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: A method including providing a substrate; treating the substrate to form a passive layer, wherein the passive layer has a thickness of at least 3 nm; and depositing an electrically conductive coating over the substrate, wherein the coating has a thickness of about 0.1 nm to about 50 nm.

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: One embodiment of the invention includes a product including a fuel cell component including a coating thereon, the coating comprising nanoparticles comprising titanium oxide or titanium containing compounds derived therefrom.

Abstract: One embodiment of the invention includes an assembly of metal oxide comprising valve metal oxide nanotubes.

Abstract: A product including a polymer electrolyte membrane, an electrode over the membrane, a gas diffusion media layer over the electrode, and a hydrophilic layer over the gas diffusion media layer.

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: A metallic bipolar plate for use in a fuel cell includes a metallic bipolar plate having one or more channels and a contact surface. The contact surface has a surface roughness defined by a plurality of peaks and valleys wherein at least a portion of the valleys are filled with an electrically conductive material. The contact surface is adapted to contact the anode diffusion layer or the cathode diffusion layer such that the contact resistance occurring at this surface is lower than when the electrically conductive material is not present. A fuel cell incorporating the metallic bipolar plate is also provided.

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

Abstract: A bipolar plate for a fuel cell that includes a hydrophilic layer deposited on the bipolar plate to a suitable thickness to satisfy hydrofluoric acid etching for the desired lifetime of the fuel cell. In one embodiment, the hydrophilic layer is a relatively thick silicon dioxide layer that is deposited on the bipolar plate as a colloidal dispersion of silicon dioxide nano-particles in a solvent. The dispersion is dried so that the solvent evaporates to form a film of the silicon dioxide nano-particles on the bipolar plate. A relatively thin layer, generally a metal oxide, is first deposited on the bipolar plate by a CVD or PVD process so that the thin layer has suitable bonding to the bipolar plate. The thicker hydrophilic layer is then deposited on the thin layer, where the bonds between the thick layer and the thin layer are suitable for the fuel cell environment.

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 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: 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: 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: An electrically conductive fluid distribution element for a fuel cell which comprises an electrically conductive substrate, a flow field for distributing fluid along a surface of the substrate, and an electrically conductive coating on the surface which comprises a noble metal, desirably Ru, Rh, Pd, Ag, Ir, Pt, Os, and preferably Au.

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.