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.

Abstract: Corrosion in manifolds and ducts in phosphoric acid fuel cells can be reduced by electroplating a chromium-fluorocarbon polymer composite coating onto the exposed metal surfaces. The chromium-fluorocarbon coating displays superior corrosion protection and improved adhesion after being subjected to a plurality of heating and cooling cycles. The improved corrosion protection enhances fuel cell operating reliability and allows the use of less expensive materials in the construction of the manifolds and ducts.

Abstract: A method for making a carbon-graphite component of the type adapted for use in an electrochemical cell is disclosed. The precursor sheet structure for the component contains cellulose and purified graphite powder which provides certain advantages during processing and in the final products.

Abstract: A method of forming thin, uniform braze joints is effected through the use of curtain coating. Braze powder is admixed with a liquid polymeric binder to form a slurry. The slurry is forced through the slots in a curtain coating head and deposited on at least one of the metal surfaces to be bonded together. The method has particular utility for bonding fin/plate sections of a heat exchanger where the fins have a U-shaped cross section. The slurry is deposited on the top portion of the fin and the side portion of the fin and wiped from the top portion leaving braze material primarily on the side wall portion. When the plates are contacted to the fins and heating performed, a bond is effected with maximum plate-to-fin contact for high heat transfer and a strong braze joint.

Abstract: A method of making a thin, flexible, pliable matrix material for a molten carbonate fuel cell is described. The method comprises admixing particles inert in the molten carbonate environment with an organic polymer binder and ceramic particle. The composition is applied to a mold surface and dried, and the formed compliant matrix material removed.

Abstract: A process for forming a fuel cell electrolyte matrix on the surface of an electrode involves passing the electrode through a vertically falling curtain or waterfall of the matrix material carried in a liquid vehicle. The coated electrode is then heat treated to remove the liquid vehicle, leaving a layer of matrix material on the electrode surface. This curtain coating process has been used to produce matrix layers of 2.5 mils having a variation in thickness of no more than 0.2 mils.

Abstract: An electrolyte reservoir layer disposed behind and adjacent one of the catalyst layers of a fuel cell is porous and hydrophilic to the electrolyte. In one embodiment the reservoir layer includes impregnations of hydrophobic material to provide reactant gas passages through the reservoir layer to the catalyst layer. Additionally the reservoir layer includes impregnations of a material similar to the fuel cell electrolyte retaining matrix material to improve electrolyte transfer from the matrix into the reservoir. The impregnations of hydrophobic material are designed to provide good distribution of the reactant gas into the catalyst layer without consuming a large volume of the reservoir. In a preferred embodiment the reservoir is also the electrode substrate whereby the catalyst layer is bonded to the surface thereof.