Abstract: A microseal for a metal bead seal joint includes a substantially horizontal surface, first and second substantially vertical surfaces disposed on opposite ends of the substantially horizontal surface, and a contoured surface operatively configured to adhere to a portion of a metal bead. The contoured surface may be disposed opposite the substantially horizontal surface and may be integral to the first and second substantially vertical surfaces. The substantially horizontal surface may be operatively configured to substantially maintain its horizontal surface orientation in both a compression state and a non-compression state.

Abstract: An electrode conductive filler precursor dispersion is provided that includes a conductive carbon-based particle selected from the group consisting of: graphene nanoplatelet (GNP), carbon nanofibers (CNF), carbon nanotubes (CNT), and combinations thereof. A stabilizing polymer comprising polyvinyl-4-pyridine (PVPy). The dispersion also includes a solvent. The electrode conductive filler precursor dispersion is substantially free of syneresis for greater than or equal to about 7 days. Methods of making the electrode conductive filler precursor dispersion and electrodes from the electrode conductive filler precursor dispersion are also provided.

Abstract: A microseal for a metal bead seal joint includes a substantially horizontal surface, first and second substantially vertical surfaces disposed on opposite ends of the substantially horizontal surface, and a contoured surface operatively configured to adhere to a portion of a metal bead. The contoured surface may be disposed opposite the substantially horizontal surface and may be integral to the first and second substantially vertical surfaces. The substantially horizontal surface may be operatively configured to substantially maintain its horizontal surface orientation in both a compression state and a non-compression state.

Abstract: A composition with latent adhesion, fuel cell stack with a bipolar plate assembly with latent adhesion and a method of assembling a fuel cell stack with a seal that has latent adhesion such that reactant or coolant leakage through the seal is reduced. Bipolar plates within the stack include reactant channels and coolant channels that are fluidly coupled to inlet and outlet flowpaths, all of which are formed within a coolant-engaging or reactant-engaging surface of the plate. One or more thin or low aspect-ratio seals are formed on a metal bead that is integrally formed on a surface of the plate and is used to help reduce leakage by maintaining fluid isolation of the reactants and coolant as they flow through their respective channels and flowpaths that are defined between adjacently placed plates.

Abstract: A fuel cell stack with a bipolar plate assembly and a method of assembling a fuel cell stack such that reactant or coolant leakage is reduced. Bipolar plates within the system include reactant channels and coolant channels that are fluidly coupled to inlet and outlet flowpaths, all of which are formed within a coolant-engaging or reactant-engaging surface of the plate. One or more thin or low aspect-ratio microseals are also formed on a metal bead that is integrally-formed on a surface of the plate and is used to help reduce leakage by maintaining fluid isolation of the reactants and coolant as they flow through their respective channels and flowpaths that are defined between adjacently-placed plates.

Abstract: A microseal for a metal bead seal joint includes a substantially horizontal surface, first and second substantially vertical surfaces disposed on opposite ends of the substantially horizontal surface, and a contoured surface operatively configured to adhere to a portion of a metal bead. The contoured surface may be disposed opposite the substantially horizontal surface and may be integral to the first and second substantially vertical surfaces. The substantially horizontal surface may be operatively configured to substantially maintain its horizontal surface orientation in both a compression state and a non-compression state.

Abstract: A fuel cell stack with a bipolar plate assembly and a method of assembling a fuel cell stack such that reactant or coolant leakage is reduced. Bipolar plates within the system include reactant channels and coolant channels that are fluidly coupled to inlet and outlet flowpaths, all of which are formed within a coolant-engaging or reactant-engaging surface of the plate. One or more thin or low aspect-ratio microseals are also formed on a metal bead that is integrally-formed on a surface of the plate and is used to help reduce leakage by maintaining fluid isolation of the reactants and coolant as they flow through their respective channels and flowpaths that are defined between adjacently-placed plates.

Abstract: A sealing assembly for a fuel cell system and a method of assembling a fuel cell system. The system is made up of numerous fluid-conveying plate assemblies stacked such that seals are placed between adjacent plates. Microseals are disposed on one or both of metal beads and subgaskets such that when fuel cells comprising such metal beads, microseals and gaskets are aligned and compressed into a housing of a fuel cell stack, the leakage impacts of any misalignment in the cells is reduced. In particular, variations in microseal design including geometric and material properties such as microseal aspect ratio, Poisson's Ratio and as-deposited shape may be tailored to provide optimum sealing between facing metal beads and subgaskets.

Abstract: A composition with latent adhesion, fuel cell stack with a bipolar plate assembly with latent adhesion and a method of assembling a fuel cell stack with a seal that has latent adhesion such that reactant or coolant leakage through the seal is reduced. Bipolar plates within the stack include reactant channels and coolant channels that are fluidly coupled to inlet and outlet flowpaths, all of which are formed within a coolant-engaging or reactant-engaging surface of the plate. One or more thin or low aspect-ratio seals are formed on a metal bead that is integrally-formed on a surface of the plate and is used to help reduce leakage by maintaining fluid isolation of the reactants and coolant as they flow through their respective channels and flowpaths that are defined between adjacently-placed plates.

Abstract: A method for forming seals in a fuel cell stack includes a step of screen printing a first sealing layer on a first flow field plate. The first sealing layer defines a first pattern and has a first predetermined sealing layer thickness. A multilayer seal is formed by screen printing a second sealing layer over the first sealing layer. The second sealing layer defines a second pattern and has a second predetermined sealing layer thickness. A third sealing layer is screen printed over a first side of a second flow field plate and has a third predetermined sealing layer thickness. A fourth sealing layer is screen printed over a second side of the second flow field plate having a fourth predetermined sealing layer thickness. The first flow field plate and the second flow field plate are combined to form flow channels for guiding reactants a fuel cell catalyst layers.

Abstract: A method for forming seals in a fuel cell stack includes a step of screen printing a first sealing layer on a first flow field plate. The first sealing layer defines a first pattern and has a first predetermined sealing layer thickness. A multilayer seal is formed by screen printing a second sealing layer over the first sealing layer. The second sealing layer defines a second pattern and has a second predetermined sealing layer thickness. A third sealing layer is screen printed over a first side of a second flow field plate and has a third predetermined sealing layer thickness. A fourth sealing layer is screen printed over a second side of the second flow field plate having a fourth predetermined sealing layer thickness. The first flow field plate and the second flow field plate are combined to form flow channels for guiding reactants a fuel cell catalyst layers.