Abstract: A method of manufacturing a fuel cell bipolar plate comprising first and second thermoformed plates. The thermoformed plates comprise at least one thermoplastic polymer. The method includes providing film cast resin mixture and forming it into a substantially flat sheet having first and second opposing major surfaces. The sheet may be preheated to a predetermined temperature and thermoformed thereby creating separator plates of a desired size and shape. First and second plates are joined to form an integral bipolar plate.

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: 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 membrane electrode assembly (MEA) comprises a polymer electrolyte membrane having at least one electrode layer on each of the opposing sides of the membrane. The electrode layer comprises a catalyst, an electrically conductive particulate material and an ionomer binder. The ionomer binder concentration on the exterior surface of the MEA is lower than the ionomer binder concentration near the electrode membrane interface. The electrode layer is formed by casting and drying a solvent ink layer between a nonporous release surface and a porous releasable decal.

Abstract: Edge designs, especially for ePTFE-reinforced membranes for proton exchange membrane (PEM) fuel cells, wherein the designs provide a proton barrier at the electrode edge of the PEM fuel cell membrane electrode assembly (MEA) to provide, among other things, resistance to membrane chemical degradation. A portion of the ePTFE layer is imbibed with a proton-impermeable polymer at the electrode edge. The polymer can include, without limitation, B-staged epoxides, B-staged phenolics, hot melt thermoplastics, and/or thermosets or thermoplastics cast from liquid dispersions.

Abstract: A fuel cell assembly and method of forming the same is disclosed, the fuel cell assembly including a membrane electrode assembly, a plurality of diffusion media, and a plurality of bipolar plates, wherein the diffusion media are adhered to the bipolar plates with an adhesive layer adapted to minimize an electrical resistance within the fuel cell assembly.

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: A fuel cell comprises a substantially contaminant free and contaminant impermeable coating disposed on at least one of a cathode, an anode, a gasket, an insulator plate, a cooler plate, a bipolar plate, a gas diffusion media layer, a polymer electrolyte membrane, an end plate, a tie-bolt, and a gas flow manifold. A process of producing a fuel cell and a fuel cell stack component are also disclosed.

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 fuel cell system is provided including a fuel cell stack having a first end and second end, the stack comprising at least one fuel cell, a first end unit disposed adjacent the first end of the fuel cell stack, a second end unit disposed adjacent the second end of the fuel cell stack, and a compression retention system. The compression retention system includes at least one generally planar strip forming at least one bend, wherein the at least one strip extends from the first end unit to the second end unit of the fuel cell system. The at least one bend of the planar strip can form at least one serpentine shape.

Abstract: An electrically conductive element for a proton exchange membrane fuel cell having low electrical contact resistance and high corrosion resistance. The conductive element comprises a corrosion susceptible metal substrate with a surface, which is preferably treated to activate the surface (i.e., to remove a passivation layer of oxides from the surface) with an acidic treatment solution. The treated surface is then overlaid with an electrically conductive, corrosion-resistant, protective coating to protect the substrate re-forming a passivation layer while exposed to the corrosive environment of the fuel cell.

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: 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: A unitized plate such as a bipolar plate for a fuel cell assembly is provided. The unitized plate includes a plurality of active regions electrically insulated from one another, and a plurality of inlet and outlet apertures formed in the plate. Each of the active regions is in fluid communication with a dedicated inlet aperture adapted to selectively deliver gaseous reactants thereto. A fuel cell assembly having a plurality of independently operable fuel cell stack units, and a method for operating the fuel cell assembly, is also provided.

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: 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 membrane electrode assembly (MEA) comprises a polymer electrolyte membrane having at least one electrode layer on each of the opposing sides of the membrane. The electrode layer comprises a catalyst, an electrically conductive particulate material and an ionomer binder. The ionomer binder concentration on the exterior surface of the MEA is lower than the ionomer binder concentration near the electrode membrane interface. The electrode layer is formed by casting and drying a solvent ink layer between a nonporous release surface and a porous releasable decal.

Abstract: A unitized plate such as a bipolar plate for a fuel cell assembly is provided. The unitized plate includes a plurality of active regions electrically insulated from one another, and a plurality of inlet and outlet apertures formed in the plate. Each of the active regions is in fluid communication with a dedicated inlet aperture adapted to selectively deliver gaseous reactants thereto. A fuel cell assembly having a plurality of independently operable fuel cell stack units, and a method for operating the fuel cell assembly, is also provided.

Abstract: A fuel cell assembly and method of forming the same is disclosed, the fuel cell assembly including a membrane electrode assembly, a plurality of diffusion media, and a plurality of bipolar plates, wherein the diffusion media are adhered to the bipolar plates with an adhesive layer adapted to minimize an electrical resistance within the fuel cell assembly.