Abstract: Apparatus for cooling a fuel cell stack. The cooling system uses vaporization cooling of the fuel stack and supersonic vapor compression of the vaporized coolant to significantly increase the temperature and pressure of the liquid coolant flowing through a heat exchanger. By increasing the heat rejection temperature of the coolant delivered to the heat exchanger, the heat transfer area of the heat exchanger can be reduced and the mass flow rate of coolant can also be reduced. The increased fluid pressure is used to circulate the coolant through the cooling system, thereby eliminating the circulation pump associated with conventional systems.

Abstract: A sensor plate for measuring current and/or temperature distribution of an operating fuel cell. The sensor plate has a circuit board interposed between an anode flow field plate and a cathode flow field plate of the fuel cell. A flow field plate is segmented into a plurality of electrically isolated regions without disrupting the flow field of the plate. The circuit board has an array of resistors and/or thermistors mounted to it wherein each resistor and/or thermistor is associated with one of the electrically isolated regions of the segmented plate. The current distribution of the electrically isolated regions of the fuel cell is calculated by using the voltage drop across the resistors and the known resistance values of the resistors mounted to the circuit board.

Abstract: A composite separator plate for use in a fuel cell stack and method of manufacture is provided. The composite separator plate includes a plurality of elongated support members oriented generally parallel to each other and a polymeric body portion formed around the support members. The body portion includes a first surface with a plurality of flow channels and a second surface opposite the first surface. A plurality of electrically conductive fibers are disposed within the polymeric body portion, each fiber extending continuously from the first surface of the polymeric body portion to the second surface of the polymeric body portion in a through plane configuration.

Abstract: A low humidification and durable fuel cell membrane is provided with water adsorbing material embedded therein in order to adsorb water under wet conditions and provide a reservoir of water to keep the membrane irrigated under dry conditions. A hydrogen oxidation catalyst is provided on the water adsorbing material which will catalyze the reaction of hydrogen and oxygen that are crossing through the membrane and will serve to irrigate the membrane and keep the water adsorbing material full of water. Accordingly, the humidification requirements to a fuel cell stack in an operating system are reduced.

Abstract: A preferential oxidation reactor is provided including a plurality of reactor sections. The reactor sections are individually optimized for operating at a preferred reaction temperature. In one embodiment, each reactor subsection includes a respective coolant flow for manipulating the operating temperature of the respective subsection. In another embodiment, a first section includes a lower temperature catalyst substrate, a second reactor section includes a higher temperature (i.e. normal) catalyst substrate and a third reactor section includes a lower temperature catalyst substrate. Yet another embodiment includes modifying the catalyst substrates of the respective subsections through the inclusion of promoters. Still another embodiment includes varying a density of the catalyst substrate across the reactor sections. Each of the embodiments enable quick light-off of the reactor, while limiting a reverse water-gas shift reaction.

Abstract: The invention relates to a process for making a thin film starting from a substrate (1) of a solid material with a plane face (2) comprising: the implantation of gaseous compounds in the substrate (1) to make a layer of micro-cavities (4) at a depth from the said plane face (2) corresponding to the thickness of the required thin film, the gaseous compounds being implanted under conditions that could weaken the substrate at the layer of micro-cavities, partial or total separation of the thin film from the rest of the substrate (1), this separation comprising a step in which thermal energy is added and pressure is applied to the said plane face (2).

Abstract: An improved fuel processor thermal management system for use with a fuel cell is disclosed. The process includes supplying an air stream and a fuel stream into a auto thermal reactor (ATR) and forming reformate gas therein. Then, preferentially oxidizing the reformate gas and the air stream in the preferential oxidizer reactor (PrOx). The temperature of the preferential oxidizer reaction is controlled with a water stream by vaporizing the water stream to form a first portion of vaporized water. Then, reacting the air stream with the reformate gas exiting the PrOx is reached in a fuel cell to form an anode exhaust stream which is subsequently combined with the air stream to heat the water stream to form a second portion of vaporized water. The first portion of vaporized water and the second portion of vaporized water form a steam fluid.

Abstract: A fuel cell stack has at least two segments of fuel cells each having reactant gas passages. Each of the cells in each segment is arranged such that the reactant gas passages of each cell are in parallel with each other cell. Flow of fuel cell fluids, normally in a gaseous state on the anode and cathode side of each cell, is in a gravity assisted downward direction. Gravity assisted flow directs water formed in each cell to lower removal points of the stack segments. Each pair of segments is separated by a separator segment having a separator channel, the separator segment forming an integral unit of the stack. Each separator channel redirects the entire flow of each fluid within the stack from the bottom of an upstream segment to the top of a next or downstream segment, without reacting the fluid, controlling relative humidity between stack segments.

Abstract: The present invention relates to an electrochemical cell having a terminal collector plate element that conducts electrical current from the stack. The terminal plate has an electrically conductive region and an electrically non-conductive region of the surface. The non-conductive region is coated with a corrosion resistant coating that comprises either a passivation layer, a corrosion-resistant polymeric layer, or both. Optionally, the conductive region of the terminal plate may be protected from oxidation, by coating with an oxidation-resistant metal layer. The oxidation-resistant layer may be further coated with a conductive oxidation-resistant polymeric layer. Other preferred aspects of the present invention include methods of treating the terminal plate to resist corrosion and oxidation while still maintaining electrical conductivity.

Abstract: A method for adjusting the timing of an internal combustion engine having a crankshaft and a camshaft to manage the thermal load on the engine. The method includes the step of altering the timing of the camshaft with respect to the timing of the crankshaft to reduce thermal load on the engine. Preferably, the step of altering the timing of the camshaft is accomplished with a variable camshaft phaser.

Abstract: A venting methodology and system for rapid shutdown of a fuel cell apparatus of the type used in a vehicle propulsion system. H2 and air flows to the fuel cell stack are slowly bypassed to the combustor upon receipt of a rapid shutdown command. The bypass occurs over a period of time (for example one to five seconds) using conveniently-sized bypass valves. Upon receipt of the rapid shutdown command, the anode inlet of the fuel cell stack is instantaneously vented to a remote vent to remove all H2 from the stack. Airflow to the cathode inlet of the fuel cell stack gradually diminishes over the bypass period, and when the airflow bypass is complete the cathode inlet is also instantaneously vented to a remote vent to eliminate pressure differentials across the stack.

Abstract: A fuel processor for a fuel cell includes a thermal start device, a mixing region and a temperature control element. The temperature control element is located between the thermal start device and the mixing region. The temperature control element reduces temperature increase in the mixing region during thermal startup. A flame arrestor is connected to the mixing region. A primary reactor is connected to the flame arrestor. The transient temperature control element has a body defining an inlet and an outlet. A plurality of bores are formed in the body.

Abstract: Recesses are located along an elongated elastomeric member. Electrical contacts are associated with the elastomeric member in registration with the recesses. The elastomeric member expands or compresses along its length to receive one of the closely spaced plates in each of the plurality of recesses and to thereby register the electrical contacts with a corresponding contact point on the plates. The elastomeric strip is confined under compression between two adjacent members which may be parts of two plates or of a single plate. The adjacent members define a recess, including locking protrusions, adapted to resist removal of the connector from within the retention recess unless the elongated elastomeric strip is compressed. An associated method optionally includes allowing the compressed elastomeric strip to push against adjacent members to generate a force which pushes the contact points against the one of the closely spaced plates.

Abstract: A formable biodegradable filament nonwoven fabric and a production method therefor are provided. A biodegradable polymer comprising a thermoplastic aliphatic polyester as its principal component is melted and extruded through a spinneret into filaments. While being quenched with quench air blow, the extruded filaments are drafted at a drafting speed of 1,000 to 2,500 m/min by means of a suction device disposed below the spinneret. The drafted filaments are spread and accumulated on a movable collector surface thereby to be formed into a web, which is then treated for formation of a nonwoven fabric. The constituent filaments of the nonwoven fabric has a polymer supercool index of 0.3 to 0.6.

Abstract: A fuel processor control system for a fuel cell stack includes water and fuel metering devices that control water and fuel provided to the fuel processor. An air flow rate sensor generates an air flow rate signal based on air flowing from a compressor to the fuel processor. A valve is located between the fuel processor and the fuel cell stack. A controller controls the valve and the water and fuel metering devices based on the air flow rate sensor. Other feedback signals such as stack voltage, stack cell voltage variation, pressure differential across the valve, and mass flow rate between the valve and the fuel cell stack can augment or be substituted for the air flow rate feedback signal. The fuel processor can be a partial oxidation reformer a steam reforming reactor, an auto thermal reformer or any combination thereof. The system may also include a water as shift reactor and a preferential oxidation reactor for carbon monoxide reduction.

Abstract: A sensor system for sensing the relative humidity level of gas stream in a fuel cell includes a humidity sensor that senses the relative humidity of a gas stream and generates a relative humidity signal. A pressure sensor senses the pressure of the gas stream and generates a pressure signal. A temperature sensor senses the temperature of the gas stream and generates a temperature signal. A compensator is connected to the humidity sensor, the temperature sensor and/or the pressure sensor. The compensator generates a compensated relative humidity signal based on the relative humidity signal, the temperature signal and/or the pressure signal. Additional inputs to the compensator can include one or more gas composition sensors that determine the concentration of one or more gases.

Abstract: A method and apparatus estimate hydrogen concentration in a reformate stream produced by a fuel processor of a fuel cell. A sensor measures carbon monoxide, carbon dioxide, and water in the reformate stream. A fuel meter controls fuel input to the fuel processor. An air meter controls air input to the fuel processor. A water meter controls water input to the fuel processor. A transport delay estimator recursively estimates transport delay of the fuel processor. A hydrogen estimator associated with the transport delay estimator, the air, water and fuel meters, and the sensor estimates hydrogen concentration in the reformate stream. The hydrogen estimator includes a fuel processor model that is adjusted using the estimated transport delay. The carbon monoxide, the carbon dioxide and the water are measured using a nondispersive infrared (NDIR) sensor.

Abstract: A cooling unit includes a radiator and an axial flow blower that draws air through the radiator along a longitudinal axis and a cross-flow fan that draws air along a lateral axis. The cross-flow fan forces air through the radiator along the longitudinal axis. The axial flow fan draws air through the radiator long the longitudinal axis. A moveable baffle is operable to selectively block air flow from the cross-flow fan.

Abstract: A diagnostic system and method identifies fuel injector failure in a fuel cell system including a fuel processor and a fuel source. A fuel injector supplies fuel from the fuel source to the fuel processor. A pressure sensor generates a pressure signal based on pressure between the fuel source and the fuel injector. A fuel injector diagnostic identifies fuel injector failure based on the pressure signal. The fuel injector diagnostic includes a moving window tracker that tracks the pressure signal over a moving window. The fuel injector diagnostic further includes a standard deviation or variance calculator that generates a standard deviation or variance based on the pressure signal in the moving window.

Abstract: Recesses are located along an elongated elastomeric member. Electrical contacts are associated with the elastomeric member in registration with the recesses. The elastomeric member expands or compresses along its length to receive one of the closely spaced plates in each of the plurality of recesses and to thereby register the electrical contacts with a corresponding contact point on the plates. The elastomeric strip is confined under compression between two adjacent members which may be parts of two plates or of a single plate. The adjacent members define a recess, including locking protrusions, adapted to resist removal of the connector from within the retention recess unless the elongated elastomeric strip is compressed. An associated method optionally includes allowing the compressed elastomeric strip to push against adjacent members to generate a force which pushes the contact points against the one of the closely spaced plates.