Abstract: A flow field plate or bipolar plate for a fuel cell that includes a conductive coating having formed nanopores that make the coating hydrophilic. Any suitable process can be used to form the nanopores in the coating. One process includes co-depositing a conductive material and a relatively unstable element on the plate, and then subsequently dissolving the element to remove it from the coating and create the nanopores. Another process includes using low energy ion beams for ion beam lithography to make the nanopores.

Abstract: A method for depositing a hydrophilic coating on flow field plates or bipolar plates and manifolds in a fuel cell stack after the stack is assembled. The method includes preparing a solution that contains hydrophilic nano-particles suspended in a suitable solvent. The cathode and anode inlet and outlet manifolds and the cathode and anode flow channels are filled with the solution. The solution is then pumped out of the stack using, for example, a stream of nitrogen. The stack is allowed to dry, using heat if desirable, to provide a film of the nano-particles formed on the anode and cathode flow channels and manifolds within the stack.

Abstract: A flow field plate or bipolar plate for a fuel cell that includes a combination of TiO2 and a conductive material that makes the bipolar plate conductive, hydrophilic and stable in the fuel cell environment. The TiO2 and the conductive material can be deposited on the plate as separate layers or can be combined as a single layer. Either the TiO2 layer or the conductive layer can be deposited first. In one embodiment, the conductive material is gold.

Abstract: One embodiment of the invention comprises a fuel cell bipolar plate comprising a substrate comprising a first face, a reactant gas flow field defined in the first face, the reactant gas flow field comprising a plurality of lands and channels, and a plurality of microgrooves formed in the first face.

Abstract: A fluid distribution element is provided for a fuel cell having a major surface facing a membrane electrode assembly (MEA) and one or more flow channels for transporting gas and liquid to and from the MEA. One or more regions of the major surface are overlaid with a super-hydrophilic corrosion-resistant layer comprising a fluoropolymer. Methods of making such a fluid distribution element are also provided.

Abstract: A process comprising: depositing a coating on a fuel cell bipolar plate using plasma assisted chemical vapor deposition.

Abstract: A bipolar plate includes angled facets oriented to form V-shaped projections on the plate edge. Liquid leaving the reactant channels is drawn back into the V-shaped grooves of the projections, leaving no liquid to obstruct the channel exit openings. The bipolar plate includes one portion of the bipolar plate offset from another portion of the bipolar plate so as to expose the reactant channels. The liquid is drawn toward the end portions of the reactant channels by capillary forces, while the gas flows can exit near the beginning of the offset portion. A fuel cell stack includes angled facets that are rotated to lie in the plane of the bipolar plate edges. The edges are chamfered so the channel exit openings of the reactant channels are at the tip portions thereof, thus allowing the liquid to flow away from the channel exit openings and the gas to exit freely.

Abstract: A fuel cell plate including a first plate having a first header edge defining a first header aperture, the first header edge having a first break and a substantially aligned second plate having a second header edge defining a second header aperture, the second header edge having a second break. The fuel cell plate, well suited for use in a vehicle fuel cell stack, for removing water from a fuel cell stack header is disclosed.

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 plate for a fuel cell is disclosed, wherein an inlet aperture is disposed at a first end of the plate and an outlet aperture is disposed at a second end of the plate. The plate includes a first side and a second side. The first side of the plate has a flow field formed therein between the inlet aperture and the outlet aperture, the flow field having a plurality of flow channels formed therein, the plurality of flow channels in communication with a plurality of outlet ports formed in the plate. The second side of the plate has a plurality of drainage channels formed therein adjacent the outlet aperture, the plurality of drainage channels in fluid communication with the outlet ports and the outlet aperture, wherein a cross-sectional area occupied by each of the plurality of flow channels is substantially equal to a cross-sectional area occupied by each of the plurality of drainage channels.

Abstract: A bi-polar plate is provided for a fuel cell stack. The bi-polar plate has improved surface wettability. The bi-polar plate includes a body including at least approximately ninety percent by weight of a metal and defining at least one flow channel. At least about 0.05 percent and up to 100 percent by weight of silicon is disposed on a surface of the at least one flow channel to form a high energy surface to form a high energy surface for the bi-polar plate. This can be achieved by adding from 0.5 to 10 weight % silicon to the steel. The percent of silicon is pre-determined based on a desired wettability of the high energy surface of the at least one flow channel.

Abstract: One embodiment disclosed includes a product comprising: a fuel cell component comprising a substrate and a first coating overlying the substrate, the coating comprising a compound comprising at least one Si—O group, at least one polar group and at least one group including a saturated or unsaturated carbon chain.

Abstract: A flow field plate or bipolar plate for a fuel cell that includes a hydrophilic coating formed on flow field channels extending through a tunnel region between a cell active area and the inlet and outlet manifolds. The flow field plates are an assembly of a cathode side unipolar plate and an anode side unipolar plate. The hydrophilic coating is deposited on the unipolar plates prior to the unipolar plates being assembled into the flow field plate so that line of site deposition processes can be used to coat the flow field channels in the tunnel region. The unipolar plates can be any suitable fuel cell unipolar plates, such as stamped unipolar plates or composite unipolar plates.

Abstract: A device and method to extract water from a moisture-rich fuel cell flowpath. A water transport unit is integrated into the fuel cell so that liquid water stagnation within flow channels and manifolds is reduced. In one embodiment, the device includes numerous flowpaths that include an active region and an inactive region. The water transport unit includes a hydrophilic member such that upon passage of a fluid with the excess water through the inactive region of the device flowpath and into the presence of the hydrophilic member, it absorbs excess water from the fluid.

Abstract: A flow field plate for a fuel cell that has one or more outer layers that makes the plate more conductive and hydrophilic. In one embodiment, the coating is co-deposited as combination of a conductive material and a metal oxide coating. A suitable conductive material is gold and suitable metal oxides include SiO2, HfO2, ZrO2, Al2O3, SnO2, Ta2O5, Nb2O5, MoO2, IrO2, RuO2 and mixtures thereof. The conductive material and metal oxide can also be deposited as two separate layers, where the metal oxide is the outer layer. According to another embodiment, a metal layer is deposited on the plate with nanopores that provide the hydrophilicity. Also, doping ions can be added to the metal oxide to provide low fluoride solubility of the coating to control the rate that hydrofluoric acid etches away the oxide layer.

Abstract: A method of depositing a conductive material is described. The method includes: providing a plate selected from anode plates, cathode plates, bipolar plates, or combinations thereof, wherein the plate includes gas flow channels; providing a diffusion media in contact with the gas flow channel side of the plate to form an assembly; introducing a gaseous precursor of the conductive material into the assembly using a chemical vapor infiltration process; infiltrating the gaseous precursor into the diffusion media and gas flow channels of the plates; and depositing a coating of the conductive material on the diffusion media, the gas flow channels of the plate, or both. An assembly having a CVI conductive coating and a fuel cell incorporating the diffusion media having the CVI conductive coating are also described.

Abstract: A fuel cell includes a first electrically conductive plate and a first gas diffusion layer. The first gas diffusion layer is disposed over the first electrically conductive plate. Characteristically, the first gas diffusion layer comprises a first fibrous sheet having fibers coated with an electrically conductive layer. A first catalyst layer is disposed over the first gas diffusion layer and an ion conducting membrane is disposed over the first catalyst layer. The fuel cell also includes a second catalyst layer disposed over the ion conducting membrane with a second gas diffusion layer disposed over the second catalyst layer. A second electrically conductive plate is disposed over the second gas diffusion layer. Methods for forming the gas diffusion layers and the fuel cell are also provided.

Abstract: A bipolar plate for use in a proton exchange membrane fuel cell having an electrically conductive polymer coated on at least one region of a surface of the plate in contact with a flow field. The coated region is hydrophobic or hydrophilic as compared to an uncoated region of the surface to prevent liquid accumulation. Electroconductive polymer coatings are applied by electrochemical polymerization.

Abstract: One embodiment disclosed includes a product comprising: a fuel cell component comprising a substrate and a first coating overlying the substrate, the coating comprising a compound comprising at least one Si—O group, at least one polar group and at least one group including a saturated or unsaturated carbon chain.

Abstract: A fuel cell assembly is provided that includes a fluid collection member disposed in a fluid inlet for a reactant, wherein the fluid collection member militates against liquid water on an inner surface of the fluid inlet from being received by a fuel cell of the fuel cell assembly.