Fuel cell separator plate having controlled fiber orientation and method of manufacture

A method of manufacturing a composite separator plate comprising the steps of:

• formulating a composite material having a polymeric material of 50% to 98% by volume and a fibrous conductive material of 2% to 50% by volume;
• molding said composite material between a first molding surface defining a first land cavity and a second molding surface having a second land cavity to form a separator plate including a first land having a first land height extending from a first side of said separator plate and a second land having a second land height extending from a second side of said separator plate, said fibrous material being oriented such that a first portion of said fibrous conductive material is disposed in said first land and a second portion of said fibrous conductive material is disposed in said second land;
• removing at least a portion of said first land, thereby reducing said first land height and forming a first exposed surface having an end of said first portion of fibrous conductive material terminating proximate said first exposed surface;
• and
• removing at least a portion of said second land, thereby reducing said second land height and forming a second exposed surface having an end of said second portion of fibrous conductive material terminating proximate said second exposed surface.

A composite separator plate comprising:

• a composite material molded to form a first land having a first land height extending from a first side of said separator plate and a second land having a second land height extending from a second side of said separator plate, said composite material including a polymeric material of 50% to 98% by volume and a fibrous conductive material of 2% to 50% by volume oriented such that a first portion of said fibrous material is disposed in said first land and a second portion of said fibrous material is disposed in said second land;
• wherein a portion of said first land is removed from said separator plate to reduce said first land height and form a first exposed surface having an end of said first portion of said fibrous conductive material terminating proximate said first exposed surface;
• and
• wherein a portion of said second land is removed from said separator plate to reduce said second land height and form a second exposed surface having an end of said second portion of said fibrous conductive material terminating proximate said second exposed surface.

A composite separator plate comprising:

• a composite material molded to form a first land having a first land height extending from a first side of said separator plate and a second land having a second land height extending from a second side of said separator plate, said composite material including a polymeric material and a fibrous conductive material said fibrous conductive material oriented such that a first portion of said fibrous material is disposed in said first land and a second portion of said fibrous material is disposed in said second land;
• wherein has a portion of said first land is removed from said separator plate to reduce said first land height and form a first exposed surface having an end of said first portion of said fibrous conductive material terminating proximate said first exposed surface;
• wherein a portion of said second land is removed from said separator plate to reduce said second land height and form a second exposed surface having an end of said second portion of said fibrous conductive material terminating proximate said second exposed surface;
• and
• wherein said fibrous conductive material is present in an amount sufficient to provide a conductive path from said first land to said second land.

A method of manufacturing a composite separator plate comprising the steps of:

• formulating a composite material having a polymeric material and a fibrous conductive material, said fibrous conductive material present in an amount of up to 50% by volume;
• molding said composite material between a first molding surface defining a first land cavity and a second molding surface having a second land cavity to form a separator plate including a first land having a first land height extending from a first side of said separator plate and a second land having a second land height extending from a second side of said separator plate, said fibrous material being oriented such that a first portion of said fibrous conductive material is disposed in said first land and a second portion of said fibrous conductive material is disposed in said second land;
• removing at least a portion of said first land, thereby reducing said first land height and forming a first exposed surface having an end of said first portion of fibrous conductive material terminating proximate said first exposed surface;
• and
• removing at least a portion of said second land, thereby reducing said second land height and forming a second exposed surface having an end of said second portion of fibrous conductive material terminating proximate said second exposed surface;
• and
• provided that said fibrous conductive material is present in an amount sufficient to provide a conductive path from said first land to said second land.