Abstract: An enhanced stability and inexpensive bipolar plate for a fuel cell is disclosed. The enhanced stability bipolar plate includes a bipolar plate substrate and a corrosion-resistant coating thermally sprayed on the bipolar plate substrate. A method for enhancing corrosion resistance of a bipolar plate is also disclosed.

Abstract: A hybrid bipolar plate assembly comprises a metallic anode plate, a polymeric composite cathode plate, and a metal layer positioned between the metallic anode plate and the composite cathode plate. The metallic anode and composite cathode plates can further comprise an adhesive sealant applied around the outer perimeter to prevent leaking of coolant. The assembly can be incorporated into a device comprising a fuel cell. Further, the device can define structure defining a vehicle powered by the fuel cell.

Abstract: A method of fabricating a corrosion-resistant and inexpensive bipolar plate for a fuel cell is disclosed. The method includes providing a bipolar plate substrate and coating a corrosion-resistant coating on the bipolar plate substrate using a kinetic spray process.

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 metal composite for use in electrochemical devices is disclosed. The metal composite comprises a stainless steel interior component and a deposited nitrided metal exterior layer, wherein the nitrided exterior layer has lower electric contact resistance and greater corrosion resistance than the stainless steel interior component. A bipolar plate made of such metal composite and methods of producing the metal composite and bipolar plate are also disclosed.

Abstract: The present invention is directed to a fuel cell dielectric coolant and evaporative cooling process using same. The coolant comprises an emulsion that defines a polar internal phase and a hydrocarbon external phase. The polar internal phase comprises an azeotropic mixture that includes one or more polar compounds selected from water, alcohol, or combinations thereof. The fuel cell is configured to react fuel with oxygen to generate an electric current and at least one reaction product, and comprises an electrochemical catalytic reaction cell configured to include a fuel flowpath, an oxygen flowpath, and a coolant flowpath fluidly decoupled from the fuel and oxygen flowpaths, and which defines a coolant isolation manifold including the fluid dielectric coolant described above. The method of cooling a fuel cell comprises, inter alia, evaporating the polar internal phase of the fluid dielectric coolant emulsion in the coolant isolation manifold.

Abstract: Methods and materials to improve water management in a fuel cell by microtexturing fuel cell elements, including the separator plate and/or the gas diffusion media. A method of manufacturing a fuel cell includes a separator plate and/or a gas diffusion media that are microtextured. Selective ablation of material and stamping can impart microtexturing, where the microtexturing facilitates water management in the fuel cell.

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 PEM fuel cell having a current collector comprising a polymer composite and a diffusion media engaging said polymer composite. The polymer composite has a hyperconductive surface layer engaging the diffusion media to reduce the contact resistance therebetween. The hyperconductive surface layer is formed by depositing or smearing an electrically-conductive material on the surface of the polymer composite.

Abstract: A method for making a super-hydrophobic composite bipolar plate including providing a substrate comprising a composite material including carbon, and a surface layer on the substrate, and wherein the surface layer includes silicon and oxygen, and heating the substrate and surface layer to cause moieties including carbon from the substrate to diffuse outwardly through the surface layer so that the moiety is attached to one of the silicon or oxygen.

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: The present invention provides an electrically conductive element for an electrochemical cell element having enhanced protection for an underlying metal substrate with a surface susceptible to forming metal oxides. One or more regions of the surface are coated with a metal coating overlaid with an adhesion promoting coating comprising a silicon containing material derived from organosilanes. The adhesion promoting coating is overlaid with a conductive, protective polymeric coating. The present invention further provides methods of making such an electrochemical cell element to have improved adhesion of conductive, protective polymer coatings.

Abstract: A stainless steel flow field plate for a fuel cell that includes a layer of titanium or titanium oxide and a layer of titanium oxide/ruthenium oxide that makes the plate conductive and hydrophilic. In one embodiment, titanium is deposited on the surface of a stainless steel bipolar plate as a metal or an oxide using a suitable process, such as PVD or CVD. A solution of ruthenium chloride in ethanol is brushed on the titanium layer. The plate is then calcinated to provide a dimensionally stable titanium oxide/ruthenium oxide layer on the stainless steel that is hydrophilic and electrically conductive in the fuel cell environment.

Abstract: A device comprising a membrane electrode assembly, porous diffusion media, and at least one pair of bipolar plate assemblies is provided. The membrane electrode assembly is interposed between a pair of diffusion media substrates, the bipolar plate assembly comprises at least one flow field passage, and the bipolar plate assembly engages the diffusion media substrate. The diffusion media substrate comprises a fibrous matrix defining opposing first and second major faces. The substrate comprises an amount of carbonaceous material sufficient to render the substrate electrically conductive. An anion exchange resin layer engages at least a portion of at least one of the first and second major faces of the diffusion media substrate and/or the flow field passage. The anion exchange resin is configured to eliminate anions through exchange with hydroxyl groups or formation of quaternary ammonium salts.

Abstract: A composite separator plate for use in a fuel cell stack and method of manufacture is provided. The composite separator plate includes a plurality of elongated support members oriented generally parallel to each other and a polymeric body portion formed around the support members. The body portion includes a first surface with a plurality of flow channels and a second surface opposite the first surface. A plurality of electrically conductive fibers are disposed within the polymeric body portion, each fiber extending continuously from the first surface of the polymeric body portion to the second surface of the polymeric body portion in a through plane configuration.

Abstract: Embodiments of an electrically conductive fluid distribution plate are provided, wherein the electrically conductive fluid distribution 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 said plate, and a coating adhered to the plate in an area of the plate including the fluid flow channels defined by the plate body. The coating comprises expanded graphite comprising less than about 0.01% by weight of impurities. The coating also comprises less than about 10% by weight expanded graphite plus carbon black, and about 70% to about 95% by wt. binder, wherein the binder is comprised of a polymeric resin.

Abstract: A separator plate in an electrochemical cell and method for making the same includes a body with an electrically conductive first section having fluid flow fields with a plurality of flow channels formed therein. A second section is provided adjacent to the first section that has a header area defining a manifold that supplies fluids to the flow fields of each fuel cell. The second section is non-conductive to prevent possible electrical interaction with any aqueous fluids of finite ionic conductivity present in the fuel cell, which may result in inefficient fuel cell operations.

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 bipolar plate assembly for a proton exchange membrane fuel cell stack advantageously connects electrically conductive plate surfaces, without the requirement to weld or braze the plate pairs. Each plate has alternating coolant channels and lands formed on an inside facing surface. An electrically conductive layer is deposited over at least the coolant channels and lands. Pairs of plates are aligned having facing electrically conductive layers. A fluid seal is disposed between the inside facing surfaces about a perimeter of the coolant channels. Each plate pair is compressed to form a plurality of electrical bond lines between adjacent lands within the perimeter seal. The perimeter seal prevents stack reactant gas oxygen from contacting and oxidizing the electrically conductive layer. A dielectric coolant is also used to reduce oxidation of the electrically conductive layer.

Abstract: A PEM fuel cell having a current collector comprising a polymer composite and a diffusion media engaging said polymer composite. The polymer composite has a hyperconductive surface layer engaging the diffusion media to reduce the contact resistance therebetween. The hyperconductive surface layer is formed by depositing or smearing an electrically-conductive material on the surface of the polymer composite.