A separator includes a base including projections. The base is made of a metal plate. The separator includes a conductive layer arranged on a top surface of each of the projections of the base. The conductive layer includes conductive carbon materials, conductive particles, and a thermosetting resin. The conductive carbon materials and the conductive particles are dispersed in the resin and are in contact with each other over an entirety of the conductive layer in a thickness direction of the conductive layer.

A separator includes a base including projections. The base is made of a metal plate. The separator includes a conductive layer arranged on a top surface of each of the projections of the base. The conductive layer includes conductive carbon materials, conductive particles, and a thermosetting resin. The conductive carbon materials and the conductive particles are dispersed in the resin and are in contact with each other over an entirety of the conductive layer in a thickness direction of the conductive layer.

A method of preparing a bipolar plate for a fuel cell is disclosed. The method includes (a) using an electrically conductive filler and a polymer binder to prepare a bipolar plate blank, (b) vacuum-sealing the bipolar plate blank in a metal foil bag, (c) applying hot isostatic pressing to the bipolar plate blank vacuum-sealed in the metal foil bag at a pressure greater than 100 MPa and a temperature of 150-400° C., and (d) peeling the bipolar plate blank that has undergone the hot isostatic pressing from the metal foil bag, and thereby obtaining the bipolar plate. A bipolar plate prepared by the method is also disclosed.

A hybrid bipolar plate assembly for a fuel cell includes a formed cathode half plate and a stamped metal anode half plate. The stamped metal anode half plate is nested with and affixed to the formed cathode half plate. Each of the half plates has a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures. The coolant side of the formed cathode half plate has support features that can be different from and need not correspond with cathode flow channels formed on the opposite reactant side. The coolant side of the stamped metal anode half plate has lands corresponding with anode channels formed on the opposite oxidant side. The lands define a plurality of coolant channels on the coolant side of the stamped metal anode half plate and abut the coolant side of the formed cathode half plate.

A hybrid bipolar plate assembly for a fuel cell includes a formed cathode half plate and a stamped metal anode half plate. The stamped metal anode half plate is nested with and affixed to the formed cathode half plate. Each of the half plates has a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures. The coolant side of the formed cathode half plate has support features that can be different from and need not correspond with cathode flow channels formed on the opposite reactant side. The coolant side of the stamped metal anode half plate has lands corresponding with anode channels formed on the opposite oxidant side. The lands define a plurality of coolant channels on the coolant side of the stamped metal anode half plate and abut the coolant side of the formed cathode half plate.

A bipolar plate for a fuel cell for generation of electrical power has a bipolar plate body having a first surface. The bipolar plate body has at least one gas flow channel on the first surface, the gas flow channel defining a first gas flow channel side wall and an opposite second gas flow channel side wall, and the gas flow channel running in a first direction to expose the electrode to the reactant. The bipolar plate also has at least one electrical conductor to run at least partly parallel to the first direction within the bipolar plate body behind the first gas flow channel side wall and/or the second gas flow channel side wall, such that, when a voltage is applied to the electrical conductor, the electrical conductor forms an electromagnetic field, the electromagnetic field to accelerate the reactant at least partly in the direction of the electrode.

Disclosed is a method for manufacturing a fuel cell separator having minimized surface defect via surface polishing using high-pressure injection, in which surface polishing is performed using a high-pressure injection scheme in which polishing-fluid is injected at high-pressure through a polishing-fluid injection nozzle before performing vision inspection, thereby minimizing the surface defect of the fuel cell separator.

A bipolar plate for a fuel cell is provided. The bipolar plate is formed by pressing a base plate, wherein the base plate is formed by a soft graphite plate. The soft graphite plate has a density of 0.8-1.3 g/cm.sup.3, a carbon content more than 98% and an ash content less than 2%. Based on the thickness of the base plate before pressing, the thickness compression ratio of the bipolar plate is 40-50%.

A bipolar plate for a fuel cell is provided. The bipolar plate is formed by pressing a base plate, wherein the base plate is formed by a soft graphite plate. The soft graphite plate has a density of 0.8-1.3 g/cm.sup.3, a carbon content more than 98% and an ash content less than 2%. Based on the thickness of the base plate before pressing, the thickness compression ratio of the bipolar plate is 40-50%.

Provided are a low-price fuel cell separator with high corrosion resistance and a method for manufacturing the separator. The present disclosure relates to a fuel cell separator including a metal substrate and a titanium layer containing titanium formed on the metal substrate, and a method for manufacturing the separator. A ratio of a (100) plane to a sum of values obtained by dividing peak intensities of the (100) plane, a (002) plane, and a (101) plane derived from titanium in an X-ray diffraction analysis of a separator surface by respective relative intensities is a constant value or more.