Abstract: A fuel cell monitor connector electrically connects a fuel cell monitor to a fuel cell stack. The fuel cell monitor connector includes a non-conductive housing. First connectors on the housing align with second connectors located on fuel cell plates of the fuel cell stack. A third connector on the housing mates with a fourth connector coupled to the monitor. Conductors connect the first connectors to the third connector. A clamping device includes a lever and has locked and released positions. When the clamping device is in the locked position, the first connectors retain the second connectors. When the clamping device is in the released position, the first connectors release the second connectors. The clamping device is a zero insertion force connector.

Abstract: A method is provided to inject liquid water into the normal stream of fuel, superheated air and superheated steam entering a primary reactor of a fuel processor. The injection location is in the steam supply line where superheated steam vaporizes a majority of the liquid water, preferably prior to injection into the primary reactor. Steam supplied by a vaporizer may temporarily lag desired steam production due to system up-power transients or startup conditions, coupled with vaporizer thermal lag time. Injection of liquid water overcomes this temporary deficit of steam. Additional air is also supplied as needed to improve reactance for a given steam volume/temperature. Injection rate or volume of the liquid water and air may also be based on one or more measured variables of the primary reactor.

Abstract: A control system and method for operating a cooling fan in a coolant system of fuel cell power plant having a high temperature coolant loop and a low temperature coolant loop. The fan controller generates a fan control signal based on a first control signal from the high temperature coolant loop and a second control signal from the low temperature coolant loop. The first control signal is a function of the waste heat energy in the high temperature coolant loop, and the second control signal is a function of the temperature in the low temperature coolant loop. The fan control signal may also be generated based on a third control signal which is a function of a localized ambient temperature such as the under hood temperature of a vehicle.

Abstract: A method and apparatus for monitoring hydrogen and optionally a non-hydrogen gas including carbon monoxide. The method and apparatus includes a sensor assembly consisting of a plurality of electrochemical cells sequentially arranged in a path of the hydrogen-containing gas stream. Reaction and consumption of hydrogen at catalytically reactive surface areas of the cells generates a current which is proportional to the amount of hydrogen in the gas stream entering the sensor.

Abstract: A catalytic combustor contains multiple sections for catalytically combusting an anode effluent. The anode effluent is divided into a plurality of portions with each portion routed to a different section or stage of the combustor. The proportioning of the anode effluent allows the combustor to be operated so that the flows combusted do not autoignite and various heat loads placed on the different stages of the combustor can be met. Additionally, the proportioning of the anode effluent allows the temperature within the various components of the combustor to be controlled so that a useful life of the combustor can be increased.

Abstract: A control system controls steam in a fuel cell system including a fuel processor. A fuel cell has run, standby and shutdown operating modes. A fuel processor provides reformate to the fuel cell. A pressure sensor generates a pressure signal based on a pressure of steam supplied to the fuel processor. A valve directs steam to or vents steam away from the fuel processor. A controller communicates with the pressure sensor, the fuel cell and the valve and controls the valve based on the operating mode of the fuel cell and the pressure signal. The controller opens the valve during the shutdown mode. The controller closes the valve during the run operating mode. The controller initially closes the valve during the standby mode. The controller opens the valve if the pressure signal exceeds a first predetermined pressure value and closes the valve when the pressure falls.

Abstract: A gas flow control system for a fuel cell includes a gas supply and a humidifier. A fuel cell stack includes a cathode flow line with an inlet and an outlet. The inlet of the cathode flow line is connected to the outlet of the humidifier. A combustor includes an inlet that receives gas from the outlet of the cathode flow line. A valve and a bypass line bypass gas around the humidifier and the fuel cell stack to the combustor. The valve is preferably one of a gas restriction valve, a throttle valve, and a directional valve. A gas flow sensor generates a gas flow signal based on gas flowing through at least one of the humidifier, the cathode flow line of the fuel cell stack, and the bypass line. A flow controller that is connected to the gas flow sensor and the valve controls the valve based on the gas flow signal.

Abstract: A control method for monitoring a fuel cell stack in a fuel cell system in which the actual voltage and actual current from the fuel cell stack are monitored. A preestablished relationship between voltage and current over the operating range of the fuel cell is established. A variance value between the actual measured voltage and the expected voltage magnitude for a given actual measured current is calculated and compared with a predetermined allowable variance. An output is generated if the calculated variance value exceeds the predetermined variance. The predetermined voltage-current for the fuel cell is symbolized as a polarization curve at given operating conditions of the fuel cell.

Abstract: A connector and method for electrically connecting to a series of closely spaced edges for use in monitoring individual cells using bipolar plates of a fuel cell stack. The connector includes an elongated elastomeric strip with electrical conductivity for a first side thereof to an opposing side thereof, but not having meaningful electrical conductivity in use along its elongated length. This elongate strip is held at an angle in relation to the closely spaced edges by alignment protrusions. This enables the use of a series of connectors which nest together to contact all the closely spaced edges. A plurality of electrically conductive elements are located on a printed circuit board against the opposing side of the elongated elastomeric strip in corresponding relationship to the closely spaced edges located against the first side of the elongate elastomeric strip. Means is provided for exerting a force to push the first side of the elongated elastomeric strip against the closely spaced edges is also provided.

Abstract: An apparatus removes CO from a hydrogen-rich gas stream in a hydrogen fuel cell system. CO fouls costly catalytic particles in the membrane electrode assemblies. Both a catalyst adapted to perform a water gas shift reaction, and a carbon dioxide adsorbent are disposed in a rotating pressure swing adsorber housing. The adsorption of carbon dioxide shifts equilibrium toward carbon monoxide consumption. A second adsorbent may be disposed in the housing for adsorbing carbon monoxide at low temperatures, and is adapted to desorb carbon monoxide at high temperatures. The present invention advantageously eliminates a unit operation from a space-constrained fuel cell vehicle by combining the WGS catalyst and a CO2 adsorbent in a single reactor/housing. The apparatus further eliminates the use of a PROX reactor, by providing an apparatus which incorporates CO2 adsorption and consequent carbon monoxide consumption in the place of the PROX reactor.

Abstract: An air control system and method for a fuel cell system includes a manifold, a air delivery device that supplies air to the manifold, and a plurality of fuel cell components. A plurality of flow controllers (FCs) control airflow from the manifold to the fuel cell components. A controller communicates with the FCs and the air delivery device and generates a manifold pressure setpoint based on a first factor that is related to fuel cell system stability and a second factor that is a based on minimum and maximum pressures of the air delivery device for a predetermined airflow. If the first and second factors are met, the controller optionally generates the manifold pressure setpoint based on a third factor that is related to fuel cell system efficiency.

Abstract: The present invention provides a combustor for a fuel processor which integrates a burner and a catalyst. The burner is utilized to quickly heat the catalyst to a light-off temperature to prepare it for normal operation. The heated catalyst is then used to react anode exhaust with air or cathode exhaust under normal operation.

Abstract: An electro-chemical fuel cell stack having a fuel cell assembly disposed between upper and lower terminal plates which are disposed between upper and lower end plates. Optionally, spacer plates can be inserted between the end plates and the terminal plates. The end plates and/or the spacer plates may have contoured surfaces to apply a generally uniform compressive load on the fuel cell assembly. The terminal plates, spacer plates, and end plates may be connected together to form rigid end assemblies that compress the fuel cell assembly.

Abstract: A proton exchange membrane fuel cell including a membrane electrode assembly comprising a proton transmissive membrane, a catalytic anode layer on one face of the membrane, and a catalytic cathode layer on the other face of the membrane. The fuel cell further includes a gas distribution layer on each of the cathode and anode layers defining a gas flow field extending over each of the catalytic layers. The membrane electrode assembly has a convoluted configuration whereby to increase the ratio of membrane area to planar fuel cell area and thereby increase the electrical output of the fuel cell for a given planar area size fuel cell. The convoluted configuration of the membrane electrode assembly also facilitates the division of the gas distribution layers into separate parallel channels thereby allowing the use of an inexpensive foam material for the gas distribution layers irrespective of the inherent variations in porosity of foam materials.

Abstract: A fuel cell system that extracts water from the effluent of a fuel cell for supply to other components of the fuel cell system that require water. A preferred embodiment is a fuel cell system, for the production of electricity from hydrogen gas and an oxidant, comprising: (a) a fuel cell comprising an anode input for a hydrogen-containing anode supply stream, a cathode input for an oxidant-containing cathode supply stream, and a cathode output for cathode effluent comprising water produced by said fuel cell; and (b) a water transfer device, connected to said fuel cell, that transfers water from said cathode effluent to said anode supply stream.

Abstract: A composite separator plate for a fuel cell having a low-carbon loading and a high-polymer loading is disclosed. The separator plate composition includes a percentage of conductive fibrous filler having a relatively high aspect-ratio oriented through the thickness of the plate to achieve desired electrical and thermal conductivity requirements. A method of manufacturing the fuel separator plate having such fibers disposed in a through-plane orientation is also disclosed. The method includes forming a separator plate having a land height for orienting the fibers in a desired through-plane direction, then removing a portion of the land height to obtained the desired geometric configuration for the separator plate.

Abstract: A control apparatus and method for efficiently controlling the amount of heat generated by a fuel cell processor in a fuel cell system by determining a temperature error between actual and desired fuel processor temperatures. The temperature error is converted to a combustor fuel injector command signal or a heat dump valve position command signal depending upon the type of temperature error. Logic controls are responsive to the combustor fuel injector command signals and the heat dump valve position command signal to prevent the combustor fuel injector command signal from being generated if the heat dump valve is opened or, alternately, from preventing the heat dump valve position command signal from being generated if the combustor fuel injector is opened.

Abstract: A method and apparatus for detecting leakage current in the coolant of a fuel cell stack. The invention eliminates the use of a conductivity sensor by using a voltmeter to measure the voltage across the coolant. If the coolant voltage is at or below a predetermined level, an excessive level of conductivity in the coolant exists, and the presence of leakage current is reported. The invention can also compare the coolant voltage to two different predetermined voltage levels, the second one higher than the first. A coolant voltage at or below the lower voltage level could signal a shut down of the stack, while a coolant voltage at or below the higher voltage level could signal an alarm or another diagnostic. The invention can optionally use a second voltmeter to measure the voltage across the stack and calculate the resistivity and conductivity of the coolant.

Abstract: A method and apparatus for injecting oxygen into a fuel cell reformate stream to reduce the level of carbon monoxide while preserving the level of hydrogen in a fuel cell system.

Abstract: The invention provides a novel method for controlling the oxidant injection to a reactor by determining fluctuations in the requirements from monitoring the flow rates and pressures of an upstream reactor. The method is used to oxidize carbon monoxide in a hydrogen-rich reformate stream supplied to a fuel cell.