Abstract: An exemplary fuel cell component includes a plate comprising an electrically conductive material. An electrical connector includes a first portion embedded in the plate. A second portion of the electrical connector extends from the plate. The second portion is configured to make an electrically conductive connection with another device.

Abstract: According to an illustrative embodiment, a method of making a fuel cell component includes removing material from a first plurality of locations along at least one surface on a plate to simultaneously establish a plurality of first channels on the surface. Each first channel has a length between a first end near a first edge of the surface and a second end spaced from a second, opposite edge of the surface. Material is also removed from a second plurality of locations along the surface to simultaneously establish a plurality of second channels on the surface. Each second channel has a length beginning at a first end spaced from the first edge and a second end near the second edge. Material is also removed from the surface near the first ends of at least some of the first channels to simultaneously establish an inlet portion for directing a fluid into the corresponding first channels.

Abstract: A method of processing a porous article includes distributing a blended material that includes an electrically conductive material and a binder into a cavity of a mold that is at a temperature below a curing temperature of the binder. The electrically conductive material is formed from particles of the electrically conductive material that have a size distribution such that 10 vol % of the particles are less than 12 micrometers in diameter, 50 vol % of the particles are less than 27 micrometers in diameter, and 90 vol % of the particles are less than 53 micrometers. The blended material is compressed within the cavity under a molding pressure, and the mold is heated to a curing temperature of the binder to form a molded article.

Abstract: A method of processing a porous article includes distributing a blended powder material including loose electrically conductive particles and loose resin particles into a mold. The blended powder material is consolidated within the mold under a molding pressure and a molding temperature into a consolidated article. The loose resin particles of the blended powder material are selected to be within a predefined particle size distribution to control a physical property of the porous article.

Abstract: According to an illustrative embodiment, a method of making a fuel cell component includes removing material from a first plurality of locations along at least one surface on a plate to simultaneously establish a plurality of first channels on the surface. Each first channel has a length between a first end near a first edge of the surface and a second end spaced from a second, opposite edge of the surface. Material is also removed from a second plurality of locations along the surface to simultaneously establish a plurality of second channels on the surface. Each second channel has a length beginning at a first end spaced from the first edge and a second end near the second edge. Material is also removed from the surface near the first ends of at least some of the first channels to simultaneously establish an inlet portion for directing a fluid into the corresponding first channels.

Abstract: An exemplary fuel cell component includes a plate comprising an electrically conductive material. An electrical connector includes a first portion embedded in the plate. A second portion of the electrical connector extends from the plate. The second portion is configured to make an electrically conductive connection with another device.

Abstract: A fuel cell includes a membrane electrode assembly comprised of a membrane sandwiched between anode and cathode catalyst structures. An anode separator plate and a cathode separator plate are arranged adjacent to the membrane electrode assembly opposite from one another. The anode and cathode separator plates include opposing sides in which one of the opposing sides of the anode and cathode respectively have fuel and oxidant flow fields in communication with the membrane. The anode separator plate is a structure having a first water permeability and is configured to permit passage of water between its opposing sides and with its flow field, and the cathode separator plate comprises a structure having a second water permeability less than the first water permeability of the anode separator plate. In one example, the anode is provided by a porous separator plate, and the cathode is provided by a non-porous, or solid, plate.

Abstract: A method of processing a porous article includes distributing a blended material that includes an electrically conductive material and a binder into a cavity of a mold that is at a temperature below a curing temperature of the binder. The electrically conductive material is formed from particles of the electrically conductive material that have a size distribution such that 10 vol % of the particles are less than 12 micrometers in diameter, 50 vol % of the particles are less than 27 micrometers in diameter, and 90 vol % of the particles are less than 53 micrometers. The blended material is compressed within the cavity under a molding pressure, and the mold is heated to a curing temperature of the binder to form a molded article.

Abstract: A fuel cell includes a membrane electrode assembly comprised of a membrane sandwiched between anode and cathode catalyst structures. An anode separator plate and a cathode separator plate are arranged adjacent to the membrane electrode assembly opposite from one another. The anode and cathode separator plates include opposing sides in which one of the opposing sides of the anode and cathode respectively have fuel and oxidant flow fields in communication with the membrane. The anode separator plate is a structure having a first water permeability and is configured to permit passage of water between its opposing sides and with its flow field, and the cathode separator plate comprises a structure having a second water permeability less than the first water permeability of the anode separator plate. In one example, the anode is provided by a porous separator plate, and the cathode is provided by a non-porous, or solid, plate.