the assembled bipolar plate, the third plurality of fluid flow channels provided between first and second corrugated plates, respectively;

the first inlet and outlet manifolds each comprising an open array of raised features formed in the first gasket configured to provide a defined separation between the bipolar plate and an adjacent layer while allowing flow of fluid between the first inlet and outlet ports and the first plurality of fluid flow channels; and

the first inlet and outlet manifolds minimize a pressure difference across the flow of fluid and maximize areas of the inlet and outlet ports which are non-nested;

wherein the first, second and third channels are coplanar;

wherein adjacent pairs of the first plurality of fluid flow channels are connected at opposing ends of the bipolar plate to form a single serpentine fluid flow path extending across the first face of the bipolar plate between the first inlet and outlet ports;

wherein each adjacent pair of the first plurality of fluid flow channels are connected by one of a plurality of transverse connecting regions extending between adjacent corrugations in the first corrugated plate, with each of the transverse connection regions having a depth less than the depth of the adjacent pair of first plurality of fluid flow channels.

2. The bipolar plate of claim 1 wherein the first and second corrugated plates are engaged with each other such that selected corrugations in the first plate lie within corresponding corrugations in the second plate.

3. The bipolar plate of claim 2 wherein the third plurality of fluid flow channels are formed between the first and second corrugated plates by omission of selected corrugations in the first or second plate.

4. The bipolar plate of claim 2 wherein the third plurality of fluid flow channels are formed between the first and second corrugated plates by narrowing of selected corrugations in the first or second plate.

5. The bipolar plate of claim 2 wherein the third plurality of fluid flow channels are formed between the first and second corrugated plates by a height reduction of selected corrugations in the first or second plate.

6. The bipolar plate of claim 1 wherein the second fluid flow channels form an array of interdigitated fluid flow channels.

7. The bipolar plate of claim 6 wherein the second face comprises barriers formed in the second corrugated plate at opposing ends of the interdigitated fluid flow channels, each barrier configured to form a fluid seal between an adjacent longitudinal fluid flow channel and an adjacent one of the second inlet and outlet ports.

8. The bipolar plate of claim 1 comprising second inlet and outlet manifolds across the second face of the bipolar plate and providing respective fluid connections between the second inlet and outlet ports and the second plurality of fluid flow channels.

9. The bipolar plate of claim 8 comprising a second gasket forming a fluid seal around a periphery of the second face of the bipolar plate and the second inlet and outlet ports and comprising the second inlet and outlet manifolds.

10. The bipolar plate of claim 9 wherein the second inlet and outlet manifolds each comprise an open array of raised features formed in the second gasket.

11. The bipolar plate of claim 8 wherein the first and second inlet and outlet manifolds at least partially overlap one another.

12. The bipolar plate of claim 8 comprising third inlet and outlet manifolds between the first and second corrugated plates and providing respective fluid connections between the third inlet and outlet ports and the third plurality of fluid flow channels.

13. The bipolar plate of claim 12 comprising a third gasket forming a fluid seal around a periphery of the bipolar plate between the first and second corrugated plates and around the third inlet and outlet ports and comprising the third inlet and outlet manifolds.

14. The bipolar plate of claim 13 wherein the third inlet and outlet manifolds each comprise an open array of raised features formed in the third gasket.

15. The bipolar plate of claim 12 wherein the first, second and third inlet and outlet manifolds at least partially overlap one another.

16. The bipolar plate of claim 15 wherein the first, second and third inlet and outlet manifolds entirely overlap one another.

17. The bipolar plate of claim 7 , wherein each of the barriers in the second corrugated plate is bonded to a corresponding transverse connecting region in the first corrugated plate.