Ballard Power Systems Corporation

Juergen Stumper

David P Wilkinson

Stephen A Campbell

Michael T Davis

Gordon J Lamont

A fuel cell fluid distribution layer, in one embodiment, comprises perforated graphite foil. The fluid distribution layer can have one or more reactant flow field channels formed in one or both major surfaces, one or more manifold openings, conductive filler on one or both major surfaces, conductive filler at least partially filling some or all perforations and/or an electrocatalyst one or both major surfaces.

Fuel cell fluid distribution layer having integral sealing capability

A fuel cell comprises a pair of separator plates and a pair of fluid distribution layers interposed between the separator plates. At least one of the fluid distribution layers comprises a sealing region and an electrically conductive, fluid permeable active region, and a thermoplastic polymeric material extending into each of the sealing region and the active region. An ion exchange membrane is interposed between at least a portion of the fluid distribution layers, and a quantity of electrocatalyst is interposed between at least a portion of each of the fluid distribution layers and at least a portion of the membrane, thereby defining the active region. Melt-bonding the thermoplastic material in the sealing region renders the at least one fluid distribution layer substantially fluid impermeable in a direction parallel to the major planar surfaces. This approach reduces or eliminates the need for separate gaskets or sealing components and integrates several functions, such as sealing, fluid distribution, and current collection in a single layer.

Fuel cell with fluid distribution layer having intergral sealing capability

A membrane electrode assembly for an electrochemical fuel cell includes a pair of electrodes and an ion exchange membrane interposed therebetween. At least one of the electrodes comprises a porous electrode substrate. The substrate comprises a preformed macroporous web having a through-plane resistivity of greater than 1 .OMEGA.*cm. The web contains an electrically conductive filler. A method for preparing the membrane electrode assembly includes the steps of (a) forming a porous electrode substrate for an electrochemical fuel cell by filling a preformed macroporous web, the web having a through-plane resistivity of greater than 1 .OMEGA.*cm, with an electrically conductive filler and (b) consolidating the electrode pair and ion exchange membrane to form a unitary assembly.

Electrochemical fuel cell membrane electrode assembly with porous

An electrochemical fuel cell comprises a pair of separator plates and a pair of fluid distribution layers interposed between the separator plates. At least one of the fluid distribution layers comprises a sealing region and an electrically conductive, fluid permeable active region, and a preformed sheet material extending into each of the sealing region and the active region. An ion exchange membrane is interposed between at least a portion of the fluid distribution layers, and a quantity of electrocatalyst is interposed between at least a portion of each of the fluid distribution layers and at least a portion of the membrane, thereby defining the active region. Compression of the preformed sheet material by urging of the pair of plates towards each other renders the at least one fluid distribution layer substantially fluid impermeable in a direction parallel to the major planar surfaces, in the sealing region. The performed sheet material included in the at least one fluid distribution layer thus has intrinsic sealing capability. This approach reduces or eliminates the need for separate gaskets or sealing components and integrates several functions, such as sealing, fluid distribution, and current collection, in a single layer.

Electrochemical cell with fluid distribution layer having integral

A porous electrode substrate for an electrochemical fuel cell comprises at least one preformed web having low or poor electrical conductivity. The web contains an electrically conductive filler. A method for preparing a porous electrode substrate for an electrochemical fuel cell comprises the step of filling a preformed web, the web having low or poor electrical conductivity, with an electrically conductive filler.

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Vancouver, Canada

Juergen Stumper