Abstract: A method of making an electrically conductive element, particularly a bipolar plate for a fuel cell, comprises molding an element from a composite material comprising a polymer and an electrically conductive material to produce an element having a polymer-rich skin and removing at least a portion of the polymer-rich skin with a plasma.

Abstract: One embodiment disclosed includes a product comprising: a fuel cell component comprising a substrate and a first coating overlying the substrate, the coating comprising a compound comprising at least one Si—O group, at least one polar group and at least one group including a saturated or unsaturated carbon chain.

Abstract: A method of making a fuel cell component using a mask, which is removed after further processing to yield a surface with variable properties.

Abstract: A process comprising: depositing a coating on a fuel cell bipolar plate using plasma assisted chemical vapor deposition.

Abstract: An improved flowfield plate design and a process for fabricating such a plate is provided. In accordance with one embodiment of the present invention, a process of fabricating a bipolar plate is provided. The bipolar plate comprises a flowfield defined between opposite, electrically conductive sides of the bipolar plate. According to the process, a flowfield skeleton is provided. The flowfield skeleton comprises a sacrificial core overplated by a hydrogen permeation barrier layer. An electrically conductive polymeric composite material is molded about the flowfield skeleton to define the opposite sides of the bipolar plate. The molded polymeric composite material is cured such that the hydrogen permeation barrier layer adheres to the composite material and the sacrificial core melts away from the composite material and the barrier layer to define a flowfield cavity between the opposite sides of the bipolar plate.

Abstract: A flow field plate for a fuel cell that includes an outer layer of a metal oxide or other material that makes the plate hydrophilic. The particular metal oxide and the thickness of the metal oxide layer are selected so that hydrofluoric acid generated by the fuel cell continuously etches away the layer at a predetermined rate so that a surface of the layer is free of contaminants over the entire life of the fuel cell. If the fuel cell does not employ a perfluorosulfonic acid membrane, then a separate hydrofluoric acid source can be provided that injects a low level solution of hydrofluoric acid into one or both of the reactant gas streams.

Abstract: A flow field plate for a fuel cell that includes a metal oxide coating that makes the plate hydrophilic. In one embodiment, the metal oxide coating is a thin film to maintain the conductive properties of the flow field plate. The metal oxide can be combined with a conductive oxide. According to another embodiment, the metal oxide coating is deposited as islands on the flow field plate so that the flow field plate is exposed between the islands. According to another embodiment, lands between the flow channels are polished to remove the metal oxide layer and expose the flow field plate. According to another embodiment, the flow field plate is blasted with alumina so that embedded alumina particles and the roughened surface of the plate provide the hydrophilicity.