Patent ID: 7378177

Claim:
A bipolar plate for an eleetrochemical cell, comprising: a first layer having a first plurality of through-hole channels oriented in a first direction; a second layer having a second plurality of through-hole channels oriented in a second different direction; a third layer disposed between, in direct contact with, and bonded to the first and second layers, the third layer having a first set of through-hole header channels in fluid communication with the first plurality of channels, and a second set of through-hole header channels in fluid communication with the second plurality of channels; a first inlet port and a first outlet port in fluid communication with the first set of header channels; a second inlet port and a second outlet port in fluid communication with the second set of header channels; wherein the first layer and third layer are metallurgically bonded together to define a first bond line that encompasses the first plurality of channels, the first inlet port and the first outlet port; wherein the first bond line is defined by a first metallic seal disposed between the first layer and the third layer, the first metallic seal comprising material from the first layer and the third layer, the first bond line having a first portion that extends partially around the perimeter of the first plurality of channels, a second portion that extends partially around the perimeter of the first inlet port and a third portion that extends partially around the perimeter of the first outlet port, the first portion of the first bond line being integral with the second and third portions of the first bond line; wherein the second layer and third layer are metallurgically bonded together to define a second bond line that encompasses the second plurality of channels, the second inlet port and the second outlet port; wherein the second bond line is defined by a second metallic seal disposed between the second layer and the third layer, the second metallic seal comprising material for the second layer and the third layer; the second bond line having a first portion that extends partially around the perimeter of the second plurality of channels, a second portion that extends partially around the perimeter of the second inlet port and a third portion that extends partially around the perimeter of the second outlet port, the first portion of the second bond line being integral with the second and third portions of the second bond line; wherein each of the first, second and third layers have distinguishable through-hole channels with respect to each other; wherein the first metallic seal and the second metallic seal are disposed and configured to prevent fluid communication between the first plurality of channels and the second plurality of channels.