ELECTRICAL CONNECTOR SYSTEMS AND METHODS FOR CONNECTING TO A FUEL CELL STACK

A connector system is provided for facilitating electrically connecting to a fuel cell stack. The connector system includes a receptacle within the fuel cell stack, a circuit board, and a connector electrically connected to and extending from the circuit board. The receptacle is configured to facilitate electrically connecting to the fuel cell stack, and the connector is receivable within the receptacle for electrically connecting the circuit board to the fuel cell stack. The connector is elastically deformable to facilitate operative positioning of the connector within the receptacle, and to facilitate an interference fit of the connector within the receptacle against a surface defining, at least in part, the receptacle to secure the connector within the receptacle, with the connector electrically connected to a fuel cell plate of the fuel cell stack.

TECHNICAL FIELD

The present invention relates, generally, to systems and methods for connecting to a fuel cell stack, and more particularly, to electrical connector systems and methods for connecting to a fuel cell stack, such as for monitoring one or more fuel cells of the fuel cell stack for variations in electrical output and functioning of the one or more fuel cells.

BACKGROUND

Fuel cells electrochemically convert fuels and oxidants to electricity and heat and can be categorized according to the type of electrolyte (e.g., solid oxide, molten carbonate, alkaline, phosphoric acid or solid polymer) used to accommodate ion transfer during operation. Moreover, fuel cell assemblies can be employed in many (e.g., automotive to aerospace to industrial to residential) environments, for multiple applications.

A Proton Exchange Membrane (hereinafter “PEM”) fuel cell converts the chemical energy of fuels, such as hydrogen, and oxidants, such as air, directly into electrical energy. The PEM is a sold polymer electrolyte that permits the passage of protons (i.e., H+ ions) from the “anode” side of the fuel cell to the “cathode” side of the fuel cell while preventing passage therethrough of reactant fluids (e.g., hydrogen and air gases). The Membrane Electrode Assembly (hereinafter “MEA”) is placed between two electrically conductive plates, each of which has a flow passage to direct the fuel to the anode side and oxidant to the cathode side of the PEM.

Two or more fuel cells may be connected together to increase the overall power output of the assembly. Generally, the cells are connected in series, wherein one side of a plate serves as an anode plate for one cell and the other side of the plate is the cathode plate for the adjacent cell. These are commonly referred to as bipolar plates (hereinafter “BPP”). Alternately, the anode plate of one cell is electrically connected to the separate cathode plate of an adjacent cell. Commonly these two plates are connected back to back and are often bonded together (e.g., bonded by adhesive, weld, or polymer). This bonded pair becomes as one, also commonly called a bipolar plate, since anode and cathode plates represent the positive and negative poles, electrically. Such a series of connected multiple fuel cells is referred to as a fuel cell stack. The stack typically includes means for directing the fuel and the oxidant to the anode and cathode flow field channels, respectively. The stack usually includes a means for directing a coolant fluid to interior channels within the stack to absorb heat generated by the exothermic reaction of hydrogen and oxygen within the fuel cells. The stack generally includes means for exhausting the excess fuel and oxidant gases, as well as product water.

The stack also includes an endplate, insulators, membrane electrode assemblies, gaskets, separator plates, electrical connectors and collector plates, among other components, that are integrated together to form the working stack designed to produce electricity. The different plates may be abutted against each other and connected to each other to facilitate the performance of particular functions.

As indicated, a fuel cell stack includes multiple connected fuel cells. Individual cell voltage monitoring is critical for system control and durability. For example, a cell with low performance can cause numerous failure mechanisms if undetected. Large stacks of fuel cells may sometimes include hundreds of cells, and cell voltage of such cells is currently detected with individual electrical wires where voltage signals are multiplexed through integrated circuits. Managing these separate electrical wires and their connections is tedious during an assembly of the multiple fuel cells into a fuel cell stack, and there are significant voltage differentials that must be managed inside the electronics. The assembly of this system of cell voltage monitors can significantly increase build time and cost of a fuel cell stack.

SUMMARY

The present invention provides, in one aspect, a connector system for facilitating electrically connecting to a fuel cell stack. The connector system includes a receptacle within the fuel cell stack, a circuit board, and a connector electrically connected to and extending from the circuit board. The receptacle is configured to facilitate electrically connecting to the fuel cell stack, and the connector is receivable within the receptacle for electrically connecting the circuit board to the fuel cell stack. The connector is elastically deformable to facilitate operative positioning of the connector within the receptacle, and facilitate an interference fit of the connector within the receptacle against a surface defining, at least in part, the receptacle to secure the connector within the receptacle, with the connector electrically connected to a fuel cell plate of the fuel cell stack.

The present invention provides, in another aspect, a method for electrically connecting to a fuel cell stack. The method includes obtaining the fuel cell stack, the fuel cell stack having a receptacle at an edge of the fuel cell stack configured to facilitate electrically connecting to the fuel cell stack. The method further includes providing a circuit board with a connector electrically connected to and extending from the circuit board. The connector is receivable within the receptacle for electrically connecting the circuit board to the fuel cell stack, and the connector is elastically deformable to facilitate operative positioning of the connector within the receptacle, and to facilitate an interference fit of the connector within the receptacle against a surface defining, at least in part, the receptacle. The method further includes operatively positioning the connector within the receptacle by elastically deforming the connector with insertion of the connector into the receptacle. The elastically deforming facilitates interference fitting of the connector within the receptacle against the surface defining, at least in part, the receptacle to secure the connector within the receptacle, with the connector electrically connected to the fuel cell plate of the fuel cell stack.

The present invention provides, in a further aspect, a fuel cell system which includes a fuel cell stack with a receptacle at an edge of the fuel cell stack, a circuit board, and a connector electrically connected to and extending from the circuit board. The receptacle is configured to facilitate electrically connecting to the fuel cell stack, and the connector is operatively positioned within the receptacle and secured in operative position via an interference fit of the connector within the receptacle against a surface defining, at least in part, the receptacle, with the connector electrically connected to a fuel cell plate of the fuel cell stack.

DETAILED DESCRIPTION

The accompanying figures, which are incorporated in and form a part of this specification, further illustrate the present invention and, together with this detailed description of the invention, serve to explain aspects of the present invention. Note in this regard that descriptions of well-known systems, processing techniques, etc., are omitted so as to not unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and this specific example(s), while indicating aspects of the invention, are given by way of illustration only, and not limitation. Various substitutions, modifications, additions, and/or other arrangements, within the spirit or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure. Note further that numerous inventive aspects or features are disclosed herein, and unless inconsistent, each disclosed aspect or feature is combinable with any other disclosed aspect or feature as desired for a particular application of the concepts disclosed.

The present invention is discussed herein in detail in terms of various exemplary embodiments with reference to the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without one or more of these specific details. In other instances, well-known structures are not shown in detail in order to avoid unnecessary obscuring of the present invention.

The implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations.

In accordance with principals of the present invention, fuel cell systems and methods for manufacturing a fuel cell stack are provided. In the example depicted inFIG.1, a fuel cell system101is referred to as the assembled, or complete, system which functionally together with the parts thereof produces electricity for powering a load60, and typically includes a fuel cell stack20and an energy storage device30. The fuel cell is supplied with a fuel13, for example, hydrogen, through a fuel inlet17. Excess fuel18can be exhausted from the fuel cell through a purge valve90and can be diluted by a fan40. In one example, fuel cell stack20can have an open cathode architecture of a PEM fuel cell, and combined oxidant and coolant, for example, air, may enter through an inlet air filter10coupled to an inlet5of fuel cell stack20. Excess coolant/oxidant16and heat can be exhausted from a fuel cell cathode of fuel cell stack20through an outlet11to fan40which can exhaust the coolant/oxidant and/or excess fuel to a waste exhaust41, such as the ambient atmosphere. In one embodiment, fuel cell system101can include a recirculation subassembly45, including a recirculation blower50(controlled by a system controller180), as well as a check valve61and a mixer70for controllably recirculating, at least in part, excess coolant/oxidant16to inlet5of fuel cell stack20. The fuel and coolant/oxidant can be supplied by a fuel supply7and an oxidant source9(e.g., air), respectively, and other components of a balance of plant, which may include compressors, pumps, valves, fans, electrical connections and sensors.

FIG.2depicts a schematic exploded view of an internal subassembly100of fuel cell stack20ofFIG.1including a cathodic plate separator110at an outer end115and a plate separator seal120on an inner side thereof. A membrane electrode assembly (MEA)130is located between seal120and a second plate separator seal150. An anode plate separator160is at a second end165of subassembly100.

MEA130includes a membrane140(e.g., an ion conducting membrane) between a cathode side catalyst layer125and an anode side catalyst layer135. A cathode side gas diffusion layer (GDL)122is located between cathode side catalyst layer125of the membrane electrode assembly and plate separator110. An anode side gas diffusion layer145is located between anode side catalyst layer135of the membrane electrode assembly and plate separator160. Seal120and seal150can be received in a channel on a respective inner side of plate separator110and plate separator160, respectively. In another example, such seals can be injection molded around an MEA (e.g., MEA130) or another fuel cell component.

In an example depicted inFIG.3, a voltage sensor300can be electrically connected to opposing bipolar plates, e.g., plate separator110and plate separator160of subassembly100of fuel cell stack20. In one embodiment, sensor300can be configured to detect and/or measure a voltage potential between plate separator110and plate separator160, between which plate separator seals120,150sandwich the membrane electrode assembly (MEA)130, which can reside within, or be encircled by, a sub-gasket301(in one embodiment).

A cell voltage monitoring pickup card or board can be used which includes multiple electrical and mechanical connectors to connect to various portions of a fuel cell stack (e.g., fuel cell stack20). Such connectors between the board(s) and plates can allow an electrical connection between the plates and sensor300, which can be connected to a data processor or controller310for measuring a voltage between the plates, for example.

In one or more embodiments, fuel cell plates (e.g., plate separator110and plate separator160) can include slots for receiving electrical connectors to allow a measurement of a voltage or potential between the fuel cell plates in a fuel cell stack (e.g., fuel cell stack20).FIGS.4-5depict one example where a connector200is being received in a receptacle210of plate separator110such that connector200makes an electrical connection with plate separator110, as shown in block diagram form from a side and cross-sectional top view, respectively, in the figures. Similarly, plate separator160(FIG.3) can have a receptacle (not shown) for receiving a second connector to allow voltage measurement between plate separator110and plate separator160. Receptacle210can include vertical/horizontal receptacle bounding surfaces211and212, and lateral recess bounding surfaces214and216. The portions of the plate separators bounding the recesses, and thus the electrical connectors (e.g., connector200), can be formed of, or otherwise include an electrically conductive material, such as copper, silver, stainless steel, nickel, or similar conductive material or alloy, which can be plated with an inert material, such as gold to prevent oxidation and corrosion.

Connector200can be formed of a stamped sheet metal (e.g., Copper, Nickel, Stainless Steel, Titanium, Monel, Inconel, or other alloys of such materials therein that are both conductive and inert whether through plating or passive formation of protection that does not impede electrical operation or solderability). Electrical contact may be made between a connector (e.g., connector200) and lateral and/or vertical bounding surfaces (e.g., lateral recess bounding surfaces214,216and/or vertical recess bounding surfaces211,212) of such a receptacle to allow a voltage measurement as described above.

As noted, a cell voltage monitoring pickup card or board can include multiple wires connected to multiple fuel cell plates to allow an electrical connection between the plates and a scanner card or device. The scanner card can be connected to a data processor, controller, or other computing device for measuring a voltage between the plates, for example.

In one or more embodiments, a cell voltage monitoring pickup board or card can include a plurality of wire loops extending away from the printed circuit board, such that the loops can contact fuel cell plates so that the voltage between the plates may be monitored. When connected to a fuel cell plate in operation, a pickup board can be exposed to a high humidity environment, along with being subject to shocks and vibrations if the fuel cell itself is used in a mobile application. Depending on the implementation, the shocks and vibrations could cause a disconnection of the pickup board relative to a fuel cell plate, thereby interrupting any monitoring (e.g., of cell voltages) that may be underway. Thus, it is useful for any connection between a fuel cell plate and pickup board to be resistant to separation. It is further advantageous if such a pickup board can be easily connected to the fuel cell plate for easy setup of the voltage monitoring.

FIGS.6A-6Gdepict a further embodiment of a connector, receptacle and electrical connector system, in accordance with one or more aspects of the present invention.

As illustrated inFIGS.6A-6B, in one or more implementations, a fuel cell plate601, such as fuel cell plates110,150, is provided with a receptacle600configured to facilitate electrical connection to the fuel cell plate. In one example, fuel cell plate601is a metallic bipolar plate. In the embodiment illustrated, receptacle600is a shaped-edge recess defined by one or more surfaces including, for instance, lower surface602, an upper surface (not shown), and a side surface603of the recess. Further, in the embodiment illustrated, receptacle600has a tapered middle region605, which facilitates securing of a connector610within receptacle600in operative position.

In one or more embodiments, connector610is sized and configured to facilitate electrically connecting a circuit board or pickup board (such as circuit board630ofFIGS.6D &6E) to the fuel cell stack, which includes fuel cell plate601. In one embodiment, connector610is elastically deformable to facilitate operative positioning the connector within receptacle600, and facilitate an interference fit of the connector within receptacle600against one or more surfaces defining, at least in part, the receptacle, to secure connector610within receptacle600, with connector610electrically connected to fuel cell plate601of the fuel cell stack. In one or more implementations, a connector (such as connector610formed as an elastically-deformable wire connector) and a receptacle (such as receptacle600) have advantages over other connection approaches or types because they allow for the electrical and mechanical engagement to occur internal to the fuel cell plate envelope, which decreases the exposed portion of the cell voltage pickup connector(s). This also advantageously maintains the overall envelope of the fuel cell stack and cell voltage monitor assembly more compact, and limits the risk to self-shorting within the fuel cell system by eliminating or reducing external connector features.

FIG.6Cdepicts further details of one embodiment of a plurality of receptacles600formed within fuel cell plates601of a fuel cell stack620. In one or more implementations, a fuel cell plate of the stack itself incorporates an edge recess or keyhole-type pocket feature, configured as receptacle600, which includes, as noted, a tapered middle region as illustrated inFIGS.6A-6C. The tapered middle region forms a narrowed section which opens to a wider section, and requires the elastically-deformable wire connector to deflect when being inserted, which provides a positive engagement of the connector to one or more internal surfaces defining receptacle600, such as lower surface602, the upper surface (not shown), and/or sidewall surface603ofFIGS.6A-6B. Note in this regard that additional engagement can be provided by incorporating a small, out-of-plane bend to the elastically-deformable wire connector. This is to make, in one or more embodiments, the connector (or pickup contact) taller than the height of the receptacle, thereby ensuring an interference fit with the lower surface and upper surface defining the receptacle.

In one or more implementations, the wire connectors, or wire-formed contacts, can be formed of an electrically conductive material, such as noted above in connection with connector200. In one specific example, connector600can be formed from BeCu wire. This wire material is commercially available, and can be plated as desired for a particular application. Advantageously, the wire connector allows for easy fabrication of connector designs via, for instance, computer numerical control (CNC) wire benders. The wire shape also allows for relatively easy integration with a circuit board, such as a printed circuit board, as illustrated inFIGS.6D-6F. Integrating a connector to a printed circuit board allows the individual contacts to be routed and collected at a common place, where the voltages can be taken to a common connector header640, disposed, for instance, on one side631of circuit board630, for easy wiring using, for instance, flex cables650(FIG.6F) over to a monitor device, such as a computer, other computing resource or data processor, electronic device, controller, etc.

As illustrated inFIGS.6D-6E, in one or more embodiments, connector610is a U-shaped wire connector, with one end612of the U-shaped wire connector being electrically coupled to circuit board630, and another end613of the U-shaped wire connector extending into and/or through a slot635in circuit board630to, for instance, facilitate operative positioning of the connector within receptacle600(FIGS.6A-6C) by allowing the connector to more readily elastically deform or collapse with operative positioning of the connector within the receptacle. In this manner, ends613of U-shaped wire connectors610are free to slide within the respective slots635, and thereby facilitate compression and operative positioning of the connector within the respective receptacles.FIG.6Dillustrates one example of ends613positioned closer to fixed ends612, as they might reside (in one embodiment) when the connectors are operatively positioned within the respective receptacles. InFIG.6E, a free-state position of ends613of connectors610is illustrated, such as when the connectors are withdrawn from the receptacles.

Note that in one or more embodiments, ends612of connectors610can each pass through or reside within a respective plated through-hole and can be, for instance, soldered to the plated through-hole to facilitate electrical connection of connector610to circuit board630, and in particular to, for instance, one or more conductive trace lines residing on or within circuit board630, to facilitate electrically connecting connectors610to connector header640. Note also that, slots635can be sized and shaped as desired to facilitate movement of slidable ends613of connectors610during operative positioning of the connectors within the respective receptacles. As illustrated inFIG.6C, an edge of fuel cell stack620can include multiple columns of receptacles600with, in one embodiment, the columns being offset and containing receptacles formed within every other fuel cell plate of the fuel cell stack. In this manner, each fuel cell plate can be contacted using a connector system, such as disclosed herein. As illustrated inFIG.6G, in one or more other implementations, receptacles600can be disposed on separate edges or sides of fuel cell plates601within the fuel cell stack.

As noted, in one or more embodiments, the circuit board can physically and electrically couple to the connector pickups via soldered connections on one end of one of the legs, with the other ends being free to slide within, for instance, respective slots in the board. This allows the free end to transition as a connector is being operatively inserted into a receptacle to lessen the force required to deflect the connectors when installing them, thereby decreasing the overall insertion force required. In one or more embodiments, the fuel cell plates themselves can incorporate the receptacles or pocket features on both ends of the plate(s), as illustrated inFIG.6G. As shown, the receptacles can be incorporated at different distances from the longer edges of the plates. In this manner, fuel cell stacks with two columns of receptacles can be constructed by rotating each plate 180 degrees from the previous. The result is that two columns of receptacle or pocket features are provided, which stagger from plate-to-plate, as shown inFIG.6C. In one or more embodiments, only every other cell pair within the fuel cell stack is monitored, in which case, only one column of the receptacles need be provided and populated with connectors. In essence, in one embodiment, this means that when a circuit board pickup assembly is installed, it will engage connectors coupled to monitor voltage for cells 1, 3, 5, etc. Depending on the implementation, if it is desirable to measure every cell voltage (e.g., cell 1, 2, 3, 4, etc.), then the same pickup board assemblies can be employed, rotated 180 degrees, to achieve the two offset columns of receptacles. For wiring conventions, mirrored assemblies can be produced so that, for instance, position1is always at the lowest potential, but this could be physically flipped and used on the other columns of pockets, if desired.

In one or more embodiments, the cell voltage monitor (CVM) and cell voltage connector system designs disclosed herein can be used with metal fuel cell plates that have finer cell pitch (that is, shorter distances between cells) than prior fuel cell plate designs, such as prior graphite plate designs. To accomplish this, the connectors and associated circuit boards have finer pitches, as well. Further, in a graphite plate design, the fuel cell plates essentially bottomed-out against each other when the stack was compressed in the build process. The finer metal plates do not, and are also more flexible. Thus, the cell pitch is not as repeatable at this stage. Pickup boards, or circuit boards, are advantageously used in the connector system to facilitate mounting or locating multiple connectors to be placed in operative position within the respective receptacles. This allows for signals to be routed to a common connector header, eliminating the need for many individual wires along the edge or side of the fuel cell stack. Rather, the circuit board and connector head configurations disclosed allow the use of multi-conductor cables, or flex cables. As noted, depending on the implementation, voltage at every fuel cell, or less than all the fuel cells, can be monitored using a connector system and method such as disclosed.

FIGS.7A-7Ddepict another embodiment of a connector system for facilitating electrically connecting to a fuel cell stack, in accordance with one or more aspects of the present invention. Referring collectively toFIGS.7A-7D, the connector system includes, in one or more implementations, receptacles or recesses700within the fuel cell stack620′, with the receptacles being configured to facilitate electrically connecting to the fuel cell stack via respective detent structures701formed as part of, or electrically connected to, the fuel cell plates of the fuel cell stack. In this implementation, rather than the receptacles being fully-formed pockets, receptacles700are defined as spaces or recesses into which the connectors (or pickup contacts) can be inserted. In the embodiment depicted, two connection arms711,712extend outward from connector710. The connection arms711,712are elastically deformable or spring-biased to allow for deflection of the arms inward, to facilitate positioning of the arms about detent structures701within the respective receptacle700. Once the arms are positioned in place, the arms are released and spring back outward to engage the detent structures formed in the respective fuel cell plate pair.

In the embodiment ofFIGS.7A-7D, connector710is a wire connector that is electrically and mechanically connected to circuit board630by, for instance, passing a portion thereof through a respective opening or slot in the circuit board, and soldering the connector to the circuit board for, for instance, electrical contact of the connector to a respective conductive trace line of the board. As illustrated, first arm711includes a first end713configured to engage a first detent structure701within receptacle700with operative positioning of the connector within the receptacle, and second arm712includes a second end714configured to engage a second detent structure701within receptacle700with operative positioning of connector710within receptacle700. In the embodiment illustrated, and by way of example only, the first and second ends713,714of first and second arms711,712, respectively, are each hook-shaped ends sized and shaped to at least partially loop around the respective detent structures701within receptacle700to facilitate electrically connecting connector710to detent structures701within receptacle700, and thereby electrically connect connector710to the respective fuel cell plate(s) of the fuel cell stack620′.

As with the embodiment ofFIGS.6A-6G, circuit board630includes one or more conductive trace lines residing on or within the circuit board to facilitate electrically connecting connector710to connector header640. In this manner, individual connector contacts can be routed and collected at a common place, where the voltages can be taken to a common connector header640disposed, for instance, on one side of circuit board630, for facilitating wiring using, for instance, one or more flex or ribbon cables for connection to a monitor device, such as a computer, computing resource, data processor, electronic device, controller, etc.

Note also that, in one or more implementations, connectors710are wire connectors, or wire-formed contacts, formed of an elastically-deformable, electrically conductive material, such as noted above with respect to connector610ofFIGS.6A-6G. In one specific example, connector710can be formed with a spring-biasing to facilitate outward pressing of arms711,712with operative positioning of connector710within receptacle700about detent structure(s)701. Note that the embodiment ofFIGS.7A-7Dpotentially consumes less space on the fuel cell plate itself, and is flexible with various iterations of different detent structures that can be used with the fuel cell plates and/or fuel cell stack. As in the embodiment discussed above with respect toFIGS.6A-6G, in one implementation, the cell voltage monitor (CVM) can be configured to measure every other cell voltage. In the embodiment illustrated, connectors can be staggered into columns, as with the connection system embodiment ofFIGS.6A-6G, if every fuel cell plate is to be sampled.

FIGS.8A-8Ddepict another embodiment of a connector system for facilitating electrically connecting to a fuel cell stack, in accordance with one or more aspects of the present invention. Referring collectively toFIGS.8A-8D, the connector system includes, in one or more implementations, recesses or receptacles800within the fuel cell stack620″, with the receptacles being configured to facilitate electrically connecting to the fuel cell stack via respective detent structures801(e.g., dimples) formed as part of, or electrically connected to, the fuel cell plates of the fuel cell stack (in one embodiment). In this implementation, receptacles800can be fully-formed pockets or recesses within the fuel cell stack into which the connectors (or pickup contacts) can be inserted. In the embodiment depicted, connectors810are electrically conductive plates or slabs with an opening811positioned and sized to receive a respective detent structure801within receptacle800with operative positioning of connector810within receptacle800, and thereby facilitate an interference-fit of connector810within receptacle800to secure connector810within receptacle800electrically connected to the fuel cell plate601of the fuel cell stack620″.

In the embodiment ofFIGS.8A-8D, connector810is a rectangular-shaped conductive pickup structure, such as a flat, spade-like contact, with an opening or slot configured to engage with the detent structure (or dimple) within the receptacle to facilitate providing proper location and engagement of features. Note that alternatively, the fuel cell plate can incorporate the opening or slot, and the pickup connector can incorporate the detent structure or dimple, as in the embodiment ofFIGS.9A-9Ddescribed below.

In one or more embodiments, connector810is bendable or elastically deformable to facilitate operative positioning of the connector within the receptacle, and to facilitate an interference-fit of the connector within the receptacle with the detent structure801residing, at least partially, within opening811to secure the connector within the receptacle, with the connector electrically connected to the fuel cell plate of the fuel cell stack.

Connector810is electrically and mechanically coupled to circuit board630by, for instance, passing a portion thereof through a respective opening or slot in the circuit board, and soldering the connector to the circuit board for, for instance, electrical contact of the connector to a respective conductive trace line of the board. In this manner, the circuit board630facilitates electrically connecting connector810to a connector header640, such as described above in connection withFIGS.6A-7D. Note also that, in this manner, individual connector contacts are routed to and collected at a common place, where the voltage can be taken to a common connector header640disposed, for instance, on one side of the circuit board, for facilitating wiring using, for instance, one or more flex or ribbon cables for connection to a monitor or control device, such as a computer, computing resource, data processor, electronic device, controller, etc.

Note also that, in one or more implementations, connectors810are electrically conductive plate-type connectors formed of an elastically-deformable, electrically conductive material, such as noted above with respect to the connectors ofFIGS.6A-7D. In one specific example, connector810can be sized and formed to allow flexing of the connector as it engages with respective detent structure(s)801within receptacle800. Note that the embodiment ofFIGS.8A-8Dutilize formed geometry (e.g., one or more detent structures, such as one or more dimples) on the fuel cell plate, in one or more embodiments, to facilitate establishing the electrical connection. As illustrated inFIG.8A, the formed geometry or detent structures can align in a column when the anode and cathode plates are joined to form bipolar fuel cell plates of the fuel cell stack. This formed dimple approach can potentially require less area on the plate, which can be significant in facilitating increasing the active-to-inactive plate area ratio of the fuel cell stack.

FIGS.9A-9Ddepict a further embodiment of a connector system for facilitating electrically connecting to a fuel cell stack, in accordance with one or more aspects of the present invention. The connector system ofFIGS.9A-9Dis a variation on the connector system ofFIGS.8A-8Ddescribed above.

Referring collectively toFIGS.9A-9D, the connector system includes, in one or more implementations, recesses or receptacles900within the fuel cell stack620″, with the receptacles being configured to facilitate electrically connecting to the fuel cell stack. In this implementation, receptacles900can be fully-formed pockets or recesses within the fuel cell stack into which the connectors (or pickup contacts) can be inserted. In the embodiment depicted, connectors910are electrically conductive plates or slabs with respective detent structures911positioned and sized to extend into, or reside within, an opening901in a surface of the respective receptacle900with operatively positioning of connector910within receptacle900, and thereby facilitate an interference-fit of connector910within receptacle900to secure connector910within receptacle900electrically connected to the fuel cell plate601of the fuel cell stack620″.

In the embodiment ofFIGS.9A-9D, connector910is a substantially rectangular-shaped conductive pickup structure, such as a flat, spade-like contact, with a detent structure sized and located to engage with an opening or slot within a wall of the receptacle to facilitate providing proper locating and engagement of features with insertion of the connector into the receptacle.

In one or more embodiments, connector910is bendable or elastically deformable to facilitate operative positioning of the connector within the receptacle, and to facilitate an interference-fit of the connector within the receptacle with the detent structure911residing, at least partially, within opening901to secure the connector within the receptacle, with the connector electrically connected to the fuel cell plate of the fuel cell stack.

In one embodiment, connector910is electrically and mechanically coupled to circuit board630by, for instance, passing a portion thereof through a respective opening or slot in the circuit board, and soldering the connector to the circuit board for, for instance, electrical contact of the connector to a respective conductive trace line of the board. In this manner, circuit board630facilitates electrically connecting connector910to a connector header640, such as described above in connection withFIGS.6A-7D. Note also that, in this manner, individual connector contacts are routed to and collected at a common place, where the voltage can be taken to a common connector header640disposed, for instance, on one side of the circuit board, for facilitating wiring using, for instance, one or more flex or ribbon cables for connection to a monitor or control device, such as a computer, computing resource, data processor, electronic device, controller, etc.

Note also that, in one or more implementations, connectors910are electrically conductive plate-type connectors formed of an elastically-deformable, electrically conductive material, such as noted above with respect to the connectors ofFIGS.6A-8D. In one specific example, connector910can be sized and formed to allow flexing of the connector as it is operatively inserted within the receptacle900to engage with the respective wall opening901within receptacle900. Note that the embodiment ofFIGS.9A-9Dutilize formed geometry (e.g., one or more detent structures, such as one or more dimples) on the connectors to facilitate establishing the electrical connections. This is one example only of the detect structure that can be used. As illustrated inFIG.9A, the formed geometry or detent structures can align in a column when the connectors are operatively positioned within the receptacles. This formed dimple approach can thus potentially require less area on the plate, which can be significant in facilitating increasing the active-to-inactive plate area ratio of the fuel cell stack.