Abstract: The present invention relates to a separator plate in an electrochemical cell having a body with an electrically conductive first section having fluid flow fields with a plurality of flow channels formed therein and a second section 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. Further, the present invention contemplates methods to form such a separator plate.

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.

Abstract: An electrode structure for an electrochemical cell is formed by forming a mixture comprising proton-conductive material and carbon particles, applying the mixture to a current collector sheet to form a film, and dispersing a catalyst in the form of metallic polycrystals in a thin layer on the exposed surface of the film. This method produces an electrode having significantly increased catalyst utilization, dramatic reduction of catalyst loading, and which is consequently less expensive to produce than electrodes produced by prior art methods. A combination electrolyte and electrode structure for an electrochemical cell is produced by hot-pressing an electrode of the above-described composition into contact with a proton-conductive polymer electrolyte membrane.

Abstract: There is provided an electrode structure comprising a current collector sheet and first and second layers of electrode material. Together, the layers improve catalyst utilization and water management.

Abstract: A method of making a combination, unitary, membrane and electrode assembly having a solid polymer electrolyte membrane, and first and second electrodes at least partially embedded in opposed surfaces of the membrane. The electrodes each comprise a respective group of finely divided carbon particles, very finely divided catalytic particles supported on internal and external surfaces of the carbon particles and a proton conductive material intermingled with the catalytic and carbon particles. A first group of finely divided carbon particles forming the first electrode has greater water attraction and retention properties, and is more hydrophilic than a second group of carbon particles forming the second electrode. In a preferred method, the membrane electrode assembly of the invention is prepared by forming a slurry of proton conductive material and at least one group of the carbon and catalyst particles.

Abstract: A combination, unitary, membrane and electrode assembly with a solid polymer electrolyte membrane, and first and second electrodes at least partially embedded in opposed surfaces of the membrane. The electrodes each comprise a respective group of finely divided carbon particles, very finely divided catalytic particles supported on internal and external surfaces of the carbon particles and a proton conductive material intermingled with the catalytic and carbon particles. A first group of finely divided carbon particles forming the first electrode has greater water attraction and retention properties, and is more hydrophilic than a second group of carbon particles forming the second electrode. In a preferred method, the membrane electrode assembly of the invention is prepared by forming a slurry of proton conductive material and at least one group of the carbon and catalyst particles.

Abstract: Corrosion resistant electrodeposit comprising a solid solution of phosphorus and nickel supersaturated with zinc. The electrodeposit is formed from an electrolyte containing nickel chloride, zinc chloride and sodium hypophosphite having a nickel ion to zinc ion molar ratio between about 7 and about 12 and deposited at current densities greater than about 0.6 A/cm.sup.2.