Abstract: In one aspect a substrate such as a sheet metal product, in particular for use as a bipolar plate in a fuel cell or in an electrolyzer, is characterized in that it has, on at least one side, a conductive and corrosion-resistant protective coating of a metal oxide having a treatment which ensures the conductivity. The coating can be produced by introducing a piece of sheet metal into a coating plant and providing it with the conductive and corrosion-resistant protective coating of the metal oxide. In another aspect, an electrochemical cell such as a fuel cell comprises an electrically conductive contact element having a first surface facing an electrode for conducting electrical current, and the contact element comprises an electrically conductive substrate and an electrically conductive coating comprising a doped metal oxide, desirably a doped tin oxide, and preferably a fluorine doped tin oxide.

Abstract: The present invention provides an electrically conductive element for a proton exchange membrane fuel cell having low electrical contact resistance and high corrosion resistance. The conductive element comprises a corrosion susceptible metal substrate with a surface, which is preferably treated to activate the surface (i.e. to remove a passivation layer of oxides from the surface) with an acidic treatment solution. The treated surface is then overlaid with an electrically conductive, corrosion-resistant, protective coating to protect the substrate re-forming a passivation layer while exposed to the corrosive environment of the fuel cell. The present invention also provides methods of preparing an electrically conductive element to have low electrical contact resistance and high corrosion resistance.

Abstract: A flow field plate or bipolar plate for a fuel cell that includes a carbon nano tube or carbon nano fiber coating that makes the bipolar plate conductive hydrophilic. Further, the carbon nano tube or carbon nano fiber coating is stable in the fuel cell environment and does not corrode.

Abstract: Devices comprising an electrochemical conversion assembly comprise a plurality of electrochemical conversion cells, and a plurality of electrically conductive bipolar plates, wherein the electrochemical conversion cells are disposed between the adjacent bipolar plates. The electrochemical conversion assembly further comprises a plurality of conversion assembly gaskets, wherein the respective conversion assembly gaskets are molded onto corresponding ones of the plurality of bipolar plates. The conversion assembly gaskets comprise a mixture including polyvinylidene fluoride (PVDF).

Abstract: Embodiments of an electrically conductive fluid distribution plate are provided, wherein the electrically conductive fluid distribution plate comprises a plate body defining a set of fluid flow channels configured to distribute flow of a fluid across at least one side of said plate, and a coating adhered to the plate in an area of the plate including the fluid flow channels defined by the plate body. The coating comprises expanded graphite comprising less than about 0.01% by weight of impurities. The coating also comprises less than about 10% by weight expanded graphite plus carbon black, and about 70% to about 95% by wt. binder, wherein the binder is comprised of a polymeric resin.

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 manufacturing a composite separator plate for a fuel cell stack. The method includes preparing expanded graphite into particles, and dispersing the expanded graphite particles into a polymeric resin. The resin, including the graphite particles, is compression molded to form the separator plate. In one embodiment, the expanded graphite is dispersed into the polymeric resin by mixing it in to the resin. In an alternate embodiment, the expanded graphite is sprinkled into the polymeric resin using an SMC-like process.

Abstract: A flow field plate or bipolar plate for a fuel cell, where a surface of the flow field plate is textured or roughened to change the surface morphology of the plate. A conductive coating is deposited on the roughened surface where the roughness of the surface of the plate increases the hydrophilic nature of the coating. Therefore, if the coating is naturally hydrophobic, the surface roughness makes the coating hydrophilic to wick water away. If the coating is a conductive hydrophilic coating, then the surface roughness makes the coating super-hydrophilic, and may counter the effects of surface contamination that would act to make the hydrophilic coating less hydrophilic.

Abstract: A fuel cell system that employs a surface active agent that reduces the surface tension of the water in the flow field channels. The fuel cell system includes humidifiers that humidify the cathode inlet airflow and the hydrogen anode gas. The surface active agent is mixed with the humidifying water in the humidifiers so that the surface active agent enters the flow field channels to reduce the surface tension of the water therein, thus allowing the water to wick the channels. In one non-limiting embodiment, the surface active agent is ethanol. Ruthenium can be added to the platinum in the catalyst layers of the fuel cells to mitigate the poisoning of platinum by carbon monoxide, which is one of the oxidation products of ethanol on the cathode side of the fuel cell.

Abstract: A flow field plate or bipolar plate for a fuel cell that includes a carbide coating that makes the bipolar plate conductive, hydrophilic and stable in the fuel cell environment. Suitable carbides include, but are not limited to, chromium carbide, titanium carbide, tantalum carbide, niobium carbide and zirconium carbide. The carbide coating is then polished or textured by a suitable process, such as laser or chemical etching, to provide a surface morphology that makes the coating more hydrophilic, and further reduces the contact resistance on its surface.

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: An electrically conductive fluid distribution element for use in a fuel cell having a conductive metal substrate and a layer of conductive non-metallic porous media. The conductive non-metallic porous media has an electrically conductive material deposited along a surface in one or more metallized regions and having an average thickness equal to about the diameter of one atom of the material. The metallized regions improve electrical conductance at contact regions between the metal substrate and the fluid distribution media.

Abstract: The present invention relates to an electrically conductive element, such as a 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 confronts one another. The first and said second coated surfaces are joined to one another by an electrically conductive epoxy adhesive which provides adhesion of the first and said second surfaces of the sheets at one or more contact regions.

Abstract: In at least one embodiment, the present invention provides an electrically conductive fluid distribution separator plate assembly, a method of making, and a system for using, the electrically conductive fluid distribution separator plate assembly. In at least one embodiment, the electrically conductive fluid distribution separator plate assembly comprises a metallic cathode plate having opposed surfaces and a first contact resistance, a polymeric composite anode plate adjacent to the metallic cathode plate, and a low contact resistance coating located on at least one of the surfaces of the plates, with the coating having a second contact resistance, less-than the first contact resistance.

Abstract: A fuel cell that employs a decomposition catalyst on one or more of the membrane, bipolar plates or diffusion media layers in the fuel cell that decomposes hydrogen peroxide, and thus reduces the generation of hydroxyl free radicals. In one embodiment, the decomposition catalyst is ruthenium oxide and is deposited on the structure by various processes, such as chemical vapor deposition process.

Abstract: An electrically conductive separator element and assembly for a fuel cell which comprises an electrically conductive substrate having a monoatomic layer coating overlying the substrate. The monatomic layer coating may comprise an electrically conductive material, for example, a noble metal, desirably Ru, Rh, Pd, Ag, Ir, Os and preferably Au. Methods of making such separator elements and assemblies are also provided.

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: A fuel cell electroconductive element, or bipolar plate, that includes a substrate with a cationic or anionic exchange resin coating deposited thereon, and a method for making the same. The bipolar plate has a fluid flow field formed therein. The ion-exchange polymer is preferably deposited on a region of the surface of the substrate by a process of dip coating or spraying. The resin coating is substantially hydrophobic in nature when dry and substantially hydrophilic when wet.

Abstract: An electrically conductive fluid distribution element for use in a fuel cell having a layer of a conductive non-metallic fiberless microporous media. In certain embodiments, an electrically conductive metal is deposited along a surface of the element to form one or more metallized regions. The metallized regions are arranged to contact a membrane electrode assembly (MEA) in a fuel cell assembly, and thus improve electrical conductance at contact regions between the MEA and the layer of media. Methods of making such a fluid distribution element and operating fuel cell assemblies are also provided.

Abstract: In at least one embodiment, the present invention provides a hydrophilic electrically conductive fluid distribution plate and a method of making, and system for using, the hydrophilic electrically conductive fluid distribution plate. In at least one embodiment, the plate comprises a plate body defining a set of fluid flow channels configured to distribute flow of a fluid across at least one side of the plate, and a composite conductive coating having a water contact angle of less than 40° adhered to the plate body. In at least one embodiment, the composite coating comprises a polymeric conductive layer adhered to the plate body having an exterior surface, and a particulate carbon layer adhered to the exterior surface of the polymeric conductive layer.