Abstract:
A method of fabricating a fuel cell component for use with or as part of a fuel cell in a fuel cell stack, the method comprising: providing a fuel cell component, providing a deposition assembly for depositing loading material particles onto the fuel cell component, and actuating the deposition assembly to cause the deposition assembly to deposit said loading material particles onto said fuel cell component.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a divisional of application Ser. No. 13/424,028, filed on Mar. 19, 2012, which is a divisional of Ser. No. 11/746,911, filed May 10, 2007 and now U.S. Pat. No. 8,137,741, the entire disclosures of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates to fuel cells and, in particular, to fuel cell assemblies and components having loaded and retained catalyst therein and to apparatus and methods for performing such loading and retaining. 
         [0003]    A fuel cell is a device which directly converts chemical energy stored in hydrocarbon fuel into electrical energy by means of an electrochemical reaction. Generally, a fuel cell comprises an anode and a cathode separated by an electrolyte, which serves to conduct electrically charged ions. In order to produce a useful power level, a number of individual fuel cells are stacked in series with an electrically conductive separator plate between each cell. 
         [0004]    In internally reforming fuel cells, a reforming catalyst is placed within the fuel cell stack to allow direct use of hydrocarbon fuels such as methane, coal gas, etc. without the need for expensive and complex reforming equipment. In a reforming reaction, fuel cell produced water and heat are used by the reforming reaction, and the hydrocarbon fuel is internally reformed to produce hydrogen for fuel cell use. Thus, the necessary hydrogen fuel is produced by the reforming reaction, and since the reaction is endothermic, it can also be used advantageously to help cool the fuel cell stack. 
         [0005]    Two different types of internal reforming have been developed for fuel cell assemblies. One type of internal reforming is indirect internal reforming, which is accomplished by placing the reforming catalyst in an isolated chamber within the stack and routing the reformed gas from this chamber into the anode compartment of the fuel cell. A second type of internal reforming is direct internal reforming. This type of internal reforming is accomplished by placing the reforming catalyst within the active anode compartment or fuel flow field, which provides the hydrogen produced by the reforming reaction directly to the anode. 
         [0006]    A typical fuel cell anode compartment comprises a separator or bipolar plate for isolating fuel from the oxidant stream of the neighboring fuel cell, an anode electrode for providing electrochemical reaction sites, and an anode current collector often provided as a corrugated plate, for conducting electronic current from the anode electrode. The anode current collector is in contact with the anode electrode and also defines flow channels for the fuel gas. The reforming catalyst is placed in these flow channels to provide the direct internal reforming. 
         [0007]    The reforming catalyst is usually available as compacted or solid particles having various solid shapes or forms such as tablet, pellet, rod, ring or sphere. However, due to the dimensions of the catalyst particles, difficulties have been encountered in trying to load the particles in the current collector channels. One difficulty is that the relatively small size of the catalyst particles makes them difficult to handle during assembly. This, in turn, makes the process of catalyst loading inefficient, and thus, unduly costly. 
         [0008]    A second difficulty sometimes arises in achieving and maintaining a desired loading pattern of the catalyst because of the tendency of the catalyst particles to shift during the loading process and the fuel cell assembly process. The importance of the desired loading pattern stems in part from the desire to maintain a required heating profile in the fuel cell stack. This profile helps promote efficient and long term operation of the stack. 
         [0009]    A manner of improving the efficiency and reliability of loading the catalyst particles in fuel cell components is thus always desirable. Additionally, the ability to better retain the loaded catalyst while concurrently enabling maximum operational efficiency is also a goal in the manufacturing process. 
       SUMMARY OF THE INVENTION 
       [0010]    In accordance with the embodiment(s) of the invention disclosed hereinafter, an apparatus and associated method are provided in a system for accurately loading catalyst particles into fuel cell components. An apparatus and associated method are also provided in a system which uses a fixing agent for retaining the loaded catalyst and, if desired, other fuel cell components. 
         [0011]    A particular system in use of the apparatus and method comprises a support for supporting a fuel cell component adapted to receive catalyst particles and a deposition assembly adapted to load the catalyst particles onto the fuel cell component. The system further optionally comprises a mechanism for applying a fixing agent to the fuel cell component and the loaded catalyst particles for retention of the catalyst particles. 
         [0012]    In a further aspect of the invention, the fixing agent applied to the fuel cell component is further adapted to permit the fuel cell component to be held to another fuel component. It is also contemplated that a like fixing agent be used with additional fuel cell components so that these additional components, the another component and the catalyst loaded component, with the aid of the fixing agent, are held together so as to in facilitate handling and stacking of the components in the formation of a fuel cell stack. 
         [0013]    In the embodiments disclosed, the fuel cell component is a corrugated anode current collector, the other component is a separator plate and the additional components are an anode, a cathode and a cathode current collector and the fixing agent is a double-sided adhesive medium. 
         [0014]    It is contemplated that the aforementioned fixing agent comprises, optionally, a double-sided acrylic adhesive tape of the type currently manufactured by the 3M Company. 
         [0015]    In one illustrative form of the invention, the deposition assembly includes individual deposition mechanisms each adapted to urge a catalyst particle delivered to the deposition mechanism onto the fuel cell component. The deposition mechanisms are arranged in a row across the width of the fuel cell component and are caused to be selectively operated based on the sensed position of the fuel cell component. As the fuel cell component is indexed, the sensed position causes an actuator assembly to selectively operate the deposition mechanisms and this continues until the fuel cell component is loaded. In this embodiment, each deposition mechanism optionally comprises a hydraulic or pneumatic cylinder or an electric actuator with a plunger and a gate assembly. The gate assembly holds the catalyst particle and prevents it from being delivered to the fuel cell component. Upon operation of the actuator assembly, the gate assembly is released and the hydraulic or pneumatic cylinder or electric actuator moves the plunger to urge the catalyst particle onto the fuel cell component. 
         [0016]    In another illustrative embodiment, the deposition assembly includes a mask gate assembly having overlying first and second plates. The first plate has openings corresponding to the predetermined areas on the fuel cell component to receive catalyst and the second plate has openings corresponding to all the areas of the fuel cell component able to receive catalyst particles. The first plate is disposed over the fuel cell component and the second plate is disposed over the first plate so that its openings are misaligned with the openings of the first plate. The second plate is then loaded with catalyst particles which come to reside in the plate openings and are blocked from entering the openings in the first plate due to the misalignment. 
         [0017]    The second plate is then shifted by the actuator assembly so that its openings then align with those in the first plate. Vibration motion being applied to the plates causes the catalysts in the aligned openings of the two plates to pass from the openings in the second plate through the aligned openings of the first plate and from these openings to the corresponding areas of the fuel cell component. The fuel component is thereby loaded with a predetermined pattern of catalyst defined by the first plate. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The above and other features and aspects of the present invention will become more apparent upon reading the following detailed description in conjunction with the accompanying drawings, in which: 
           [0019]      FIG. 1  shows a molten carbonate fuel cell with a first reforming catalyst member. 
           [0020]      FIG. 1A  shows a molten carbonate fuel cell with a second reforming catalyst member. 
           [0021]      FIG. 2  shows a system for the placement of catalyst particles in the form of pellets onto a current collector associated with the anode electrode of a fuel cell assembly. 
           [0022]      FIG. 3  shows the system of  FIG. 2  and subsequent placement of a fixing agent to retain positioning of the loaded catalyst particles relative to the current collector 
           [0023]      FIGS. 3A-3C  show the details of the deposition mechanisms of the system of  FIGS. 2 and 3  and the sequence of operation of these mechanisms. 
           [0024]      FIG. 4  shows final placement of the catalyst members in a chosen pattern relative to the current collector. 
           [0025]      FIG. 4A  shows the second catalyst member as shown in  FIG. 1A . 
           [0026]      FIG. 5  shows, demonstrably, the process of using a fixing agent in adhering a current collector loaded with the catalyst particles to other components in the forming of a fuel cell assembly. 
           [0027]      FIG. 6  shows an exploded view of the components of a fuel cell assembly joined together with a fixing agent. 
           [0028]      FIG. 7  shows a vacuum press unit for compressing under heat the fuel cell assembly of 
           [0029]      FIG. 6 . 
           [0030]      FIG. 8  shows a further system for the placement of catalyst particles in the form of pellets onto a current collector. 
           [0031]      FIG. 9  shows the mask gate assembly of the system of  FIG. 8 . 
           [0032]      FIGS. 10 and 11  show an exploded view of a portion of the mask gate assembly of  FIG. 9  with the mask gate closed and opened, respectively 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    Referring to  FIGS. 1 ,  1 A and  6 , there is shown a fuel cell stack formed by stacking assemblies  10  one on the other with an electrolyte matrix  11  between adjacent assemblies. The electrolyte matrix  11  is adapted hold an electrolyte such as, for example, a carbonate electrolyte. Each assembly  10  comprises an anode electrode  12  and an associated current collector  14 , shown as having corrugations  14 A. Each assembly  10  further comprises a bipolar separator  16  which separates the anode electrode  12  and current collector  14  from a cathode electrode  18  and its associated current collector  20 , also shown as having corrugations  20 A. The corrugations  14 A of the anode current collector  14  define with the bipolar separator plate  16  and the anode electrode  12 , first and second sets of fuel gas channels  14 B and  14 C. The anode current collector is further loaded with a plurality of catalyst particles  22  situated in the channels  14 B and, in particular, in the areas  14 D between and engaged by the legs of adjacent corrugations  14 A. The catalyst particles  22  can take on various configurations. In  FIG. 1 , the catalyst particles  22  are shown as having a square cross-section and in  FIG. 2  as having a circular cross-section. Other cross-section shapes such as hexagonal and “star” to improve the available surface area can also be used for the catalyst particles  22 . 
         [0034]    The catalyst particles  22  promote further reforming of the hydrocarbons in the fuel gas in the channels  14 B to increase the hydrogen content of the gas. A portion of the further reformed gas in the channels  14 B then passes into the channels  14 C via openings in or discontinuities in the corrugations  14 A as the gas continues traveling along the channels  14 B. The further reformed gas thus combines with the fuel gas introduced directly into the channels  14 C and the combined gas is thereby made available to participate in the electrochemical conversion reaction at the anode  12 . 
         [0035]    In order that the above-mentioned reforming reaction takes place efficiently in the fuel gas channels  14 B and also in order to promote a desired heating profile for the fuel cell stack, it is desirable to load the anode current collector  14  with the catalyst particles  22  in a certain pattern and to retain that pattern. Accordingly, the following provides an advantageous way in which to achieve both the loading and retaining of the catalyst particles in a desired pattern. 
         [0036]    Referring to  FIGS. 2-3 , there is shown schematically a system  24  for the loading and retaining of the catalyst particles  22  on the anode current collector  14 . The catalyst particles  22 , optionally provided in the form of pellets as shown in  FIG. 2 , are fed from a hopper  26  situated in the vicinity of the current collector  14 . The current collector  14  rests on an X-Y movable support or table  51  capable of moving in the X and Y directions. Looking at  FIGS. 2 and 3 , the hopper  26  is provided with a hopper feed  28  containing a plurality of feed channels  28 A arranged in a row so as to span the width (X direction) of the current collector  14 . The feed channels  28 A lead to a deposition assembly  29  comprised of a row or line of deposition mechanisms  30  also situated to span the width of the current collector  14 . 
         [0037]    Each of the deposition mechanisms  30  is fed by one of the feed channels  28 A and is further aligned with one of the areas  14 D between adjacent legs of the corrugations  14 A spanning the width of the current collector. By selecting the number of deposition mechanisms  30  to be equal to the number of spaces  14 D, each space  14 D across the width of the collector plate  14  is able to be fed a catalyst particle  22  by its respective deposition mechanism. Moreover, as shown in  FIG. 3  and as above-mentioned, the corrugations  14 A are discontinuous in the length direction (Y direction) of the current collector so that they form a plurality of spaced rows  36 . Accordingly by bringing each row  36  of corrugations in line with the row of deposition mechanisms  30 , the spaces  14 D in each row are able to be fed catalyst particles  22  by the associated deposition mechanisms  30 . 
         [0038]    More particularly, the hopper  26 , as a result of vibratory motion imparted thereto, delivers a catalyst particle  22  to each of the feed channels  28 A of the hopper feed  28 . Each feed channel, in turn, brings a catalyst particle  22  to its respective deposition mechanism  30 . In the case shown, as can be seen in more detail in  FIGS. 3A-3C , each deposition mechanism  30  defines a chamber  30 A in which the fed catalyst particle  22  settles and is held by a gate assembly shown optionally as a spring loaded ball assembly  30 B. Other forms of the gate assembly might be an actuator or cylinder assembly. Above the gate assembly, the deposition mechanism  30  includes a hydraulic or pneumatic cylinder or electric actuator  30 C equipped with a plunger  35  which contacts the catalyst particle. 
         [0039]    Actuation of a deposition mechanism  30  then results in the sequence of operations in  FIGS. 3A-3C . The assembly  30 B is first retracted allowing the passage of the catalyst particle  22  downward through the chamber  30 A. The hydraulic or pneumatic cylinder or electric actuator  30 C then operates causing its plunger to force the catalyst particle  22  downward into the area  14 D between the feet of the adjacent corrugations  14 . At this time, the plunger also blocks entry of further catalyst particles  22  into the chamber. This blockage can also be accomplished by a clamp bar or similar type of assembly that is brought into the path of the further catalyst particles in conjunction with the plunger being moved downward. The hydraulic or pneumatic cylinder or electric actuator cylinder  30 C then completes its stroke forcing the catalyst particle  22  to be held between the corrugations. 
         [0040]    Once this operation completes, the hydraulic or pneumatic cylinder or electric actuator  30 C retracts the plunger and the spring loaded ball assembly  30 B returns to its original position. This allows the next catalyst particle  22  from the feed chamber  28 A to be delivered to and held in the chamber  30 A of the deposition mechanism  30  for subsequent supply to the current collector  14 . 
         [0041]    Whether a particular deposition mechanism  30  in the deposition assembly is actuated is determined by an actuating assembly in the form of a programmed controller  38 . The controller also controls the operation of the other components of the system  24  including the X-Y table or support  51 . 
         [0042]    Indexing of the table  51  under the control of the programmed controller  38  successively brings each of the rows  36  of corrugations  14 A into line with the row of deposition mechanisms  30  which in the present case remain stationary. A sensor  40  acts as to indicate to the programmed controller  38  that a row  36  of corrugations  32  (see,  FIG. 4 ) has now been brought into line with the row of mechanisms  30  of the deposition assembly  29 . A simple counting mechanism in the controller, counts the rows, so that the programmed controller can identify a particular row. The controller  38  then based on a predetermined stored catalyst pattern which correlates row numbers and associated areas  14 D to receive catalyst particles  22 , actuates the particular depositions mechanisms  30  associated with the catalyst receiving areas. This results in deposition of catalyst particles  22  by the mechanisms  30  in the particular row in accordance with the predetermined pattern. 
         [0043]    Continued indexing of the table  51  in the Y direction and actuation of the deposition mechanisms  30  by the controller  38  thus results in the deposition of the catalysts particles  22  into all the rows of the corrugations of the collector  14  in accordance with the predetermined catalyst pattern. It is to be understood that the controller  38  can be programmed to obtain any desired predetermined pattern or to change the predetermined pattern for the catalyst deposition. Accordingly, the deposition of catalyst particles in the current collector  14  can be made so as to achieve a predetermined pattern for heat management throughout the fuel cell stack to realize a maximum energy yield. 
         [0044]    With continued reference to  FIGS. 2-3 , there is also provided in the system  24 , a fixing agent  42  for retaining the placement of each of the catalyst particles  22  within their respective areas  14 D of the corrugations  14 A. The fixing agent  42  is carried on a supply roller  61  and is, optionally, in the form of a dual-sided medium comprising double sided acrylic tape. The tape comprises an exposed adhesive side  43  and a covered adhesive side  45  protected by a backing  47  (see,  FIG. 5 ). 
         [0045]    In use, once the catalyst particles  22  are in position, application of the tape  42  on the supply roller  61  occurs by use of the press roller  62  which guides and presses the tape  42  on the catalyst members  22  and corrugations  14 A in a manner well understood by one of ordinary skill in the art. Such application enables sealing of the catalyst particles  22  against the respective legs of the corrugations  14 A of the collector  14 . This occurs, as will be understood by one of ordinary skill in the art, since the side  43  is urged against the catalyst particles and corrugations  14 A by the press roller  62  while the side  47  is free from contact therewith. 
         [0046]    As shown in  FIG. 3  by the cutout portion thereof, the resultant placement of the catalyst particles  22  is retained, as is represented by  FIG. 4 . It is to be understood that the fixing agent of the present invention may also be arranged for use with an alternatively shaped catalyst member  46 , optionally provided as an extruded material dimensioned substantially cylindrically, as shown in  FIG. 4A . With the option of using an alternative member  46  such as that shown and corresponding to member  23  of  FIG. 1A , any one such member  46  may be provided in a dimension extending substantially the length of the collector plate  14 . 
         [0047]    With reference to  FIGS. 5-6 , the process of assembling the fuel cell assembly  10  using the fixing agent  42  is described. Once application of the adhesive side  43  of the tape  42  occurs such that the uncovered adhesive attaches atop the catalyst particles  22  and portions of the collector plate  14 , the backing  47  covering the opposed side  45  of the tape  42  is available for removal therefrom. This removal is shown as indicated by arrow “A” in  FIG. 5 . 
         [0048]    Referring to  FIGS. 6 ,  1  and  1 A, there is shown, diagrammatically, the assembly shown in  FIGS. 1 and 1A . Such assembly comprises the use of the fixing agent  42  not only in retention of the catalyst particles  22  to the collector plate  14 , but also in retention of the electrodes  12  and  18  and their associated collector plates  14  and  20  to the bipolar separator plate  16 . As such, it may be seen that the anode electrode  12  is assembled to its respective current collector plate  14  by strips of the tape  42  described hereinabove and situated on the top side of the plate. The underside  48  of the collector plate  14  housing the catalyst members  22  is covered with the exposed adhesive side  43  of the tape  42 . The backing  47 , as shown in  FIG. 5 , is then removed to enable adherence to, and thus construction with, the bipolar separator plate  16 . Accordingly, the anode half of the fuel cell assembly  10  is then achieved. 
         [0049]    Construction of the cathode half of the fuel cell assembly  10  begins by attaching the underside  54  of the cathode current collector  20  to the underside  56  of the bipolar separator plate  16  via the tape strips  42  on the underside of the bipolar plate after removal of the backing  47  of these strips exposing the adhesive layer  43 . Thereafter, with the exposed adhesive side  43  of the tape  42  covering the surface  58  of the cathode current collector  20 , the backing  47  thereof is ready to be removed. Once removed, the cathode electrode  18  may be adhered thereto to complete assembly of the cathode half of the fuel cell assembly  10 . 
         [0050]    In order to ensure that the components of the assembly  10  remain in tact, the assembly  10  can be subjected to pressure and heat in order to enhance the retention power of the tape  42 .  FIG. 7  shows a vacuum press unit  71  which can be used of this purpose. The unit  71  includes upper and lower platens  72  and  73  supported, respectively, on a top cover  74  pivotably attached to a base assembly  75 . The top cover  74  carries a vacuum sealing gasket  76  which borders the periphery of the upper platen  72 . When the cover  74  is lowered by pivoting, the upper and lower platens  72  and  73  are brought together by locating pins  77  on the base assembly  75  and corresponding locating holes  78  in the cover to form a sealed vacuum chamber for receiving the assembled fuel cell assembly  10 . 
         [0051]    A heated air inflow unit  79  is then turned on to draw-in outside air and to heat the air. The heated air is then delivered to the sealed vacuum chamber through a plenum along the side  75 A of the base assembly. Air delivery ports  81  convey the heated air from the plenum to the sealed vacuum chamber between the platens when the platens are brought together with the assembly  10  secured between them. 
         [0052]    The heated air heats the assembly  10  and passes from the vacuum chamber via air exit ports  82  on the other side  75 B of the base assembly  75  to a plenum on this side of the assembly. After assembly  10  reaches a desired temperature, the heated air unit  79  closes or shuts off and a blower or fan  83  is turned on. This allows the blower or fan  83  to draw vacuum from the base assembly  75  with the assembly  10  in it via the air exit ports  82  and the plenum on the side  75 B of the base assembly  75 . As a result, a thermo-vacuum pressing of the assembly  10  is carried out. After a predetermined time, the pressing of the assembly  10  is complete and the fan  83  is turned off. The platens  72  and  73  are then separated by pivoting the top cover  74  upward, thereby allowing removal of the assembly  10 . 
         [0053]      FIGS. 8-11  show a further assembly for deposition of the catalyst particles into preselected of the areas  14 D of the current collector  14 . As shown the system comprises a mass block or base member  91  which supports a vibratory block  92 . A mask gate assembly  93  is supported by the vibratory block  92  against the anode current collector  14  which is to be loaded with catalyst particles. A hopper  94  holds catalyst particles in the form of pellets and these are fed to the mask gate assembly  93 . 
         [0054]    The mask gate assembly is shown in more detail in  FIGS. 9-11  and comprises clamp bars  93 C,  93 D and pneumatic clamps  93 E which clamp overlying gate and mask plates  93 A and  93 B together and to the vibratory block over the current collector  14 . As shown, the mask plate  93 B lies above the gate plate  93 A and the gate plate  93 A faces the current collector. Spring loaded pins  93 F provide a downward force across the surface of the mask plate  93 B, while still permitting catalyst pellets to have access to the openings in the mask plate as discussed further hereinbelow. The clamping of the plates is such that the gate plate  93 A can be shifted or translated laterally (in the direction of the arrow B) relative to the mask plate  93 B via a mechanical force applied by an operator either directly or via an actuator. 
         [0055]    The mask plate  93 B has through openings equal in number and positioned to coincide with the pre-selected areas  14 D between the legs or feet of adjacent corrugations of the collector which are to receive catalyst pellets in accordance with the desired pattern. The gate plate  93 A, in turn, also has through openings. These openings, however, are equal in number and positioned to coincide with all the areas  14 D of the collector. 
         [0056]    As shown in  FIG. 10 , the mask gate assembly  93  is clamped to the vibratory block  92  over the current collector so that the through openings in the gate plate  93 A are misaligned with the areas  14 D of the current collector while the through openings of the mask plate  93 B are aligned with these openings. Solid areas of the gate plate  93 A thus block movement from the through openings of the mask plate  93 B to the areas  14 D of the current collector. In this closed position of the gate assembly  93 , vibration is used to move catalyst pellets from the hopper  94  so that they distribute along the length of the mask plate  93 B and deposit in the through openings of the mask plate. 
         [0057]    The mask plate  93 B is designed such that only one catalyst pellet can reside in each of its openings. The catalyst pellets also cannot sit on top of one another due to the mask plate thickness being less than the pellet diameter. This creates channels for the catalyst pellets to travel along until they reach an empty opening in the mask plate. Once the openings in the mask plate  93 B are all filled, the gate plate  93 A is shifted laterally as shown by the arrow B in  FIG. 10  to bring the mask gate assembly  93  to its open position as shown in  FIG. 11 . 
         [0058]    In this position, due to the shifting of the gate plate  93 A, the through openings in the gate plate now align with the areas  14 D of the current collector and also with the through openings in the mask plate  93 B. The catalyst pellets thus fall in the direction of the arrow C from the openings in the mask plate  93 B through the corresponding openings in the gate plate  93 A into the underlying areas  14 D of the current collector. The current collector  14  thus becomes loaded with catalyst pellets in accordance with the desired predetermined pattern. 
         [0059]    Moreover, the vibratory motion imparted to the current collector by the block  92  causes the catalyst pellets to orient themselves in the areas or pockets  14 D of the current collector in such a way as to not protrude above the height of the legs defining the areas. This allows for further processing of the catalyst loaded current collector as by application of an adhesive fixing agent to hold the catalyst pellets in the current collector as discussed above. 
         [0060]    To aid in securing the catalyst pellets in the areas  14 D of the current collector, the vibratory block  92  is adapted to be subjected to a vacuum which secures the current collector to the block via an adhesive membrane on the current collector. This provides an intimate contact between the collector and a very smooth, even transmission of vibration. As a result, the catalyst pellets are moved into and settle into the areas  14 D so as to not protrude from the current collector as above-described. 
         [0061]    In all cases it is to be understood that the above-described subject matter is merely illustrative of the many possible specific embodiments, which represent applications of the present invention. Numerous and varied other arrangements can be readily devised in accordance with the principles of the present invention, without departing from the spirit and scope of the invention. In particular, while the invention has been illustrated in terms of loading an anode current collector with catalyst particles, it is evident that the principles of the invention extend to loading of other fuel cell components defining or forming the anode flow field or fuel flow field of a fuel cell. Loading of a bipolar separator plate with catalyst particles might be one example.