Abstract: A filtration device for a fuel cell system is provided. The filtration device includes a filter adapted to receive a reactant for a fuel cell. The filter includes a molecular sieve material adapted to separate a contaminant from the reactant supplied to the fuel cell. A membrane electrode assembly having the filter integrally formed therewith, and a fuel cell stack having the filter disposed adjacent at least one of the end plates of the fuel cell stack, are also provided.

Abstract: A filtration device for a fuel cell system is provided. The filtration device includes a filter adapted to receive a reactant for a fuel cell. The filter includes a molecular sieve material adapted to separate a contaminant from the reactant supplied to the fuel cell. A membrane electrode assembly having the filter integrally formed therewith, and a fuel cell stack having the filter disposed adjacent at least one of the end plates of the fuel cell stack, 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: 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: A method of forming a fuel cell may include treating a surface of a membrane electrode assembly (MEA) of the fuel cell, positioning a preformed adhesive insert on the treated surface, and bonding an electrically conductive member to the treated surface with the adhesive. Treating the surface may include a pre-treatment to increase adhesive properties thereof. Positioning the adhesive insert may include locating the adhesive insert on a surface of the membrane electrolyte adjacent to an edge of the electrode.

Abstract: One aspect of the invention includes the discovery that pinholes in the membrane of the membrane electrode assembly may be caused by hygroexpansive ratcheting. In one embodiment of the invention, a fuel cell stack including a plurality of cells each having a membrane electrode assembly each including a membrane manufactured by an extrusion method and operated so that the rate of drying during humidity cycling is sufficiently low to reduce or eliminate build up stresses in the membrane electrode assembly.

Abstract: The present invention is directed to addressing performance issues attributable to membrane electrode assemblies, and the components thereof, in electrochemical conversion cells. In accordance with one embodiment of the present invention, a device comprising at least one electrochemical conversion cell is provided. The cell is configured to convert first and second reactants to electrical energy and comprises a membrane electrode assembly and at least one membrane reinforcement layer. The combination of elastic modulus and thickness of the reinforcement layer and the bond between the reinforcement layer and the membrane electrode assembly are sufficient to enhance the structural integrity of the membrane electrode assembly beyond the operational degradation threshold of the assembly.

Abstract: Fuel cells are provided that are at least partially resistant to corrosion, including the use of components that are comprised of materials that are at least partially resistant to corrosion. The fuel cells include subgasket materials and designs, involving geometric arrangements of the subgasket that reduce oxygen permeation from, the cathode to the anode side of the membranes and/or hydrogen permeation from the anode to the cathode side of the membranes. In addition to using protonically non-conductive subgasket materials with lower oxygen and/or hydrogen permeabilities, versus ionomeric subgaskets which are protonically conducting and have high O2 permeation rates, the elimination of the microporous layer (e.g., coated onto the diffusion medium) directly beneath the permeable subgasket materials will also reduce production of corrosive species. The elimination of direct contact between the bipolar plate material surface and PFSA ionomer membrane material also prevents corrosion to the metal bipolar plates.

Abstract: In accordance with one embodiment of the present invention, an electrochemical conversion assembly comprises a plurality of electrochemical conversion cells and a plurality of electrically conductive bipolar plates. The electrochemical conversion cells are configured to communicate with first and second reactant supplies. Adjacent ones of the electrochemical conversion cells are separated by respective ones of the plurality of bipolar plates. The bipolar plates comprise an alloy comprising Fe and Cr. Respective surface portions of the bipolar plates are provided with electrically conductive, corrosion resistant layers that are placed in contact with portions of the electrochemical conversion cells. The corrosion resistant electrically conductive layers may comprise graphitic layers characterized predominantly by sp2 hybridized carbon-carbon bonding, molybdenum doped indium oxide layers, an electrically conductive Cr+N layer, or an electrically conductive MoSi2 layer.

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. The plate comprises a plate body having a surface defining a set of fluid flow channels configured to distribute flow of a fluid across at least one side of the plate, at least a portion of the surface having a roughness average of 0.5 to 5 ?m and a contact resistance of less than 40 mohm cm2 when sandwiched between carbon papers at 200 psi.

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 gasket formed of compressed graphite that is resistant to, damage, freezing, and high temperatures. The gasket provides advantages in fuel cells.

Abstract: An improved flowfield plate design and a process for fabricating such a plate is provided. In accordance with one embodiment of the present invention, a process of fabricating a bipolar plate is provided. The bipolar plate comprises a flowfield defined between opposite, electrically conductive sides of the bipolar plate. According to the process, a flowfield skeleton is provided. The flowfield skeleton comprises a sacrificial core overplated by a hydrogen permeation barrier layer. An electrically conductive polymeric composite material is molded about the flowfield skeleton to define the opposite sides of the bipolar plate. The molded polymeric composite material is cured such that the hydrogen permeation barrier layer adheres to the composite material and the sacrificial core melts away from the composite material and the barrier layer to define a flowfield cavity between the opposite sides of the bipolar plate.

Abstract: An assembly for a fuel cell including an ionically conductive member, an electrode, and an electrically conductive member. The assembly also includes an adhesive disposed at a peripheral edge of the assembly that adheres the electrically conductive member, the electrode, and the ionically conductive member, as well as provides mechanical support and inhibits the permeation of reactant gas through the ionically conductive member.

Abstract: Nitrided bipolar plates and a scheme for their fabrication are provided. The present invention also contemplates device incorporating bipolar plates according to the present invention. For example, in accordance with one embodiment of the present invention, an electrochemical conversion assembly is provided. The electrochemical conversion cells of the assembly are separated by respective bipolar plates comprising an alloy of Fe and Cr. A surface portion of the bipolar plates comprises a single phase nitrided structure. According to another embodiment of the present invention, a plasma nitriding process is utilized to create a single phase nitrided structure along a surface portion of respective ones of said bipolar plates.

Abstract: A device configured to convert a hydrogenous fuel source to electrical energy is provided, the device comprising an electrochemical conversion assembly compressively loaded along a loading axis of the conversion assembly and at least one side plate. The side plate includes a proximal end, a distal end, and at least one spring element positioned between the proximal end and the distal end. The spring element is configured to maintain the compressive loading along the loading axis of the electrochemical conversion assembly. The device can further comprise a fuel cell, and the device can further comprises structure defining a vehicle powered by the fuel cell.

Abstract: An improved bipolar plate stainless steel alloy comprises, in weight percent, about 20% to about 30% chromium, about 10% to about 25% nickel, about 1% to about 9 % molybdenum, and up to about 4% copper, where the weight percentage of chromium plus nickel plus molybdenum is greater than about 51 percent. The weight percentage of chromium plus molybdenum may be greater than about 1.66 times the weight percentage of nickel. In addition, the ratio of chromium equivalents to nickel equivalents may be greater than about 1.66.

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.