Bipolar plates and end plates for fuel cells and methods for making the same

A method of making a bipolar plate for a fuel cell stack, the method comprising the steps of:

• providing a semi-conductive or conductive substrate having a first face and a second face opposite the first face;
• etching a first reactant flow channel from the first face;
• etching a second reactant flow channel from the second face;
• coating the first reactant flow channel with a reforming catalyst;
• creating at least one internal conduit that passes through the substrate between and parallel to the first and second faces;
• and
• creating a heating element wherein the heating element is located within the bulk of the bipolar plate or on the surface of the bipolar plate and is adapted to heat the bipolar plate.

A method of making a plate for a fuel cell stack, the method comprising:

• providing a semi-conductive substrate having a first face and a second face opposite the first face;
• forming a first reactant fuel flow channel in the first face, using photolithography and etching, configured to deliver fuel to said fuel cell stack;
• forming a second oxidant flow channel in the second face, using photolithography and etching, configured to deliver oxidant to said fuel cell stack;
• and
• after forming said first and second flow channels in said same substrate:
• coating the first reactant flow channel with a reforming catalyst;
• forming at least one internal conduit that passes through the substrate between the first and second faces;
• and
• coating the conduit with a reforming catalyst;
• wherein the conduit is configured to enable heating of the bipolar plate.

A method of making a bipolar plate for a fuel cell stack, the method comprising the steps of:

• providing a semi-conductive or conductive substrate having a first face and a second face opposite the first face;
• etching a first reactant flow channel from the first face;
• etching a second reactant flow channel from the second face;
• coating the first reactant flow channel with a reforming catalyst;
• and
• creating at least one internal conduit that passes through the substrate between and parallel to the first and second faces;
• wherein
• the at least one conduit is at least one of a heating conduit configured to enable heating fluid to flow therethrough and an exhaust conduit containing a catalytic combustor.