Molding process for making fuel cell components
An illustrative method of making a fuel cell component includes obtaining at least one blank plate including graphite and a polymer; establishing a temperature of the blank that is sufficient to maintain the polymer in an at least partially molten state; and applying a compression molding force to the blank until the polymer is essentially solidified to form a plate including a plurality of channels on at least one side of the plate. The blank plate has a central area having a first thickness. The blank plate also has two generally parallel edges on opposite sides of the central area. The edges have a second thickness that is greater than the first thickness.
1. A method of making a fuel cell component, comprising the steps of:
extrusion molding a mixture of a graphite and a polymer to form a first blank plate that has two generally parallel first edges that are thicker than a central portion of the first blank plate; and
a second blank plate that has two generally parallel second edges that are thicker than a central portion of the second blank plate;
establishing a temperature of the blank plates during the extrusion molding that is sufficient to maintain the polymer in a partially molten state;
transferring the blank plates into a compression mold while the temperature is the established temperature;
situating the first blank plate adjacent the second blank plate with the first edges generally perpendicular to the second edges; and
applying a compression molding force to the situated first and second blank plates in the compression mold at least until the polymer essentially solidifies to form a plate including a plurality of channels on at least one side of the plate.
2. A method of making a fuel cell component, comprising:
obtaining a first blank plate that has two generally parallel first edges that are thicker than a central portion of the first blank plate;
obtaining a second blank plate that has two generally parallel second edges that are thicker than a central portion of the second blank plate, the first and second plates each comprising graphite and a polymer;
situating the first blank plate adjacent the second blank plate with the first edges generally perpendicular to the second edges;
establishing a temperature of the blank plates that is sufficient to maintain the polymer in each plate in a partially molten state; and
applying a compression molding force to the situated first and second blank plates at least until the polymer in each blank plate essentially solidifies to form a plate including a plurality of channels on at least one side of the plate.
3. The method of claim 2 , wherein the polymer comprises fluorinated ethylene propylene (FEP).
4. The method of claim 2 , wherein the graphite comprises flake graphite.
5. The method of claim 2 , wherein the formed plate comprises a bipolar separator plate.