Abstract: In at least one embodiment, the present invention provides a hydrophilic electrically conductive fluid distribution plate and a method of making, and system for using, the hydrophilic electrically conductive fluid distribution plate. In at least one embodiment, the plate comprises a plate body defining a set of fluid flow channels configured to distribute flow of a fluid across at least one side of the plate, and a composite conductive coating having a water contact angle of less than 40° adhered to the plate body. In at least one embodiment, the composite coating comprises a polymeric conductive layer adhered to the plate body having an exterior surface, and a particulate carbon layer adhered to the exterior surface of the polymeric conductive layer.

Abstract: In at least one embodiment, the present invention provides an electrically conductive fluid distribution plate and a method of making, and system for using, the electrically conductive fluid distribution plate. In at least one embodiment, the plate comprises a plate body defining a set of fluid flow channels configured to distribute flow of a fluid across at least one side of the plate, and a polymeric porous conductive layer proximate the plate body, with the porous conductive layer having a porosity sufficient to result in a water contact angle of the surface of less than 40°.

Abstract: The present invention provides an electrically conductive element for an electrochemical cell element having enhanced protection for an underlying metal substrate with a surface susceptible to forming metal oxides. One or more regions of the surface are coated with a metal coating overlaid with an adhesion promoting coating comprising a silicon containing material derived from organosilanes. The adhesion promoting coating is overlaid with a conductive, protective polymeric coating. The present invention further provides methods of making such an electrochemical cell element to have improved adhesion of conductive, protective polymer coatings.

Abstract: The present invention discloses a method of efficiently manufacturing fuel cells having coated bipolar plates. The present invention contemplates the laser welding together of individual plates already having a coating thereon to form the bipolar plates that are used in a fuel cell. The laser welding of the coated plates together does not result in sensitization of the plates to a magnitude sufficient to cause an undesirable level of corrosion resistance. This result is achieved regardless of the presence of the organic coating in the region of the plates being welded and regardless of the ablating of the organic coating by the laser beam.

Abstract: A UEA-subgasket assembly for a fuel cell system and a method of production thereof is disclosed. The UEA-subgasket assembly includes a membrane electrolyte assembly, diffusion media, and a subgasket, wherein the subgasket permeates into one of the diffusion media to form a substantially fluid-tight seal.

Abstract: A bipolar plate for use in a proton exchange membrane fuel cell having an electrically conductive polymer coated on at least one region of a surface of the plate in contact with a flow field. The coated region is hydrophobic or hydrophilic as compared to an uncoated region of the surface to prevent liquid accumulation. Electroconductive polymer coatings are applied by electrochemical polymerization.

Abstract: A fuel cell of the type having a membrane electrode assembly (MEA) interdisposed between a pair of bipolar plate assemblies. The MEA may have a convoluted configuration to maximize the effective surface area of the MEA for a given planar area. Each bipolar plate assembly includes a gas distribution layer of open cell conductive foam material which is divided into a plurality of generally parallel segments to define a plurality of generally parallel porous reactant paths. The segments are defined by selectively varying the porosity of the foam material and/or selectively varying the thickness of the foam material. The foam material may be a conductive graphite foam media or a conductive metallic foam media. Each bipolar plate assembly further includes a non-porous, conductive separator plate. The bipolar plate assembly distributes the reactant gases delivered via a manifold structure across the face of the MEA.

Abstract: A separator assembly for use in a stack of electrochemical cells is provided, having a first conductive metallic substrate with a first surface and a second conductive metallic substrate with a second surface, wherein each of the first and second surfaces are overlaid with an ultra-thin electrically conductive metal coating. The first and second surfaces form electrically conductive paths at regions where the metal coating of the first and second layer contact one another. The contact of the surfaces overlaid with metal coating is sufficient to join the first and second substrates to one another. Preferred metal coatings comprise gold (Au). Methods of making such separator assemblies are also provided.

Abstract: A fuel cell or electrochemical cell has a catalytic electrode and an electrically conductive contact element facing the electrode. The electrically conductive contact element conducts electrical current from the electrode and has a surface that includes a plurality of passivated regions and a plurality of non-passivated regions dispersed among the passivated regions. The surface is further coated with an electrically conductive, corrosion resistant coating. Methods include treating the electrically conductive contact element by passivation to resist corrosion while still maintaining electrical conductivity of the element.

Abstract: A separator assembly for use in a stack of electrochemical cells is provided, having a first conductive metallic substrate with a first surface and a second conductive metallic substrate with a second surface, wherein each of the first and second surfaces are overlaid with an ultra-thin electrically conductive metal coating. The first and second surfaces form electrically conductive paths at regions where the metal coating of the first and second layer contact one another. The contact of the surfaces overlaid with metal coating is sufficient to join the first and second substrates to one another. Preferred metal coatings comprise gold (Au). Methods of making such separator assemblies are also provided.

Abstract: A separator assembly for use in a stack of electrochemical cells is provided, having a first conductive metallic substrate with a first surface and a second conductive metallic substrate with a second surface, wherein each of the first and second surfaces are overlaid with an ultra-thin electrically conductive metal coating. The first and second surfaces form electrically conductive paths at regions where the metal coating of the first and second layer contact one another. The contact of the surfaces overlaid with metal coating is sufficient to join the first and second substrates to one another. Preferred metal coatings comprise gold (Au). Methods of making such separator assemblies are also provided.

Abstract: The present invention provides an electrically conductive element for an electrochemical cell element having enhanced protection for an underlying metal substrate with a surface susceptible to forming metal oxides. One or more regions of the surface are coated with a metal coating overlaid with an adhesion promoting coating comprising a silicon containing material derived from organosilanes. The adhesion promoting coating is overlaid with a conductive, protective polymeric coating. The present invention further provides methods of making such an electrochemical cell element to have improved adhesion of conductive, protective polymer coatings.

Abstract: The present invention relates to an electrically conductive element for an electrochemical cell comprising an electrically conductive corrosion-susceptible metal substrate having a surface susceptible to passivation by forming oxides in the presence of oxygen. The surface is treated to remove any oxides present, and then is overlaid with an electrically conductive corrosion-resistant coating comprising one or more elements from Groups 4, 5, 10, or 11 of the Periodic Table, and then a corrosion-resistant electrically conductive polymer-based coating. The underlying substrate thus has improved corrosion-resistance while maintaining electrical conductivity. Other preferred aspects of the present invention include methods of treating the electrically conductive contact element to resist corrosion while still maintaining electrical conductivity.

Abstract: The present invention relates to an electrochemical cell having a catalytic electrode and an electrically conductive contact element facing the electrode. The electrically conductive contact element conducts electrical current from the electrode and has a surface comprising a plurality of passivated regions, and a plurality of non-passivated regions dispersed among the passivated regions. The surface further is coated with an electrically conductive, corrosion resistant coating. Other preferred aspects of the present invention include methods of treating the electrically conductive contact element by passivation to resist corrosion while still maintaining electrical conductivity.

Abstract: A bipolar plate for use with a fuel cell is provided including an electrically conductive foam as a coolant layer between thin metal foil layers. The thin metal foil layers are provided with serpentine flow field patterns on a surface thereof.

Abstract: The present invention relates to an electrochemical cell having a catalytic electrode and an electrically conductive contact element facing the electrode. The electrically conductive contact element conducts electrical current from the electrode and has a surface comprising a plurality of passivated regions, and a plurality of non-passivated regions dispersed among the passivated regions. The surface further is coated with an electrically conductive, corrosion resistant coating. Other preferred aspects of the present invention include methods of treating the electrically conductive contact element by passivation to resist corrosion while still maintaining electrical conductivity.

Abstract: The present invention relates to an electrochemical cell having a terminal collector plate element that conducts electrical current from the stack. The terminal plate has an electrically conductive region and an electrically non-conductive region of the surface. The non-conductive region is coated with a corrosion resistant coating that comprises either a passivation layer, a corrosion-resistant polymeric layer, or both. Optionally, the conductive region of the terminal plate may be protected from oxidation, by coating with an oxidation-resistant metal layer. The oxidation-resistant layer may be further coated with a conductive oxidation-resistant polymeric layer. Other preferred aspects of the present invention include methods of treating the terminal plate to resist corrosion and oxidation while still maintaining electrical conductivity.

Abstract: The present invention relates to an electrochemical cell having a terminal collector plate element that conducts electrical current from the stack. The terminal plate has an electrically conductive region and an electrically non-conductive region of the surface. The non-conductive region is coated with a corrosion resistant coating that comprises either a passivation layer, a corrosion-resistant polymeric layer, or both. Optionally, the conductive region of the terminal plate may be protected from oxidation, by coating with an oxidation-resistant metal layer. The oxidation-resistant layer may be further coated with a conductive oxidation-resistant polymeric layer. Other preferred aspects of the present invention include methods of treating the terminal plate to resist corrosion and oxidation while still maintaining electrical conductivity.

Abstract: The present invention relates to an electrochemical cell having a catalytic electrode and an electrically conductive contact element facing the electrode. The electrically conductive contact element conducts electrical current from the electrode and has a surface comprising a plurality of passivated regions, and a plurality of non-passivated regions dispersed among the passivated regions. The surface further is coated with an electrically conductive, corrosion resistant coating. Other preferred aspects of the present invention include methods of treating the electrically conductive contact element by passivation to resist corrosion while still maintaining electrical conductivity.

Abstract: A PEM fuel cell having electrical contact elements comprising a corrosion-susceptible substrate metal coated with an electrically conductive, corrosion-resistant polymer containing a plurality of electrically conductive, corrosion-resistant filler particles. The substrate may have an oxidizable metal first layer (e.g., stainless steel) underlying the polymer coating.