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: 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 diffusion media is provided for implementation with a PEM fuel cell. The diffusion media is a permeable sheet that is rigid along a transverse axis, flexible along a lateral axis and has a substantially incompressible thickness. The diffusion media is able to be mass produced in large sheets and rolled along the lateral axis for transport and storage. The rigidity of the transverse axis is provided by either inclusion of larger fibers or metallic strips aligned in the transverse direction and prevents tenting of the diffusion media into flow channels of the PEM fuel cell. The diffusion media is water and gas permeable and electrically conductive.

Abstract: The present invention provides 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. The present invention also provides methods of preparing an electrically conductive element to have low electrical contact resistance and high corrosion resistance.

Abstract: The present invention provides 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. The present invention also provides methods of preparing an electrically conductive element to have low electrical contact resistance and high corrosion resistance.

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: The present invention relates to an electrically conductive element (e.g. bipolar plate) for a fuel cell which has an improved adhesive bond. The conductive element generally comprises a first and a second conductive sheet, each having a surface that confront one another. The surfaces that confront one another are overlaid with an electrically conductive primer coating providing corrosion protection and low contact resistance to said first and said second sheets respectively in regions where the first and second sheets contact one another. The first and said second coated surfaces are joined to one another by an electrically conductive adhesive which provides adhesion of said first and said second coated surfaces of said sheets at the contact region. Further, the present invention contemplates methods to form such an improved bond in an electrically conductive element.

Abstract: A method and apparatus for making cylindrical glass preforms with convex, optical quality convex end surfaces is taught. A glass ball preform is placed on a heated lower platen. The temperature of the glass ball preform is raised to a temperature above the glass transition temperature of the glass ball preform. The glass ball preform is engaged with an upper platen. At least one of the upper platen and the lower platen is moved vertically to cause the gap between the upper platen and the lower platen to narrow to a predetermined dimension. Simultaneously, at least one of the upper platen and the lower platen is moved horizontally relative to the other platen to cause the glass ball preform to roll between the upper platen and the lower platen and form a cylindrical preform having a predetermined diameter, the cylindrical preform having convex, optical quality end surfaces.

Abstract: A method and apparatus are taught for molding glass lens elements from glass preforms. A glass preform is placed on a first mold surface of a first mold element which resides in a first sleeve segment. The temperature of the glass preform, the first mold element, the first sleeve segment, a second mold element, and a second sleeve segment are elevated to at least the glass transition temperature of the glass preform, the second mold element residing in the second sleeve segment. The second mold element and second sleeve segment are moved toward the first mold element and first sleeve segment to form a mold cavity, the mold cavity including a lens chamber and an annular channel projecting from the lens chamber. The glass preform is compressed in the mold cavity to form a glass lens element with the excess glass from the glass preform flowing into the annular channel.

Abstract: A slitter cutting element for slitting a sheet of web material has an axially displaceable blade member arranged on a blade carrier. The axially displaceable blade member is biased by an elastomeric biasing member that provides a continuous and uniform contact force with a face of the blade member. The elastomeric biasing member is restrained from axial expansion by being bonded to the blade carrier.

Abstract: A method and apparatus for making cylindrical glass preforms with convex, optical quality convex end surfaces is taught. A glass ball preform is placed on a heated lower platen. The temperature of the glass ball preform is raised to a temperature above the glass transition temperature of the glass ball preform. The glass ball preform is engaged with an upper platen. At least one of the upper platen and the lower platen is moved vertically to cause the gap between the upper platen and the lower platen to narrow to a predetermined dimension. Simultaneously, at least one of the upper platen and the lower platen is moved horizontally relative to the other platen to cause the glass ball preform to roll between the upper platen and the lower platen and form a cylindrical preform having a predetermined diameter, the cylindrical preform having convex, optical quality end surfaces.

Abstract: A method for fabricating a mold tool for molding optical elements is taught which comprises heating a mold tool blank made from a vitreous material to a temperature above the glass transition temperature of the vitreous material; generating an axial viscosity gradient in the mold tool blank; pressing a punch into an optical quality mold surface of the mold tool blank, the punch including a pressing surface with a predetermined geometry for forming an optical feature; cooling the mold tool blank to a temperature below the glass transition temperature of the material; and removing the punch from the mold tool blank thereby creating the optical feature in the optical quality mold surface. The axial viscosity gradient is achieved by creating an axial thermal gradient.

Abstract: A method for making working mold tools for use in a compression molding process for molding optical glass elements from high temperature glasses having Tg's in the range of from about 400° C. to about 850° C. An yttria aluminosilicate glass is fabricated by traditional melting and casting processes to thereby make an amorphous base material having a minimum apparent viscosity of 1015 poise at the temperature at which the optical glass elements are to be molded. A mold preform is made from the base material. A first surface figure for the optical element to be molded with the working mold tool is defined. A second surface figure for a master mold tool and a third surface figure for the working mold tool are computed based upon the first surface figure and the coefficients of thermal expansion of the optical element, the master mold tool, and the working mold tool, the temperature at which the working mold tool is molded, and the temperature at which the optical element is to be molded.

Abstract: According to one aspect of the present invention, a method of making a lens assembly with a plurality of lens arrays having a plurality of lenslets and at least one spacer having a plurality of holes, includes the steps of (i) arranging at least two lens arrays and the spacer, such that the spacer is located between the two lens arrays and the lenslets of one of the two lens arrays overlay the lenslets of another one of the two lens arrays and, the holes of the spaces are located between the corresponding lenslets of the two lens arrays; (ii) fixedly attaching the lens arrays and the spacer to one another to form an array assembly; and (iii) dividing the array assembly to create a plurality of individual lens systems. According to another aspect of the present invention, the optical assembly includes at least two lens arrays and at least one spacer with a plurality of holes. The spacer is located between the two lens arrays and is fixedly attached to the two lens arrays. The spacer has a thickness of 0.

Abstract: A slitter cutting element for slitting a sheet of web material has an axially displaceable blade member arranged on a blade carrier. The axially displaceable blade member is biased by an elastomeric biasing member that provides a continuous and uniform contact force with a face of the blade member. The elastomeric biasing member is restrained from axial expansion by being bonded to the blade carrier.

Abstract: An apparatus for slitting a sheet of web material has an at least one first fixed blade member and axially displaceable at least one second blade member. The axially displaceable second blade member is biased by an elastomeric biasing member that provides a continuous and uniform contact force with a face of the second blade member. The elastomeric biasing member is restrained from axial movement by a bonded ring member.

Abstract: A method and apparatus is disclosed for compression molding arrays optical elements which may be later singulated. The apparatus includes first and second mold halves with the second mold half having a central nest and a plurality of predetermined negative optical surface features therein. A glass preform is placed in the central nest and the first and second mold halves and the glass preform are heated to at least the glass transition temperature of the glass preform. The glass preform is then pressed between the first and second mold halves to thereby form an integral array of optical elements with each of the optical elements being a positive of the predetermined negative optical surface features. The integrally formed array of optical elements is then cooled to below the glass transition temperature and removed from the first and second mold halves.

Abstract: A light weight x-ray cassette formed from Hylite which is an metal/polymer/metal material. The cassette comprises: a front panel and a back panel formed from the Hylite composite material with the front and the back panels being operatively hinged together by a hinging element attached to the panels so as to form a cavity between the panels; an x-ray film contained within the cavity between the first panel and the second panel; at least one intensifying screen held in contact with the x-ray film; and a latching element to open and close the cassette.

Abstract: Galvanic protection of steel is provided by teaching of a technique for determining alloys of compositions useful for the cathodic protection. The technique includes determining the critical cathodic protection potential for steel and the galvanic current and corrosion potential for candidate metal alloy compositions followed by coupling to the steel of one such alloy composition whose determined corrosion potential is lower than the critical corrosion potential for the steel in the corrosive environment in which protection is sought.

Abstract: Galvanic protection of steel is provided by means of coupling thereto of ternary alloys of Al/2.5 to 4% wt. Mg, 0.5 to 35% wt. Si, and Al/2.5-4% wt. Mg, 0.5 to 3.5% wt. Ge with teachings of steel having either alloy coupled thereto, as well as the alloys per se. Also, a technique for determining alloys useful for the cathodic protection is presented including determining the critical cathodic protection potential for steel and the galvanic current and corrosion potential for candidate alloy compositions followed by coupling to the steel of one such alloy composition whose determined corrosion potential is lower than the critical corrosion potential for the steel in the corrosive environment in which protection is sought.