Patent ID: 7914947

Claim:
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.