Abstract: A composite plate (26) is formed in a mold (8) by placing one of two preforms (15, 23) of between about 80 wt. % and about 85 wt. % flake graphite, balance polymer binder, into the mold and disposing a coolant tube array (18) thereon, depositing a powder (21) of the flake/polymer around the tube array, placing a second preform on the powder and a mold plunger (27) on the second preform, heating the mold to the melting temperature of the polymer under a pressure of 625 psi (4311 kPa), cooling the mold to the solidification temperature of the polymer while still under pressure, cooling the mold further, disassembling the mold, and removing the composite plate. The composite plate has reactant gas flow field channels (31, 32) in major surfaces thereof, is devoid of any acid edge protection layer or film and is devoid of any acid impervious separator plate between either of the fuel cell reactant gas flow fields and the coolant tube array.

Abstract: A composite plate (26) is formed in a mold (8) by placing one of two preforms (15, 23) of between about 80 wt.% and about 85 wt.% flake graphite, balance polymer binder, into the mold and disposing a coolant tube array (18) thereon, depositing a powder (21) of the flake/polymer around the tube array, placing a second preform on the powder and a mold plunger (27) on the second preform, heating the mold to the melting temperature of the polymer under a pressure of 625 psi (4311 kPa), cooling the mold to the solidification temperature of the polymer while still under pressure, cooling the mold further, disassembling the mold, and removing the composite plate. The composite plate has reactant gas flow field channels (31, 32) in major surfaces thereof, is devoid of any acid edge protection layer or film and is devoid of any acid impervious separator plate between either of the fuel cell reactant gas flow fields and the coolant tube array.

Abstract: A flowable substance is applied to at least one predetermined area of a major surface of a plate-shaped fuel cell component by directing at least one stream of the flowable substance toward a predetermined zone that is situated in a plane along which the major surface of the component extends, facing the stream. The size of the predetermined zone is smaller than that of the predetermined area, and relative movement along the plane is effected between the component and the predetermined zone so that at least the entire predetermined area of the major surface gradually advances through the predetermined zone in a predetermined advancement direction and path. The stream is controlled so that it is in existence only while the zone is completely within the predetermined area, and until the zone has coincided with all of the predetermined area.

Abstract: A flowable substance is applied to at least one predetermined area of a major surface of a plate-shaped fuel cell component by directing at least one stream of the flowable substance toward a predetermined zone that is situated in a plane along which the major surface of the component extends, facing the stream. The size of the predetermined zone is smaller than that of the predetermined area, and relative movement along the plane is effected between the component and the predetermined zone in such a manner that at least the entire predetermined area of the major surface gradually advances through the predetermined zone in a predetermined advancement direction and path. The stream is controlled in such a manner that it is in existence only while the zone is completely within the predetermined area, and until the zone has coincided with all of the predetermined area.