An illustrative example fuel cell electrolyte management device includes a first component having a first density and a second component having a second density that is less than the first density. The first component has a first side including a pocket and a second side facing opposite the first si
An illustrative example fuel cell electrolyte management device includes a first component having a first density and a second component having a second density that is less than the first density. The first component has a first side including a pocket and a second side facing opposite the first side. The second side of the first component includes a first plurality of fluid flow channels. The second component has a porosity configured for storing electrolyte in the second component. The second component fits within the pocket. The second component has a first side received directly against the first side of the first component. The second component has a second side including a second plurality of fluid flow channels.
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1. A fuel cell electrolyte management device, comprising: a first component having a first density, the first component having a first side including a pocket and a second side facing opposite the first side, the second side including a first plurality of fluid flow channels; anda second component h
1. A fuel cell electrolyte management device, comprising: a first component having a first density, the first component having a first side including a pocket and a second side facing opposite the first side, the second side including a first plurality of fluid flow channels; anda second component having a second density that is lower than the first density, the second component having a porosity configured for storing electrolyte in the second component, the second component fitting within the pocket, the second component having a first side received directly against the first side of the first component, the second component having a second side including a second plurality of fluid flow channels. 2. The device of claim 1, wherein the first component comprises a first type of graphite and a first type of resin; andthe second component comprises a second type of graphite that is different from the first type of graphite and a second type of resin that is different from the first type or resin. 3. The device of claim 2, wherein the first type of graphite comprises at least graphite flakes; andthe second type of graphite comprises at least non-flake graphite. 4. The device of claim 2, wherein the first resin comprises a fluoropolymer resin; andthe second resin comprises a thermosetting polymeric resin. 5. The device of claim 4, wherein the fluoropolymer resin is between 10% and 50% by weight of the first component. 6. The device of claim 1, wherein the second component is at least temporarily bonded to the pocket by an adhesive that decomposes at a temperature above an ambient or room temperature. 7. The device of claim 1, wherein the second component is at least temporarily bonded to the pocket by an adhesive that is situated along a border of the pocket. 8. The device of claim 6, wherein the first density is at least 2 gm/cm3. 9. The device of claim 1, wherein the first density is effective as a barrier to prevent electrolyte migration through the first component. 10. The device of claim 1, wherein the device has a through plane electrical resistivity that is less than 0.0017 mVmill at approximately 100 psi axial load and 100 ASF; anda through plane thermal conductivity that is greater than 7 W/mK and less than 12 W/mK at approximately 140 psi. 11. The device of claim 1, wherein the second component is between 30% and 75% porous. 12. The device of claim 1, wherein pores of the second component have a size between 3 microns and 20 microns. 13. The device of claim 1, wherein the first component includes a rib on each of at least two edges of the pocket;the ribs have a height;the second component has a thickness in a direction between the first and second sides of the second component; andthe height is approximately equal to the thickness. 14. The device of claim 1, wherein the first component includes a rib on each of two edges of the pocket;the ribs are parallel to the second plurality of fluid flow channels; anda seal member is situated on each of the ribs. 15. The device of claim 14, wherein each seal member includes a flap portion extending laterally outward beyond an edge of the corresponding rib. 16. The device of claim 14, wherein the first plurality of fluid flow channels are generally perpendicular to the ribs;a first component seal member is situated on each laterally outermost edge of the second side of the first component; andthe first component seal members are parallel to the first plurality of fluid flow channels. 17. A method of making a fuel cell electrolyte management device, the method comprising: forming a first component from a first mixture comprising a first type of graphite and a first resin, the first component having a first density;providing the first component with a pocket on a first side of the first component;forming a second component from a second mixture comprising a second type of graphite and a second resin, the second component having a second density that is less than the first density, the second component having a porosity that is configured to store electrolyte in the second component;situating the second component in the pocket with a first side of the second component received directly against the first side of the first component; andproviding fluid flow channels on each of the first component and the second component. 18. The method of claim 17, wherein forming the first component comprises pressing the first mixture into a first preform using a pressure of 4000 psi at ambient temperature;subsequently pressing the preform using a pressure of 800 psi at a temperature of 550° F. for about an hour;subsequently pressing the preform using a pressure of 800 psi at a temperature of 140° F. for about an hour; andforming the second component comprises pressing the second mixture into a second preform using a pressure of 200 psi at 180° C. for about 30 minutes; andsubsequently converting the second resin to carbon by heating the second preform at a temperature of about 900° C. while the second preform is exposed to an inert gas. 19. The method of claim 17, wherein providing the first component with the pocket comprises at least one ofmachining a portion of the first component away to establish the pocket; orforming the pocket during the forming of the first component. 20. The method of claim 17, wherein the first density is at least 2 gm/cm3; andthe second component is between 30% and 75% porous. 21. The method of claim 17, comprising at least temporarily bonding the second component to the pocket by an adhesive that decomposes at a temperature above an ambient or room temperature. 22. The method of claim 17, comprising placing an adhesive along a border of the pocket; andat least temporarily bonding the second component to the pocket using the adhesive. 23. The method of claim 17, wherein the second mixture comprises a wax that vaporizes at an elevated temperature; andthe second component has pores in locations occupied by the wax prior to the wax vaporizing. 24. The method of claim 17, wherein the device has a through plane electrical resistivity that is less than 0.0017 mVmill at 100 psi axial load and 100 ASF; anda through plane thermal conductivity that is greater than 7 W/mK and less than 12 W/mK at approximately 140 psi. 25. The method of claim 17, wherein the first mixture comprises about 85% flake graphite and about 15% fluoropolymer resin by mass; andthe second mixture comprises about 80% non-flake graphite and about 20% thermosetting polymeric resin by mass.
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이 특허에 인용된 특허 (11)
Taylor William A. (Glastonbury CT), Coke and graphite filled separator plate for electrochemical cells.
Feigenbaum Haim (Highland Park NJ) Pudick Sheldon (Sayreville NJ) Singh Rajindar (Ridgewood NJ), Edge seal for a porous gas distribution plate of a fuel cell.
Kaufman Arthur (West Orange NJ) Werth John (Princeton NJ), Fabrication of gas impervious edge seal for a bipolar gas distribution assembly for use in a fuel cell.
Emanuelson Roger C. (Glastonbury CT) Luoma Warren L. (Manchester CT) Taylor William A. (Glastonbury CT), Method for making improved separator plates for electrochemical cells.
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