Abstract: A method for coating a fuel cell component is provided. The method includes the steps of providing a fuel cell component, and forming a coating on a surface of the fuel cell component with a plasma jet. The step of forming the coating may include applying a coating precursor to a surface of the fuel cell component and then reacting the coating precursor with the plasma jet to form the coating. The step of forming the coating may also include growing the coating on the surface of the fuel cell component by delivering the plasma jet containing the coating precursor.

Abstract: A flow field plate for fuel cell applications includes an electrically conductive plate having a first surface defining a plurality of channels. An active area section and an inactive area section characterize the flow field channels. A hydrophobic layer is disposed over at least a portion of the inactive area section while a hydrophilic layer is disposed over at least a portion of the active area section.

Abstract: A product including a polymer electrolyte membrane, an electrode over the membrane, a gas diffusion media layer over the electrode, and a hydrophilic layer over the gas diffusion media layer.

Abstract: A fuel cell stack includes a first fuel cell assembly and a last fuel cell assembly. The first fuel cell assembly includes a first end plate assembly, which has a first end plate cooling channel adapted to receive a coolant. The last fuel cell assembly includes a last end plate assembly that has a last end plate cooling channel. A first electrical potential exists between the first end plate and the last end plate. The fuel cell stack also includes a connecting cooling channel is in fluid communication with the first end plate cooling channel and the last end plate cooling channel. A coolant is contained within the connecting coolant channel, the first end plate cooling channel, and a last end plate cooling channel. The fuel cell stack further includes a coolant electrode positioned in the coolant channel, which contacts the coolant.

Abstract: A metal composite for use in electrochemical devices is disclosed. The metal composite comprises a stainless steel interior component and a deposited nitrided metal exterior layer, wherein the nitrided exterior layer has lower electric contact resistance and greater corrosion resistance than the stainless steel interior component. A bipolar plate made of such metal composite and methods of producing the metal composite and bipolar plate are also disclosed.

Abstract: In one aspect a substrate such as a sheet metal product, in particular for use as a bipolar plate in a fuel cell or in an electrolyzer, is characterized in that it has, on at least one side, a conductive and corrosion-resistant protective coating of a metal oxide having a treatment which ensures the conductivity. The coating can be produced by introducing a piece of sheet metal into a coating plant and providing it with the conductive and corrosion-resistant protective coating of the metal oxide. In another aspect, an electrochemical cell such as a fuel cell comprises an electrically conductive contact element having a first surface facing an electrode for conducting electrical current, and the contact element comprises an electrically conductive substrate and an electrically conductive coating comprising a doped metal oxide, desirably a doped tin oxide, and preferably a fluorine doped tin oxide.

Abstract: A fuel cell includes a first electrically conductive plate and a first gas diffusion layer. The first gas diffusion layer is disposed over the first electrically conductive plate. Characteristically, the first gas diffusion layer comprises a first fibrous sheet having fibers coated with an electrically conductive layer. A first catalyst layer is disposed over the first gas diffusion layer and an ion conducting membrane is disposed over the first catalyst layer. The fuel cell also includes a second catalyst layer disposed over the ion conducting membrane with a second gas diffusion layer disposed over the second catalyst layer. A second electrically conductive plate is disposed over the second gas diffusion layer. Methods for forming the gas diffusion layers and the fuel cell are also provided.

Abstract: An enhanced stability and inexpensive bipolar plate for a fuel cell is disclosed. The enhanced stability bipolar plate includes a bipolar plate substrate and a corrosion-resistant coating provided on the bipolar plate substrate. A method for enhancing corrosion resistance of a bipolar plate is also disclosed.

Abstract: In at least one embodiment, the present invention provides an electrically conductive fluid distribution separator plate assembly, a method of making, and a system for using, the electrically conductive fluid distribution separator plate assembly. In at least one embodiment, the electrically conductive fluid distribution separator plate assembly comprises a metallic cathode plate having opposed surfaces and a first contact resistance, a polymeric composite anode plate adjacent to the metallic cathode plate, and a low contact resistance coating located on at least one of the surfaces of the plates, with the coating having a second contact resistance, less than the first contact resistance.

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 flow field plate for fuel cell applications includes a metal with a carbon layer disposed over at least a portion of the metal plate. The carbon layer is overcoated with a titanium oxide layer to form a titanium oxide/carbon bilayer. The titanium oxide/carbon bilayer may be activated to increase hydrophilicity. The flow field plate is included in a fuel cell with a minimal increase in contact resistance. Methods for forming the flow field plates are also provided.

Abstract: A flow field plate for fuel cell applications includes a metal with a carbon layer disposed over at least a portion of the metal plate. The carbon layer is overcoated with a silicon oxide layer to form a silicon oxide/carbon bilayer. The silicon oxide/carbon bilayer may be activated to increase hydrophilicity. The flow field plate is included in a fuel cell with a minimal increase in contact resistance. Methods for forming the flow field plates are also provided.

Abstract: A fuel cell assembly is disclosed that utilizes a fuel cell plate having hydrophobic portions adjacent an inlet and an outlet formed therein, and a hydrophilic portion formed in the flow channels of the fuel cell plate adjacent the hydrophobic portions, wherein the hydrophilic portion and the hydrophobic portion facilitate the transport of liquid water from the fuel cell plate.

Abstract: A flow field plate or bipolar plate for a fuel cell, where a surface of the flow field plate is textured or roughened to change the surface morphology of the plate. A conductive coating is deposited on the roughened surface where the roughness of the surface of the plate increases the hydrophilic nature of the coating. Therefore, if the coating is naturally hydrophobic, the surface roughness makes the coating hydrophilic to wick water away. If the coating is a conductive hydrophilic coating, then the surface roughness makes the coating super-hydrophilic, and may counter the effects of surface contamination that would act to make the hydrophilic coating less hydrophilic.

Abstract: In at least one embodiment, the present invention provides an electrically conductive fluid distribution separator plate assembly, a method of making, and a system for using, the electrically conductive fluid distribution separator plate assembly. In at least one embodiment, the electrically conductive fluid distribution separator plate assembly comprises a metallic cathode plate having opposed surfaces and a first contact resistance, a polymeric composite anode plate adjacent to the metallic cathode plate, and a low contact resistance coating located on at least one of the surfaces of the plates, with the coating having a second contact resistance, less-than the first contact resistance.

Abstract: A method for depositing a hydrophilic and electrically conductive layer onto a bipolar plate substrate for a fuel cell in a one step process. The method includes mixing a solution of a conductive material, such as gold particles, and a hydrophilic material, such as silicon dioxide particles, in a suitable solvent, such as ethanol. The solution is then deposited on the bipolar plate substrate by any suitable low cost process. Once the solution dries and the ethanol has evaporated, a thin layer of the conductive and hydrophilic particles remains on the substrate. In one embodiment, the conductive particles are significantly larger than the hydrophilic particles to provide both the desirable hydrophilicity and the low contact resistance.

Abstract: A flow field plate having a low resistance coating for fuel cell applications is described. In one embodiment, the flow field plate includes a metal plate having a first surface and a second surface, the first surface defining a plurality of channels for directing flow of a first gaseous composition; and an activated carbon coating disposed adjacent to at least a portion of the plate, the activated carbon coating having a surface resistance of less than about 20 m?·cm2, the surface resistance being stable. Fuel cells incorporating the flow field plates and methods of making the flow field plates are also described.

Abstract: An electrically conductive fluid distribution element for use in a fuel cell includes a conductive metal substrate and a layer of conductive non-metallic porous media. The conductive non-metallic porous media has an electrically conductive material deposited along a surface in one or more metallized regions and having an average thickness less than about 40 nm. The metallized regions improve electrical conductance at contact regions between the metal substrate and the fluid distribution media.

Abstract: A fuel cell component includes an electrode support material made with nanofiber materials of Titania and ionomer. A bipolar plate stainless steel substrate and a carbon-containing layer doped with a metal selected from the group consisting of platinum, iridium, ruthenium, gold, palladium, and combinations thereof.

Abstract: A method of enhancing water management capabilities of a fuel cell is disclosed. The method includes providing a fuel cell component having hydrophilic or weakly hydrophobic surfaces, increasing a hydrophobicity of at least one of said hydrophilic surfaces and assembling the fuel cell component into the fuel cell.