Abstract: A method for forming a hydrolytically-stable hydrophilic coating on a fuel cell flow field plate comprises contacting a flow field plate with a titanium oxide sol to form a titanium oxide layer disposed upon the flow field plate. The coated flow field plate is subsequently contacted with a silicon oxide sol to form a silicon oxide/titanium oxide bilayer disposed upon the flow field plate. A flow field plate formed by the method is also provided.

Abstract: A bipolar plate for a fuel cell is provided including a plate having an active surface with a plurality of flow channels formed therein. The plurality of flow channels have a hydrophilic coating deposited thereon and define a plurality of lands disposed therebetween. The plurality of lands is substantially free of the hydrophilic coating. Furthermore, a thickness of the hydrophilic coating is substantially constant along a length of the active surface and an edge of the hydrophilic coating adjacent the plurality of lands is substantially continuous. A method for preparing the bipolar plate is also provided.

Abstract: A fuel cell comprises a bipolar plate having a cationic polymer layer and a conductive and hydrophilic surface layer disposed on at least a portion of its exterior area. The surface layer comprises a conductive carbon material having a hydrophilic organic group ionically attached to its surface. A process of producing a bipolar plate and a fuel cell is also disclosed.

Abstract: Bipolar plates useful for fuel cell applications include a plate body having a channel-defining surface that is at least partially coated with a hydrophilic layer. This hydrophilic layer comprises residues of a silane-coupling agent in a sufficient amount such portions of the first hydrophilic layer have a contact angle less than a predetermined value.

Abstract: A sealed assembly is made using sealant including a deformable spacer to control thickness without adversely impacting elasticity and sealing force. Deformable spacers (e.g., elastomer, polyolefin, etc.) are mixed with an elastomeric precursor material and dispensed onto an assembly component, such as a fuel cell bipolar plate, and the remaining component(s) are assembled by pressing against the deformable spacer to ensure a defined seal thickness. The precursor is cured to form a seal that is further compressed to provide an effective sealing force. The deformable spacers control the thickness of a sealed area and allow use of form-in-place sealing processes.

Abstract: An electrode plate is disclosed. The electrode plate includes a plate having an active area, a feed region in fluid communication with the active region, and a tunnel region in fluid communication with the feed region and a manifold region, an ultralyophobic coating on one or more of at least a portion of the tunnel region, at least a portion of the feed region, and an interface between the tunnel region and the manifold region. Fuel cells using the electrode plate and methods of making electrode plates are also described.

Abstract: Bipolar plates useful for fuel cell applications include a plate body having a channel-defining surface that is at least partially coated with a hydrophilic layer. This hydrophilic layer comprises residues of a silane-coupling agent in a sufficient amount such portions of the first hydrophilic layer have a contact angle less than a predetermined value.

Abstract: One variation may include a method which may include depositing a hydrophilic coating over at least a portion of a fuel cell bipolar plate. The bipolar plate may include a reactant gas header opening communication with the plurality of tunnels. Moreover, the tunnels may be communicating with a plurality of channels which may be defined by reactant gas flow field which may include a plurality of lands. At least a portion of the hydrophilic coating may be reacted with the material including a hydrophobic group which may provide a hydrophobic portion. Thereafter, at least a portion of the hydrophobic portion comprising oxidizing the hydrophobic group may be removed in order to regenerate the hydrophilic coating.

Abstract: A sealed assembly is made using sealant including a deformable spacer to control thickness without adversely impacting elasticity and sealing force. Deformable spacers (e.g., elastomer, polyolefin, etc.) are mixed with an elastomeric precursor material and dispensed onto an assembly component, such as a fuel cell bipolar plate, and the remaining component(s) are assembled by pressing against the deformable spacer to ensure a defined seal thickness. The precursor is cured to form a seal that is further compressed to provide an effective sealing force. The deformable spacers control the thickness of a sealed area and allow use of form-in-place sealing processes.

Abstract: A sealed assembly is made using sealant including a deformable spacer to control thickness without adversely impacting elasticity and sealing force. Deformable spacers (e.g., elastomer, polyolefin, etc.) are mixed with an elastomeric precursor material and dispensed onto an assembly component, such as a fuel cell bipolar plate, and the remaining component(s) are assembled by pressing against the deformable spacer to ensure a defined seal thickness. The precursor is cured to form a seal that is further compressed to provide an effective sealing force. The deformable spacers control the thickness of a sealed area and allow use of form-in-place sealing processes.

Abstract: A hydrophobic composite bipolar plate for a fuel cell including a substrate having a composite material including carbon and a surface layer on the substrate. The surface layer includes silicon and oxygen, and a hydrocarbon moiety attached to at least one of the silicon or oxygen.

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 for a fuel cell is provided including a plate having an active surface with a plurality of flow channels formed therein. The plurality of flow channels have a hydrophilic coating deposited thereon and define a plurality of lands disposed therebetween. The plurality of lands is substantially free of the hydrophilic coating. Furthermore, a thickness of the hydrophilic coating is substantially constant along a length of the active surface and an edge of the hydrophilic coating adjacent the plurality of lands is substantially continuous. A method for preparing the bipolar plate is also provided.

Abstract: A bipolar plate for a fuel cell is provided including a plate having an active surface with a plurality of flow channels formed therein. The plurality of flow channels have a hydrophilic coating deposited thereon and define a plurality of lands disposed therebetween. The plurality of lands is substantially free of the hydrophilic coating. Furthermore, a thickness of the hydrophilic coating is substantially constant along a length of the active surface and an edge of the hydrophilic coating adjacent the plurality of lands is substantially continuous. A method for preparing the bipolar plate is also provided.

Abstract: A sealed assembly is made using sealant including a deformable spacer to control thickness without adversely impacting elasticity and sealing force. Deformable spacers (e.g., elastomer, polyolefin, etc.) are mixed with an elastomeric precursor material and dispensed onto an assembly component, such as a fuel cell bipolar plate, and the remaining component(s) are assembled by pressing against the deformable spacer to ensure a defined seal thickness. The precursor is cured to form a seal that is further compressed to provide an effective sealing force. The deformable spacers control the thickness of a sealed area and allow use of form-in-place sealing processes.

Abstract: A method of coating a surface of a fuel cell plate is disclosed herein, and involves forming a sol gel mixture by mixing a weak acid and a composition including at least two metal oxide precursors. One of the metal oxide precursors is configured to be hydrolyzed by the weak acid to form a mixed metal oxide framework with an other of the metal oxide precursors having at least one organic functional group that is not hydrolyzed by the weak acid. The mixture is applied to the surface, and is condensed by exposure to air at least one predetermined temperature and for a predetermined time. The sol gel mixture is immersed in water at a predetermined temperature and for a predetermined time to form a porous, hydrophilic, and conductive film on the surface.

Abstract: A method for recovering ruthenium oxide or gold and titanium or titanium oxide from a bipolar plate at the end of the life of a fuel cell stack so as to use these materials in other fuel cell stacks thereafter. The bipolar plate is immersed in a solution including a suitable acid that dissolves the titanium or titanium oxide. The ruthenium oxide or gold will be released from the plate and will float on the solution from which it can be removed. The solution is then heated to evaporate the acid solution leaving a powder of the titanium oxide. The stainless steel of the bipolar plate is thus cleaned of the titanium or titanium oxide, and can be reused.

Abstract: An electrode plate is disclosed. The electrode plate includes a plate having an active area, a feed region in fluid communication with the active region, and a tunnel region in fluid communication with the feed region and a manifold region, an ultralyophobic coating on one or more of at least a portion of the tunnel region, at least a portion of the feed region, and an interface between the tunnel region and the manifold region. Fuel cells using the electrode plate and methods of making electrode plates are also described.

Abstract: An electrically conductive plate for fuel cell applications comprises a plate body having at least one channel-defining surface and an electrically conductive hydrophilic layer disposed over at least a portion of the channel-defining surface. The electrically conductive layer includes residues of a silane coupling agent and electrically conductive hydrophilic carbon.