Composite end cell thermal barrier with an electrically conducting layer

Abstract

A barrier layer for a fuel cell assembly includes a thermally insulating layer having a first surface and a second surface. An electrically conducting layer is formed on the first surface of the thermally insulating layer. The thermally insulating layer is a micro-truss structure. A plurality of columnar members cooperate to form the micro-truss structure, having void spaces formed between the columnar members.

What is claimed is: 
     
         1 . A barrier layer for a fuel cell assembly comprising:
 a thermally insulating layer having a first surface and a second surface; and   an electrically conducting layer formed on the first surface of the thermally insulating layer;   wherein the thermally insulating layer is a micro-truss structure.   
     
     
         2 . The barrier layer of  claim 1 , further comprising a plurality of columnar members cooperating to form the micro-truss structure, wherein void spaces are formed between the columnar members. 
     
     
         3 . The barrier layer of  claim 2 , wherein the columnar members have a substantially circular cross-sectional shape. 
     
     
         4 . The barrier layer of  claim 2 , wherein the columnar members have one of an ovular, triangular, or rectangular cross-sectional shape. 
     
     
         5 . The barrier layer of  claim 2 , wherein the electrically conducting layer is formed on an outer surface of each of the columnar members. 
     
     
         6 . The barrier layer of  claim 1 , wherein the first surface of the thermally insulating layer is configured to contact a unipolar end plate of the fuel cell assembly and the second surface of the thermally insulating layer is configured to contact a terminal plate of the fuel cell assembly. 
     
     
         7 . The barrier layer of  claim 1 , wherein the micro-truss structure is formed from a thermally insulating plastic material of a light/radiation curing polymer. 
     
     
         8 . The barrier layer of  claim 1 , wherein the electrically conducting layer is formed on the second surface of the thermally insulating layer. 
     
     
         9 . The barrier layer of  claim 1 , wherein the thermally insulating layer includes a plurality of apertures formed therethrough, and the electrically conducting layer is formed on portions of the thermally insulating layer forming the plurality of apertures. 
     
     
         10 . A barrier layer for a fuel cell assembly comprising:
 a thermally insulating layer having a first surface and a second surface; and   an electrically conducting layer formed on the first surface of the thermally insulating layer;   wherein the thermally insulating layer is a micro-truss structure having a plurality of columnar members cooperating to form the micro-truss structure, wherein void spaces are formed between the columnar members.   
     
     
         11 . The barrier layer of  claim 10 , wherein the electrically conducting layer is formed from a metal. 
     
     
         12 . The barrier layer of  claim 11 , wherein the metal is one of a nickel-based metal and a chromium-based metal. 
     
     
         13 . The barrier layer of  claim 10 , wherein the thermally insulating layer is formed from one of a carbon foam, a syntactic foam, and a plastic. 
     
     
         14 . The barrier layer of  claim 10 , wherein the electrically conducting layer is an application using one of an electroless plating process, an electroplating process, a brushing process, a spraying process, or a dipping process to the micro-truss structure. 
     
     
         15 . A barrier layer for a fuel cell assembly, comprising:
 a thermally insulating layer having a first surface, a second surface, and a plurality of apertures formed therethrough; and   an electrically conducting layer formed on the first surface of the thermally insulating layer, the second surface of the thermally insulating layer, and portions of the thermally insulating layer forming the plurality of apertures;   wherein the thermally insulating layer is a micro-truss structure having a plurality of columnar members cooperating to form the micro-truss structure.   
     
     
         16 . The barrier layer of  claim 15 , wherein each of the plurality of apertures is formed entirely through the barrier layer. 
     
     
         17 . The barrier layer of  claim 15 , wherein the columnar members have a substantially circular cross-sectional shape. 
     
     
         18 . The barrier layer of  claim 15 , wherein the columnar members have one of an ovular, triangular, or rectangular cross-sectional shape. 
     
     
         19 . The barrier layer of  claim 15 , wherein the micro-truss structure is formed from a thermally insulating plastic material of a light/radiation curing polymer. 
     
     
         20 . The barrier layer of  claim 15 , wherein the first surface of the thermally insulating layer is directed toward a unipolar end plate of the fuel cell assembly, and the second surface of the thermally insulating layer is directed toward a terminal plate of the fuel cell assembly.