Abstract: Thermal management of a fuel-cell-powered electric vehicle having at least one high temperature heat transfer circuit and one low temperature heat transfer circuit each using the same dielectric heat transfer medium as the other. The circuits are in flow communication with each other so that hot heat transfer medium can flow from the high temperature circuit into the low temperature circuit, and cooler heat transfer medium can flow from the low temperature circuit into the high temperature circuit under controlled conditions for heating the fuel cell when it is cold, cooling a fuel processor when it is hot, and otherwise meeting the thermal demands of the vehicle.

Abstract: A PEM fuel cell having electrical contact elements comprising a corrosion-susceptible substrate metal coated with an electrically conductive, corrosion-resistant polymer containing a plurality of electrically conductive, corrosion-resistant filler particles. The substrate may have an oxidizable metal first layer (e.g., stainless steel) underlying the polymer coating.

Abstract: Method for managing the temperature of a fuel-cell-powered electric vehicle having at least one high temperature heat transfer circuit and one low temperature heat transfer circuit each using the same dielectric heat transfer medium as the other. The circuits are in flow communication with each other and the heat transfer medium is pumped from one circuit to the other in response to the thermal demands of the vehicle.

Abstract: A method of heating a cold MEA to accelerate cold start-up of a PEM fuel cell. The MEA is locally heated from below freezing to a suitable operating temperature by the exothermal chemical reaction between H2 and O2 on the anode and/or cathode catalysts. To their end, H2 is introduced into the O2-rich cathode feed stream and/or O2 is introduced into the H2-rich anode feed stream.

Abstract: A PEM fuel cell having serpentine flow field channels wherein each channel has an inlet leg, an exit leg, at least one medial leg therebetween and hairpin curves connecting the legs to each other. The legs all extend in the same general direction between a gas supply and gas exhaust manifold. One of the inlet and exit legs is longer than the other while the medial leg is shorter than the shortest of the inlet/exit leg. The land(s) defining the medial leg(s) of adjacent channels are generally aligned lengthwise.

Abstract: A PEM fuel cell is vacuum-dried before storing under freezing conditions.

Abstract: A PEM fuel cell having serpentine flow field channels comprising a plurality of serially-linked serpentine segments extending between inlet and exhaust manifolds. Each segment has an inlet leg, an exit leg, at least one medial leg therebetween and hairpin curved ends connecting the medial leg(s) to other legs of the segment. A bridging section of each flow channel connects adjacent segments of the same channel one to the next. The hairpin-curved ends of the medial legs are spaced from bridging sections by different distances depending on the difference in pressure in the bridging section and the hairpin-curved ends.

Abstract: An apparatus and method by which tracer compounds and combustion products in the exhaust of an internal combustion engine are more completely combusted, so that oil consumption of the engine can be more precisely and concurrently measured on a real-time basis using tunable diode laser spectroscopy. The apparatus includes a furnace capable of completely burning nonradioactive stable organobromo compounds and combustion products within the exhaust gas of the engine, without being reactive with the compounds or the resulting tracer gas or isotopic specie of the compounds. The furnace generally has at least one passage through which the exhaust gas passes. The wall surfaces of the passage are formed of a material with a high concentration of titanium, such that the exhaust gas is substantially limited to contact with the high-Ti material while within the furnace.

Abstract: There is provided an electrode structure comprising a current collector sheet and first and second layers of electrode material. Together, the layers improve catalyst utilization and water management.

Abstract: A fuel cell system including a dry compressor for pressurizing air supplied to the cathode side of the fuel cell. An injector sprays a controlled amount of water on to the compressor's rotor(s) to improve the energy efficiency of the compressor. The amount of water sprayed out the rotor(s) is controlled relative to the mass flow rate of air inputted to the compressor.

Abstract: The method of lost foam casting uses a polystirene foam pattern molded from polystirene beads preexpanded from raw polystirene beads that have a raw bead diameter in the range of about 0.1 to about 0.6 millimeters and that include isopentane as a relatively slow diffusing blowing agent alone, or together with normal pentane as a relatively high diffusing blowing agent, the isopentane being present in an amount of at least about 40% by weight of the total blowing agent of the raw beads to significantly reduce post-molding dimensional pattern shrinkage and to render the molded patterns inherently more dimensionally stable. The patterns can be used directly in the lost foam casting of molten metal without the need for any intermediate pattern dimension-stabilizing treatment.

Abstract: A method of operating a H2—O2 fuel cell fueled by hydrogen-rich fuel stream containing CO. The CO content is reduced to acceptable levels by injecting oxygen into the fuel gas stream. The amount of oxygen injected is controlled in relation to the CO content of the fuel gas, by a control strategy that involves (a) determining the CO content of the fuel stream at a first injection rate, (b) increasing the O2 injection rate, (c) determining the CO content of the stream at the higher injection rate, (d) further increasing the O2 injection rate if the second measured CO content is lower than the first measured CO content or reducing the O2 injection rate if the second measured CO content is greater than the first measured CO content, and (e) repeating steps a-d as needed to optimize CO consumption and minimize H2 consumption.

Abstract: A thermally integrated two-stage methanol reformer including a heat exchanger and first and second reactors colocated in a common housing in which a gaseous heat transfer medium circulates to carry heat from the heat exchanger into the reactors. The heat transfer medium comprises principally hydrogen, carbon dioxide, methanol vapor and water vapor formed in a first stage reforming reaction. A small portion of the circulating heat transfer medium is drawn off and reacted in a second stage reforming reaction which substantially completes the reaction of the methanol and water remaining in the drawn-off portion. Preferably, a PrOx reactor will be included in the housing upstream of the heat exchanger to supplement the heat provided by the heat exchanger.

Abstract: A fuel cell system including a fuel reformer heated by a catalytic combustor fired by anode and cathode effluents. The combustor includes a turbulator section at its input end for intimately mixing the anode and cathode effluents before they contact the combustors primary catalyst bed. The turbulator comprises at least one porous bed of mixing media that provides a tortuous path therethrough for creating turbulent flow and intimate mixing of the anode and cathode effluents therein.

Abstract: There is provided a method and apparatus for treatment of a hydrogen-rich gas to reduce the carbon monoxide content thereof by reacting the carbon monoxide in the gas with an amount of oxygen sufficient to oxidize at least a portion of the carbon monoxide in the presence of a catalyst in a desired temperature range without substantial reaction of hydrogen. The catalyst is an iridium-based catalyst dispersed on, and supported on, a carrier. In the presence of the catalyst, carbon monoxide in a hydrogen-rich feed gas is selectively oxidized such that a product stream is produced with a very low carbon monoxide content.

Abstract: A multi-stage, isothermal, carbon monoxide preferential oxidation (PrOx) reactor comprising a plurality of serially arranged, catalyzed heat exchangers, each separated from the next by a mixing chamber for homogenizing the gases exiting one heat exchanger and entering the next. In a preferred embodiment, at least some of the air used in the PrOx reaction is injected directly into the mixing chamber between the catalyzed heat exchangers.

Abstract: Method and apparatus for monitoring an H.sub.2 -O.sub.2 PEM fuel cells to detect and correct flooding. The pressure drop across a given H.sub.2 or O.sub.2 flow field is monitored and compared to predetermined thresholds of unacceptability. If the pressure drop exists a threshold of unacceptability corrective measures are automatically initiated.

Abstract: A PEM fuel cell having serpentine flow field channels wherein the input/inlet legs of each channel border the input/inlet legs of the next adjacent channels in the same flow field, and the output/exit legs of each channel border the output/exit legs of the next adjacent channels in the same flow field. The serpentine fuel flow channels may be longer, and may contain more medial legs, than the serpentine oxidant flow channels.

Abstract: A fuel cell system including a fuel reformer heated by a catalytic combustor fired by anode effluent and/or fuel from a liquid fuel supply providing fuel for the fuel cell. The combustor includes a vaporizer section heated by the combustor exhaust gases for vaporizing the fuel before feeding it into the combustor. Cathode effluent is used as the principle oxidant for the combustor.

Abstract: The present invention contemplates a PEM fuel cell having electrical contact elements (including bipolar plates/septums) comprising a titanium nitride coated light weight metal (e.g., Al or Ti) core, having a passivating, protective metal layer intermediate the core and the titanium nitride. The protective layer forms a barrier to further oxidation/corrosion when exposed to the fuel cell's operating environment. Stainless steels rich in CR, Ni, and Mo are particularly effective protective interlayers.