Abstract: A liquid separator includes a housing, a separation chamber disposed within the housing and having a substantially cylindrical inner surface, wherein the inner surface of the separation chamber is aligned about a substantially vertical chamber axis, an inlet channel configured to communicate the fluid stream from a first inlet end to a second inlet end disposed within the housing and proximate an upper region of the separation chamber, and an outlet channel configured to communicate the fluid stream from a first outlet end positioned proximate the upper region of the separation chamber, to a second outlet end remote from the separation chamber. Proximate the second inlet end the inlet channel is aligned about an inlet axis. A deflector vane may also be provided which is substantially aligned about the chamber axis and intersecting the inlet axis. The inlet axis is preferably proximate to and substantially parallel with a tangent to the inner surface of the separation chamber.

Abstract: A pressure control system for controlling the pressure of a process fluid stream at a certain location having a pressure regulator disposed in the process fluid stream, through which the process fluid stream flows. A first pilot controller senses the pressure of the process fluid at the location and receives a control pressure from a control source. A second pilot controller receives the control pressure from the control source and provides added pressure. An inspirator receives the added pressure from the second pilot controller and generates a differential pressure. The differential pressure is used to control the pressure of the process fluid stream within the pressure regulator. The pressure regulator comprises a first chamber and a second chamber therein separated by a flexible element and a divider is disposed in the first chamber and operative to abut against the flexible element to divide the first chamber into separate spaces.

Abstract: A system and reactor stack for generating hydrogen from a hydride solution in presence of a catalyst. The reactor stack includes a number of reactor plates and separator plates alternate with one another, to define reaction chambers alternating with coolant chambers. Each reactor plate has a first face defining a solution flow field and an opposing second face defining a coolant flow field. Each solution flow field comprises a common reaction chamber and a plurality of channels opening into the common reaction chamber. The catalyst is provided in the common reaction chamber. Each reaction chamber is configured to receive the hydride solution and to bring at least a portion of the hydride solution in contact with the catalyst. Each reaction chamber is in fluid communication with an adjacent reaction chamber and each coolant chamber is in fluid communication with an adjacent coolant chamber.

Abstract: Moisture recovery and humidification in a fuel cell system involving (i) intermittently switching each dryer in a plurality of dryers into and out of one of a first mode of operation for recovering moisture from an outgoing oxidant stream and a second mode of operation for humidifying an incoming oxidant stream such that during use at least one dryer is in the first mode of operation and at least one dryer is in the second mode of operation; (ii) directing the outgoing oxidant stream from the cathode through at least one dryer in the first mode of operation to recover moisture from the outgoing oxidant stream; and (iii) directing the incoming oxidant stream through at least one dryer in the second mode of operation to humidify the incoming oxidant stream with moisture.

Abstract: A fuel cell powered vehicle includes a fuel cell power module having at least one fuel cell electrically connected to a drive unit for delivering power to the drive unit, a battery pack having at least one battery electrically connected to the drive unit for independently delivering power to the drive unit, and an ultra-capacitor pack having at least one ultra-capacitor electrically connected to the drive unit for independently delivering power to the drive unit. When the power requirement is low, only the fuel cell power module delivers electric power to the drive unit. The battery pack supplements the power to the drive unit for medium power requirements. The ultra-capacitor pack supplements the power to the drive unit for high power requirements. The ultra-capacitor pack can be recharged by regenerative braking.

Abstract: A system and method used to regulate the operation of fuel cell systems. In one embodiment, a fuel cell system comprises a fuel cell stack, the fuel cell stack comprising at least one fuel cell and electric outputs for driving a load; a balance of plant system for supplying and withdrawing process fluids to and from the fuel cell stack; and a controller that controls the operation of the fuel cell stack and the balance of plant system by measuring and setting process parameters; where the controller comprises a storage device adapted to, for at least one of the process parameters, store at least one baseline table of set values of the process parameter and to optionally store at least one correction table of correction values of the process parameter. Correction values are stored in real-time as changes are made to the process parameter during the operation of the fuel cell stack.

Abstract: A fuel cell power system has a plurality of fuel cell power modules, each module including a fuel cell and associated peripheral devices. Each fuel cell power module is controlled by its own local controller. A master controller controls each of the local controllers in accordance with overall system requirements. Optionally, a bypass allows the master controller to shut down and bypass a particular fuel cell power module, providing this system with greater flexibility, robustness and reliability. The modular system architecture also simplifies manufacturing, maintenance and repair.

Abstract: A sealing technique is provided for forming complex and multiple seal configurations for fuel cells and other electrochemical cells. To provide a seal, for sealing chambers for oxidant, fuel and/or coolant, a groove network is provided extending through the various elements of the fuel cell assembly and a seal material is then injected into the groove network. Several structural improvements have been made to cell components in relation to this seal in place process to reduce manufacturing cost and improve the performance of the electrochemical cells.

Abstract: During testing, a controllable condition of the fuel cell is controlled based on a control value, and a measurable condition of the fuel cell is measured to provide a data value. A data processor receives a user-readable input value and provides a user-readable output value. The user-readable input value is converted to the control value and the data value is converted to the user readable output value. A mapped file is generated by and is accessible by the data processor. The mapped file includes a plurality of tag records including a control tag record for storing the control value and a data tag record for storing the data value.

Abstract: A fuel cell stack comprising a plurality of fuel cells, each having an anode flow field plate, a cathode flow field plate and a membrane electrode assembly disposed between the flow field plates. The anode and cathode flow field plates have primary channels and ribs separating the primary channels. At least a portion of the anode and cathode primary channels are disposed directly opposite one another with a membrane exchange assembly therebetween and with at least some of the ribs on the anode and cathode flow field plates located directly opposite one another to sandwich the membrane exchange assembly therebetween. The flow field plates can also have inlet distribution and outlet collection channels. Each of these distribution and collection channels is connected to a plurality of the primary channels, preferably located centrally, so as to improve flow distribution of the reactants.

Abstract: A hydrogen production and water recovery system for a fuel cell utilizes hydrogen storage in a metal hydride or the like. An exhaust stream from the fuel cell is passed through the storage media, simultaneously to cool the exhaust stream to promote condensation of water vapor and to heat the media to promote generation of hydrogen. The recovered water can be stored, returned to a coolant loop, and at a later time electrolyzed to generate hydrogen.

Abstract: A system and method in a data processor for controlling a controllable condition of a fuel cell via a control device is provided. The system and method involve (a) providing a script language comprising a control command type having an operating level field for receiving a selected operating level of the control device; (b) deriving a control command from the control command type by inserting the selected operating level of the control device into the operating level field of the control command; (c) writing a test script using the script language such that the test script includes the control command; (d) compiling the test script to provide a test program; and, (e) controlling the control device according to the test program.

Abstract: A manifold for a fuel cell system, has a manifold body and a plurality of first ports in the manifold body, for connecting to fuel cell peripherals. A plurality of second ports in the manifold body provide connections to a fuel cell. A plurality of first fluid passages within the manifold provide communication between respective ones of the first ports and respective ones of the second ports, whereby, in use, the fluid passages communicate fluids between the fuel cell stack and fuel cell peripherals. The manifold provides a higher degree of system integration, considerably reduced piping, fittings and associated hardware and hence generally reduces the size and weight of the fuel cell system. Thermal-fluid related system losses are also minimized.

Abstract: A method and apparatus are provided for humidifying fuel, and optionally oxidant, supplied to a fuel cell system, which can be a single fuel cell or a multiplicity of fuel cells. A catalytic reactor is provided, which is supplied with a portion of the fuel and the oxidant. The fuel is supplied in excess of the oxidant to the catalytic reactor, so as to generate a stream of fuel which is both heated and humidified. For a closed system, a heated and humidified fuel flow, and optionally a heated and humidified oxidant flow, are mixed with additional flows of these gases supplied to the fuel cell.

Abstract: A fuel cell stack comprising a plurality of fuel cells, each having an anode flow field plate, a cathode flow field plate and a membrane electrode assembly disposed between the flow field plates. The anode and cathode flow field plates have primary channels and ribs separating the primary channels. At least a portion of the anode and cathode primary channels are disposed directly opposite one another with a membrane exchange assembly therebetween and with at least some of the ribs on the anode and cathode flow field plates located directly opposite one another to sandwich the membrane exchange assembly therebetween. The flow field plates can also have inlet distribution and outlet collection channels. Each of these distribution and collection channels is connected to a plurality of the primary channels, preferably located centrally, so as to improve flow distribution of the reactants.

Abstract: A manifold for a fuel cell system comprises a plurality of first ports for connecting to fuel cell peripherals; a plurality of ports for connecting to a fuel cell stack; and a plurality of fluid passages within the manifold in communication with the said plurality of ports connecting to the fuel cell peripherals and with the first and second ports for providing, communication of fluids between the fuel cell stack and fuel cell peripherals. The manifold provides a higher degree of system integration, considerably reduced piping, fittings and associated hardware and hence generally reduces the size and weight of the fuel cell system. Thermal-fluid related system losses are also minimized.

Abstract: A hydrogen distribution system and method for distributing hydrogen between a plurality of hydrogen receiving units arranged in parallel. Hydrogen may be supplied to the system from a hydrogen source such as a hydrogen generator, or a hydrogen storage tank. The system and method may distribute hydrogen to receiving units such as a storage system, a user, or a fuel cell power module.

Abstract: A back pressure valve, comprises: a first housing including a first chamber formed therein having an inlet and an outlet for a first fluid; a second housing including a second chamber formed; a flexible diaphragm having an outer peripheral edge portion abutting the second housing; and closing off the second chamber; a back pressure member moveably disposed in the first chamber of the first housing, wherein the first chamber is defined by the first housing and the back pressure member; wherein the flexible diaphragm is fixed onto and moveable together with the back pressure member, whereby pressure in the second chamber determines fluid pressure required to maintain the back pressure member in a steady position.

Abstract: A liquid separator configured to separate liquid from a fluid stream. The separator includes a housing, a separation chamber disposed within the housing, a drain having a drain passageway for draining liquid from the separation chamber, an inlet chamber configured to receive the fluid stream, an inlet channel configured to communicate the fluid stream from the inlet chamber to the separation chamber, a swirler disposed within the inlet channel, and an outlet channel configured to communicate the fluid stream from a first outlet end positioned proximate the second inlet end, to a second outlet end remote from the separation chamber. Preferably, the separator also includes a separator mounting face proximate the inlet chamber, the mounting face configured for mounting the separator to a humidifier. The housing preferably includes a base and a cap which is removably mountable to the base.

Abstract: A bracket for a fuel cell system having at least one fuel cell stack and a number of peripheral devices is disclosed. The bracket includes first and second spaced apart side frames joined to each other by one or more end frames. The first side frame and the second side frame surround a portion of one or more fuel cell stacks. The fuel cell stack is removably mounted between the first and second side frames, and the peripheral devices are removably mounted to an outside face of the side frames. A fuel cell system is also disclosed. The fuel cell system includes one or more fuel cell stacks and one or more peripheral devices. The fuel cell stacks and the peripheral devices are removably mounted to a bracket, as described above.