Abstract: A method of making a membrane-electrode-assembly (MEA) for a PEM/SPE fuel cell comprising applying a slurry of electrode-forming material directly onto a membrane-electrolyte film. The slurry comprises a liquid vehicle carrying catalyst particles and a binder for the catalyst particles. The membrane-electrolyte is preswollen by contact with the vehicle before the electrode-forming slurry is applied to the membrane-electrolyte. The swollen membrane-electrolyte is constrained against shrinking in the "x" and "y" directions during drying. Following assembly of the fuel cell, the MEA is rehydrated inside the fuel cell such that it swells in the "z" direction for enhanced electrical contact with contiguous electrically conductive components of the fuel cell.

Abstract: The CO concentration in the H.sub.2 feed stream to a PEM fuel cell stack is monitored by measuring current and/or voltage behavior patterns from a PEM-probe communicating with the reformate feed stream. Pattern recognition software may be used to compare the current and voltage patterns from the PEM-probe to current and voltage telltale outputs determined from a reference cell similar to the PEM-probe and operated under controlled conditions over a wide range of CO concentrations in the H.sub.2 fuel stream. The PEM-probe is intermittently purged of any CO build-up on the anode catalyst (e.g., by (1) flushing the anode with air, (2) short circuiting the PEM-probe, or (3) reverse biasing the PEM-probe) to keep the PEM-probe at peak performance levels.

Abstract: An anti-intrusion barrier comprising a corrugated metal sheet and at least one mounting flange integral with the sheet. The flange comprises extensions of the corrugations which have been collapsed inwardly upon themselves so as to provide a plurality of plateaus each defined by a pair of pleats formed by collapsed walls of the corrugations.

Abstract: The CO concentration in the H.sub.2 feed stream to a PEM fuel cell stack is monitored by measuring current and/or voltage behavior patterns from a PEM-probe communicating with the reformate feed stream. Pattern recognition software may be used to compare the current and voltage patterns from the PEM-probe to current and voltage telltale outputs determined from a reference cell similar to the PEM-probe and operated under controlled conditions over a wide range of CO concentrations in the H.sub.2 fuel stream. A CO sensor includes the PEM-probe, an electrical discharge circuit for discharging the PEM-probe to monitor the CO concentration, and an electrical purging circuit to intermittently raise the anode potential of the PEM-probe's anode to at least about 0.8 V (RHE) to electrochemically oxidize any CO adsorbed on the probe's anode catalyst.

Abstract: Nesting electrical connectors comprising a substrate and a silver-nickel-carbon electrodeposit atop the substrate. The electrodeposit is at least about 0.5 micrometers thick, and comprises about 10 to about 25 atomic percent nickel which is dispersed as a discontinuous phase throughout a continuous phase of the silver and has a Scherrer grain size less than about 5 nanometers. The carbon comprises about 5 to about 15 atomic percent of the deposit and has a non-crystalline graphite structure.

Abstract: A two-chamber furnace for the low pressure countergravity casting of metal wherein the first chamber is a molten metal supply chamber connected by a submerged orifice closable by a stopper rod valve to a sealed second chamber that is pressurizable to fill a superjacent mold. The stopper rod valve is readily replaceable from the top of the furnace without having to empty the melt from the furnace.

Abstract: The CO-concentration in the H.sub.2 feed stream to a PEM fuel cell stack is monitored by measuring current and voltage behavior patterns from an auxiliary cell attached to the end of the stack. The auxiliary cell is connected to the same oxygen and hydrogen feed manifolds that supply the stack, and discharges through a constant load. Pattern recognition software compares the current and voltage patterns from the auxiliary cell to current and voltage signature determined from a reference cell similar to the auxiliary cell and operated under controlled conditions over a wide range of CO-concentrations in the H.sub.2 fuel stream.

Abstract: A battery pack has a plurality of batteries connected in series to provide a high voltage energy source and energy storage. The battery pack has a high voltage receptacle in which a high voltage harness is connected when power is to be distributed or stored. a cover guard prevents inadvertent access to the harness connector. The cover guard has integral therewith an electrical disconnect mechanism and latch mechanism which must be manipulated prior to exposing the harness connector. The disconnect mechanism eliminates the electrical connection of the batteries to a receptacle in which the harness connector is installed. The latch mechanism prevents removal of the cover guard prior to manual disconnection and also prevents reconnection prior to the cover guard being properly positioned.

Abstract: A cast iron exhaust manifold having an inside surface covered with a ceramic coating comprising, by weight, about 30% to about 70% unfused silica, about 5% to about 30% magnesia, about 5% to about 20% alumina and about 3% to about 10% sodium oxide. The coating will preferably be built up in multiple layers at least one of which is relatively porous and another is relatively dense resulting from vacuum degassing of the slurry used to deposit the coating.

Abstract: An anti-intrusion barrier comprising a corrugated metal sheet and at least one mounting flange integral with the sheet. The flange comprises extensions of the corrugations which have been collapsed inwardly upon themselves so as to provide a plurality of plateaus each defined by a pair of pleats formed by collapsed walls of the corrugations.

Abstract: Method of making porous, fibrillose bodies from fibrils bonded together into a self-supporting structure. A mixture of fibrils and a viscous, non-newtonian, liquid vehicle including an organic hydrosorbent and water is (1) injected into a mold, (2) frozen in the mold to form a frozen precursor of the article, (3) ejected from the mold while still frozen, (4) freeze-dried, and (5) finally heated to remove the hydrosorbent and bond the particles together. The process is particularly effective for making fibrillose preforms for infiltrating with metal in the manufacture of metal matrix composites.

Abstract: A battery pack including a cover overlying a plurality of individual batteries and a plurality of inter-battery connectors for electrically coupling the several batteries together. The inter-battery connectors are secured to the cover such that upon removal of the cover all of the connectors are removed from the batteries en masse.

Abstract: A reciprocating engine having an aluminum engine block, and an aluminum piston wherein the piston's skirt has a hard anodized first layer directly on the aluminum and a composite polymer coating atop the hard anodized layer.

Abstract: Pb-Ca battery grids are dipped into a bath of molten Pb-Sn or Pb-Ag to prolong the useful life of the battery as determined by the high temperature SAE J240 test.

Abstract: A printed-circuit-type electrical contact pad having a plurality of electrically conductive metal traces and a plurality of protuberant electrical contacts projecting from the traces. The protuberances comprise an electrically conductive elastomer having a wide base portion anchored in the end of the trace by a truncated portion of the trace upstanding from the face of the pad. A denuded tip portion of the elastomer extends from the base portion for resiliently engaging a contact site on an electrical device to which the pad is coupled. A unique process for making the aforesaid pad is disclosed and claimed.

Abstract: A foundry mold member made from a plurality of sand particles bound together with a binder which is concentrated at the contact points between contiguous sand particles and consists essentially of gelatins having a Bloom rating less than about 175 Bloom grams. The sand particles are first coated with a sol of the gelatin, cooled to ambient temperature and conditioned to a prescribed water content necessary to effect migration of the gelatin to the interparticle contact points upon heating of the coated particles in a pattern mold.

Abstract: An anti-snagging loop striker for use with a door latch for securing a door in a closed position on a vehicle. The striker includes a ramp adjacent the rivet head connecting the crossbar to the leading leg of the striker to prevent sheet metal from the door from catching on such head and impeding opening of the door from outside the vehicle following an accident.

Abstract: A liquid-cooled, bipolar plate separating adjacent cells of a PEM fuel cell comprising corrosion-resistant metal sheets brazed together so as to provide a passage between the sheets through which a dielectric coolant flows. The brazement comprises a metal which is substantially insoluble in the coolant.

Abstract: A titania exhaust gas oxygen sensor including an alumina substrate, thin-film electrodes deposited thereon, and a thick-film titania layer deposited atop the electrodes. The electrodes comprise a noble metal (e.g., platinum) having a plurality of titania particles dispersed throughout for promoting bonding to the titania, resistive layer when the titania layer is fired.

Abstract: A foundry mold member made from a plurality of sand practice bound together with a binder which is concentrated at the contact points between contiguous particles and consists essentially of gelatins having a Bloom rating less than about 175 Bloom grams. The sand particles are first coated with a sol of the gelatin, cooled to ambient temperature and conditioned to prescribed water content necessary to effect migration of the gelatin to the interparticle contact points upon heating of the coated particles in a pattern mold.