An illustrative method of making a fuel cell component includes obtaining at least one blank plate including graphite and a polymer; establishing a temperature of the blank that is sufficient to maintain the polymer in an at least partially molten state; and applying a compression molding force to the blank until the polymer is essentially solidified to form a plate including a plurality of channels on at least one side of the plate. The blank plate has a central area having a first thickness. The blank plate also has two generally parallel edges on opposite sides of the central area. The edges have a second thickness that is greater than the first thickness.

An illustrative method of making a fuel cell component includes obtaining at least one blank plate including graphite and a polymer; establishing a temperature of the blank that is sufficient to maintain the polymer in an at least partially molten state; and applying a compression molding force to the blank until the polymer is essentially solidified to form a plate including a plurality of channels on at least one side of the plate. The blank plate has a central area having a first thickness. The blank plate also has two generally parallel edges on opposite sides of the central area. The edges have a second thickness that is greater than the first thickness.

A flow battery includes an electrochemical cell that has a first electrode, a second electrode spaced apart from the first electrode, and a separator layer arranged between the first electrode and the second electrode. The separator layer is formed of a polymer that has a polymer backbone with cyclic groups that are free of unsaturated nitrogen and one or more polar groups bonded between the cyclic groups.

A flow battery includes an electrochemical cell that has a first electrode, a second electrode spaced apart from the first electrode, and a separator layer arranged between the first electrode and the second electrode. The separator layer is formed of a polymer that has a polymer backbone with cyclic groups that are free of unsaturated nitrogen and one or more polar groups bonded between the cyclic groups.

A heat and chemical resistant sealant for fuel cells that includes a fluoroelastomer sealant and a fluoroplastic gasket. The fluoroelastomer sealant is dispensed around a perimeter of a top surface of a bipolar plate. The compliant sealant conforms to surface imperfections of the bipolar plate. A fluoroplastic gasket is positioned over the fluoroelastomer sealant and bipolar plate. When compressed, the combination of the fluoroelastomer sealant and fluoroplastic gasket provide a reliable seal that can withstand the high operating temperatures of fuel cells.

[Problem] To provide a separator excellent in corrosion resistance and a sealing property for a fuel gas.

[Means for Resolution] Provided is a separator (4) for fuel cells. The separator (4) includes a conductive substrate (41), and a protective layer (42) that covers at least a part of a surface of the substrate (41). The protective layer (42) contains a self-restoring material.

The present disclosure provides a separator-integrated gasket and a manufacturing method therefor, with which the likelihood of the gasket peeling away from the separator can be reduced while reducing the number of manufacturing steps. The separator-integrated gasket includes gaskets 210, 220 that are provided integrally with a separator 200 forming a fuel cell, wherein the separator 200 is formed from carbon to which a thermoplastic first resin material has been added, and the gaskets 210, 220 are formed from a thermoplastic second resin material that is compatible with the first resin material.

The invention relates to a bipolar separator (17) including a first (33) and a second (35) polar plate each comprising an inner surface and an outer surface in which at least one distribution channel (53, 55) is formed, the channels formed in the outer surfaces of the first and the second polar plate enabling fuel and oxidizer, respectively, to flow. The bipolar separator further includes an inner layer (29) provided to be sandwiched and compressed between the substantially planar inner surfaces of the first (33) and the second (35) polar plate, so as to form a laminated structure. The inner layer is formed by a perforated sheet comprising a group of through-grooves that form branchless channels, the ends of which lead, respectively, to two manifolds such that the coolant is able to flow between the first (33) and the second (35) polar plate.

The invention relates to a bipolar separator (17) including a first (33) and a second (35) polar plate each comprising an inner surface and an outer surface in which at least one distribution channel (53, 55) is formed, the channels formed in the outer surfaces of the first and the second polar plate enabling fuel and oxidizer, respectively, to flow. The bipolar separator further includes an inner layer (29) provided to be sandwiched and compressed between the substantially planar inner surfaces of the first (33) and the second (35) polar plate, so as to form a laminated structure. The inner layer is formed by a perforated sheet comprising a group of through-grooves that form branchless channels, the ends of which lead, respectively, to two manifolds such that the coolant is able to flow between the first (33) and the second (35) polar plate.

The present invention relates to a method of coating one or more metal components of a fuel cell stack, such as a bipolar plate, an electrode, gaskets etc., the method comprising the steps of providing an uncoated metal component; etching said uncoated metal component; optionally depositing an adhesion layer on the etched uncoated metal component; and depositing a carbon coating on either the adhesion layer or on the etched uncoated metal component, with the adhesion layer and the carbon coating respectively being deposited by means of one of a physical vapor deposition process, an arc ion plating process, a sputtering process, and a Hipims process. The invention further relates to a component of a fuel cell stack and to an apparatus for coating one or more components of a fuel cell stack.