Metal fluid distribution plate with an adhesion promoting layer and polymeric layer

1. A method of manufacturing a fluid distribution plate comprising:

providing a metallic plate body having a body defining a set of fluid flow channels configured to distribute flow of a fluid across at least one side of the fluid distribution plate wherein the metallic plate body includes lands adjacent the channels;

forming a metal-containing adhesion promoting layer having a thickness less than 100 nm on the metallic plate body, the metal-containing adhesion promoting layer including a pure valve metal layer or a valve metal-containing alloy layer; and

forming a composite polymeric conductive layer disposed on the metallic layer such that the adhesion promoting layer adheres the composite polymeric conductive layer to the metallic plate body wherein the metal-containing adhesion promoting layer in the channels is substantially free of composite polymeric conductive material disposed thereon.

2. The method of claim 1 wherein the step of disposing a metal-containing adhesion promoting layer on the body comprises depositing a metal on the metallic plate body via physical vapor deposition.

3. The method of claim 1 wherein the valve metal is selected from the group consisting of titanium, zirconium, tantalum, niobium and mixtures thereof.

4. The method of claim 1 wherein the metallic plate body comprises stainless steel.

5. A method of manufacturing a fluid distribution plate, the method comprising:

providing a metallic plate body defining a set of fluid flow channels configured to distribute flow of a fluid across at least one side of the fluid distribution plate wherein the metallic plate body includes lands adjacent the channels;

forming a metal-containing adhesion promoting layer having a thickness less than 75 nm on the metallic plate body, the metal-containing adhesion promoting layer comprising a valve metal selected from the group consisting of titanium, zirconium, tantalum, niobium and mixtures thereof, the metal-containing adhesion promoting layer including a pure valve metal layer or a valve metal-containing alloy layer; and

forming a composite polymeric conductive layer on the metal-containing adhesion promoting layer such that the metal-containing adhesion promoting layer adheres the composite polymeric conductive layer to the metallic plate body wherein the metal-containing adhesion promoting layer in the channels is substantially free of composite polymeric conductive material disposed thereon.

6. The method of claim 5 wherein the metal-containing adhesion promoting layer further includes an outer surface portion comprising a metal oxide layer, wherein the outer surface portion is present in an amount that does not substantially increase total contact resistance of the metallic plate body relative to a plate body not having the outer surface portion.

7. The method of claim 5 wherein the metal is titanium.

8. The method of claim 5 wherein the metal is zirconium.

9. The method of claim 5 wherein the metal is niobium.

10. The method of claim 5 wherein the metal is tantalum.

11. The method of claim 5 wherein the metal-containing adhesion promoting layer is disposed on the metallic plate body by physical vapor deposition.

12. The method of claim 6 wherein the metal oxide is titanium oxide.

13. The method of claim 5 wherein the metallic plate body comprises stainless steel.

14. The method of claim 5 wherein the fluid distribution plate has a spreading pressure of at least 200 dyne/centimeters.