Low cost fuel cell bipolar plate and process of making the same

Abstract

Fuel cell bipolar plates are made by depositing a pinhole free corrosion resistant and/or a conductive layer on a metal plate using an atomic layer deposition method. In one embodiment, a conductive layer is deposited on an anodized metal plate using atomic layer deposition method. In another embodiment, at least one corrosion resistant metal oxide layer and at least one conductive layer are deposited on a metal plate individually using atomic layer deposition method. In yet another embodiment, a corrosion resistant and conductive metal oxynitride layer is deposited on a metal plate using an atomic layer deposition method.

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         7 . A fuel cell bipolar plate comprising:
 a conductive metal plate having at least one fuel cell reactant gas channel formed therein configured for fluid passage, wherein the conductive metal plate is anodized to form a corrosion resistant surface layer having a water contact angle less than 40 degree, and wherein at least one conductive layer is deposited above said corrosion resistant surface layer; said conductive layer comprising at least one of metal oxides or metal oxynitrides.   
     
     
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         12 . A bipolar plate comprising:
 a conductive metal plate having a plurality of lands and channels in a face thereof to define a reactant gas flow field, wherein a uniform and pinhole free corrosion resistance layer comprising at least one metal oxide is deposited on said metal plate, and wherein at least one conductive layer is deposited above said corrosion resistance layer; said conductive layer comprising at least one of metal oxides or metal oxynitrides.   
     
     
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         19 . A bipolar plate comprising:
 a conductive metal plate having a plurality of lands and channels in a face thereof to define a reactant gas flow field, wherein at least one atomic layer comprising a metal oxynitride is deposited on said conductive metal plate.   
     
     
         20 . A product comprising:
 a fuel cell bipolar plate having a reactant gas flow field defined therein comprising a plurality of lands and channels, a conductive layer over at least a portion of the bipolar plate defining the reactant gas flow field, the conductive layer comprising at least one of metal oxides or metal oxynitrides the conductive layer comprising one monolayer.   
     
     
         21 . A product as set forth in  claim 20  further comprising a plurality of monolayers and so that the conductive layer has a thickness ranging from about 1-5000 nm.