Abstract: A method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and a second radiation-sensitive material adjacent the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has the first sensitivity and a second sensitivity different from the first sensitivity. At least one mask is placed between at least one radiation source and the first and second radiation-sensitive materials. The mask has a plurality of substantially radiation-transparent apertures. The first and second radiation-sensitive materials are then exposed to a plurality of radiation beams through the radiation-transparent apertures in the mask to form a first construct in the first radiation-sensitive material and a second construct in the second radiation-sensitive material. The first construct and the second construct cooperate to form the radiation-cured structure.

Abstract: A method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and applying a second radiation-sensitive material to the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has a second sensitivity different from the first sensitivity. At least one mask is placed between at least one radiation source and the first and second radiation-sensitive materials. The mask has a plurality of substantially radiation-transparent apertures. The first and second radiation-sensitive materials are then exposed to a plurality of radiation beams through the radiation-transparent apertures in the mask to form a first construct in the first radiation-sensitive material and a second construct in the second radiation-sensitive material. The first construct and the second construct cooperate to form the radiation-cured structure.

Abstract: A method for fabricating a fuel cell component includes the steps of providing a mask having a plurality of radiation transparent apertures, a radiation-sensitive material having a sensitivity to the plurality of radiation beams, and a flow field layer. The radiation-sensitive material is disposed on the flow field layer. The radiation-sensitive material is then exposed to the plurality of radiation beams through the radiation transparent apertures in the mask to form a diffusion medium layer with a micro-truss structure.

Abstract: A method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and applying a second radiation-sensitive material to the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has a second sensitivity different from the first sensitivity. At least one mask is placed between at least one radiation source and the first and second radiation-sensitive materials. The mask has a plurality of substantially radiation-transparent apertures. The first and second radiation-sensitive materials are then exposed to a plurality of radiation beams through the radiation-transparent apertures in the mask to form a first construct in the first radiation-sensitive material and a second construct in the second radiation-sensitive material. The first construct and the second construct cooperate to form the radiation-cured structure.

Abstract: A method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and applying a second radiation-sensitive material to the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has a second sensitivity different from the first sensitivity. At least one mask is placed between at least one radiation source and the first and second radiation-sensitive materials. The mask has a plurality of substantially radiation-transparent apertures. The first and second radiation-sensitive materials are then exposed to a plurality of radiation beams through the radiation-transparent apertures in the mask to form a first construct in the first radiation-sensitive material and a second construct in the second radiation-sensitive material. The first construct and the second construct cooperate to form the radiation-cured structure.

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: A product comprising a fuel cell component comprising a substrate and a coating overlying the substrate, the coating comprising nanoparticles having sizes ranging from 2 to 100 nanometers.

Abstract: A product comprising a fuel cell component comprising a substrate and a coating overlying the substrate, the coating comprising nanoparticles having sizes ranging from 2 to 100 nanometers.

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: A separator plate for a fuel cell is provided, including a substrate having a radiation-cured first flow field layer disposed thereon. A method for fabricating the separator plate is also provided. The method includes the steps of providing a substrate; applying a first radiation-sensitive material to the substrate; placing a first mask between a first radiation source and the first radiation-sensitive material, the first mask having a plurality of substantially radiation-transparent apertures; and exposing the first radiation-sensitive material to a plurality of first radiation beams to form a radiation-cured first flow field layer adjacent the substrate. A fuel cell having the separator plate is also provided.

Abstract: A combined subgasket and membrane support for a fuel cell is provided. The combined subgasket and membrane support includes a substantially fluid impermeable feed region circumscribing a porous membrane support region. The membrane support region is integrally formed with the feed region. At least one of the membrane support region and the feed region is at least partially formed by a radiation-cured structure. A method for fabricating the subgasket and membrane support for the fuel cell is also provided.

Abstract: A bipolar plate assembly for a fuel cell is provided. The bipolar plate assembly includes a first unipolar plate disposed adjacent to a second unipolar plate. The first unipolar plate and the second unipolar plate are bonded by a plurality of localized electrically conductive nodes. A fuel cell stack including the bipolar plate assembly and a method for preparing the bipolar plate assembly are also described.

Abstract: A battery assembly includes a casing with a casing wall having inner and outer surfaces and an opening therethrough and being shaped such that a coolant chamber is formed within the casing adjacent to the opening. A sleeve including a compressible material is inserted through the opening. The sleeve is shaped such that a sealing portion thereof is positioned over the outer surface of the casing wall. A battery cell is inserted into the sleeve such that at least a portion of the battery cell is positioned within the coolant chamber. A sealing member is coupled to the casing such that a force is applied onto the sealing portion of the sleeve causing the sealing portion of the sleeve to at least partially compress and seal the coolant chamber.

Abstract: A fuel cell component is provided, including a substrate disposed adjacent at least one radiation-cured flow field layer. The flow field layer is one of disposed between the substrate and a diffusion medium layer, and disposed on the diffusion medium layer opposite the substrate. The flow field layer has at least one of a plurality of reactant flow channels and a plurality of coolant channels for the fuel cell. The fuel cell component may be assembled as part of a repeating unit for a fuel cell stack. A method for fabricating the fuel cell component and the associated repeating unit for the fuel cell is also provided.

Abstract: A combined subgasket and membrane support for a fuel cell is provided. The combined subgasket and membrane support includes a substantially fluid impermeable feed region circumscribing a porous membrane support region. The membrane support region is integrally formed with the feed region. At least one of the membrane support region and the feed region is at least partially formed by a radiation-cured structure. A method for fabricating the subgasket and membrane support for the fuel cell is also provided.

Abstract: A separator plate for a fuel cell is provided, including a substrate having a radiation-cured first flow field layer disposed thereon. A method for fabricating the separator plate is also provided. The method includes the steps of providing a substrate; applying a first radiation-sensitive material to the substrate; placing a first mask between a first radiation source and the first radiation-sensitive material, the first mask having a plurality of substantially radiation-transparent apertures; and exposing the first radiation-sensitive material to a plurality of first radiation beams to form a radiation-cured first flow field layer adjacent the substrate. A fuel cell having the separator plate is also provided.

Abstract: A fuel cell component is provided, including a substrate disposed adjacent at least one radiation-cured flow field layer. The flow field layer is one of disposed between the substrate and a diffusion medium layer, and disposed on the diffusion medium layer opposite the substrate. The flow field layer has at least one of a plurality of reactant flow channels and a plurality of coolant channels for the fuel cell. The fuel cell component may be assembled as part of a repeating unit for a fuel cell stack. A method for fabricating the fuel cell component and the associated repeating unit for the fuel cell is also provided.

Abstract: A separator plate for a fuel cell is provided, including a substrate having a radiation-cured first flow field layer disposed thereon. A method for fabricating the separator plate is also provided. The method includes the steps of providing a substrate; applying a first radiation-sensitive material to the substrate; placing a first mask between a first radiation source and the first radiation-sensitive material, the first mask having a plurality of substantially radiation-transparent apertures; and exposing the first radiation-sensitive material to a plurality of first radiation beams to form a radiation-cured first flow field layer adjacent the substrate. A fuel cell having the separator plate is also provided.

Abstract: One embodiment of the invention comprises a fuel cell bipolar plate comprising a substrate comprising a first face, a reactant gas flow field defined in the first face, the reactant gas flow field comprising a plurality of lands and channels, and a plurality of microgrooves formed in the first face.

Abstract: A fuel cell component is provided, including a substrate disposed adjacent at least one radiation-cured flow field layer. The flow field layer is one of disposed between the substrate and a diffusion medium layer, and disposed on the diffusion medium layer opposite the substrate. The flow field layer has at least one of a plurality of reactant flow channels and a plurality of coolant channels for the fuel cell. The fuel cell component may be assembled as part of a repeating unit for a fuel cell stack. A method for fabricating the fuel cell component and the associated repeating unit for the fuel cell is also provided.