Abstract: A fuel cell component having a coating thereon including binary and ternary nitrides and oxynitrides of elements of IVb and Vb groups of the periodic table of elements.

Abstract: A method of making a fuel cell component using a mask, which is removed after further processing to yield a surface with variable properties.

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 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 assembly is disclosed that utilizes a water transport structure extending from fuel cell plates of the assembly into fuel cell assembly manifolds, wherein the water transport structure facilitates the transport of liquid water from the fuel cell plates thereby minimizing the accumulation of liquid water and ice in the fuel cell stack.

Abstract: A method for optimizing a fuel cell diffusion media having a spatially varying mass transport resistance is provided. The method includes at least two passes where a first-pass D/Deff profile for the fuel cell diffusion media is provided and applied to a computational model of the fuel cell having a baseline variable profile. At least one first-pass variable profile resulting from the application of the first-pass D/Deff profile to the computational mode is calculated and compared to a desired variable range. The first-pass D/Deff profile is refined, if necessary, to provide a second-pass D/Deff profile. A relative performance of the fuel cell with a second-pass variable profile resulting from an application of the second-pass D/Deff profile is determined. The second-pass D/Deff profile is refined, if necessary, until the second-pass variable profile has a desirable performance. An effective D/Deff profile is thereby provided.

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 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: 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 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 bipolar plate for a fuel cell is provided that includes a flowfield having an active surface with an inlet region and an outlet region. The active surface of the flowfield is in communication with the inlet region and the outlet region and has at least one flow channel formed therein. The at least one flow channel further has a cross-sectional area at the outlet region that is less than a cross-sectional area at the inlet region. In particular embodiments, the at least one flow channel is bifurcated. A fuel cell stack including a fuel cell and the bipolar plate is also provided.

Abstract: A bipolar plate for a fuel cell is disclosed including a first unipolar plate having an active surface with a plurality of flowfield channels formed therein. The first unipolar plate further includes an inlet header disposed at a first end of the unipolar plate that is in communication with the active surface, and an outlet header disposed at a second end of the unipolar plate having an exhaust opening formed therethrough. A peripheral edge of the exhaust opening is chamfered and is also in communication with the active surface. The chamfered exhaust opening forms a water removal channel in the bipolar plate. A fuel cell stack including the bipolar plate is also disclosed.

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 fuel cell stack is disclosed that utilizes a porous material internally disposed in the fuel cell outlet manifolds, wherein the porous material facilitates the transport of liquid water from the plate outlets thereby minimizing the accumulation of liquid water in the fuel cell stack.

Abstract: A product including a fuel cell gas diffusion media layer and a plurality of electrically conductive lands secured thereto.

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 diffusion media and a scheme for spatially varying the parameters of the diffusion media to address issues related to water management in electrochemical cells and other devices employing the diffusion media are provided. A device is configured to convert a hydrogenous fuel source to electrical energy and comprises an electrochemical conversion assembly, first and second reactant inputs, first and second product outputs, and first and second diffusion media. The device is configured such that a mesoporous layer is carried along at least a portion of a major face of one of the first and second diffusion media substrates. The mesoporous layer comprises a hydrophilic carbonaceous component and a hydrophobic component. The mesoporous layer occupies a substantially greater portion of one of the high or low H2O regions of the device, relative to the other of the high or low H2O region of the device.

Abstract: A fuel cell and a method for manufacturing a fuel cell including a membrane electrode assembly that includes an ionically conductive member and an electrode disposed at the ionically conductive member. Further, the fuel cell includes an electrically conductive member or gas diffusion medium that includes a flow field formed of conductive particles dispersed in a binder.

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: 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.