DOT PATTERN CONTACT LAYER

1 . A method of making a dot pattern contact layer, comprising:

providing droplets of a first ink onto at least one of a first fuel cell electrode or a fuel cell interconnect; and

solidifying the first ink to form a first plurality of discrete protrusions;

wherein:

the first ink comprises a first conductive material that is capable of forming an electrical contact between the interconnect and the first electrode.

2 . The method of claim 1 , wherein:

the step of providing droplets of a first ink comprises depositing the droplets of the first ink using a screen printing process such that each deposited droplet is not in physical contact with any other deposited droplet; and

the step of solidifying the first ink comprises at least one of drying or cooling the deposited droplets.

3 . The method of claim 2 , further comprising:

providing a second ink onto a second fuel cell electrode;

solidifying the second ink to form a second plurality of discrete protrusions; and

placing the fuel cell interconnect in contact with at least one of the first or second pluralities of discrete protrusions;

wherein:

the step of providing the first ink comprises providing the first ink onto the first fuel cell electrode; and

the first and second pluralities of discrete protrusions are located on opposite sides of a fuel cell.

4 . The method of claim 2 , further comprising:

providing a second ink onto the interconnect;

solidifying the second ink to form a second plurality of discrete protrusions; and

placing the fuel cell electrode in contact with the interconnect;

wherein:

the step of providing the first ink comprises providing the first ink onto the interconnect;

the interconnect comprises two opposite major surfaces each comprising a series of channels disposed between a series of ribs; and

the first and second pluralities of discrete protrusions are located on the ribs of the two opposite major surfaces.

5 . The method of claim 1 , wherein the dot pattern contact layer electrically connects the first fuel cell electrode to the interconnect.

6 . The method of claim 1 , wherein the step of solidifying occurs after the fuel cell electrode or the fuel cell interconnect are provided into a fuel cell stack.

7 . A method of making a dot pattern contact layer, comprising:

providing an adhesive and a plurality of discrete, electrically conductive ball protrusions embedded in the adhesive, onto at least one of a fuel cell electrode or ribs of a fuel cell interconnect; and

contacting the protrusions such that at least a portion of the protrusions are in physical contact with the fuel cell electrode and the fuel cell interconnect and form an electrical contact between the interconnect and the fuel cell electrode.

8 . The method of claim 7 , wherein:

the step of providing the adhesive and the plurality of discrete, electrically conductive ball protrusions comprises providing an adhesive layer onto the ribs of the interconnect; and

the step of contacting comprises placing the fuel cell electrode onto the protrusions to at least partially deform the protrusions.

9 . The method of claim 8 , wherein:

the fuel cell electrode comprises an anode and the discrete protrusions comprise nickel balls having a spherical or a substantially spherical shape;

prior to the step of contacting, the balls comprise a diameter that is smaller than a width of a rib of the interconnect; and

after the step of contacting, the balls have a deformed spherical shape.

10 . The method of claim 9 , wherein a diameter of the balls is about 50 μm to about 200 μm.

11 . The method of claim 7 , further comprising sintering the fuel cell to chemically or physically decompose the adhesive after the step of contacting.

12 . (canceled)

13 . The method of claim 7 , wherein the ball protrusions comprise hollow balls.

14 . The method of claim 7 , wherein the ball protrusions have a shell made of a first material, and a filler made of a second material.

15 . The method of claim 1 , wherein the ink comprises a liquid phase of the first conductive material.

16 . The method of claim 1 , wherein the ink comprises an aqueous suspension of solid particles of the first conductive material.

17 . A method of making a dot pattern contact layer, comprising:

depositing droplets of a first ink onto a fuel cell interconnect such that each deposited droplet is not in physical contact with any other deposited droplet; and

solidifying the first ink by cooling the deposited droplets to form a first plurality of discrete protrusions;

depositing droplets of a second ink onto the interconnect;

solidifying the second ink to form a second plurality of discrete protrusions; and

placing the fuel cell electrode in contact with the interconnect;

wherein:

the interconnect comprises two opposite major surfaces each comprising a series of channels disposed between a series of ribs;

the first and second pluralities of discrete protrusions are located on the ribs of the two opposite major surfaces; and

the first ink comprises a first material that is capable of forming an electrical contact between the interconnect and the first electrode.