Abstract: A method for use in manufacturing a fuel cell stack includes assembling a membrane electrode assembly to have a membrane between a first gas diffusion layer and a second gas diffusion layer. A bypass blocker is located at a space between a first gas diffusion layer of the membrane electrode assembly and a seal. The blocker is deformed on the seal and deformation is avoided of the blocker at the space such that the blocker inhibits a bypass flow of a reactant through the space between the gas diffusion layer and the seal in a direction of flow of the reactant during operation of the fuel cell. The membrane electrode assembly is located between a first fluid flow plate and a second fluid flow plate.

Abstract: A heat exchanger comprises an inlet, an outlet, a heat exchanging channel, and an opening. The heat exchanging channel surrounds a cavity. The opening provides access to the cavity. The inlet is coupled to one end of the heat exchanging channel and the outlet is coupled to another end of the heat exchanging channel. The heat exchanging channel is isolated from the cavity. No access or passage is present between the heat exchanging channel and the cavity. During operation, heat exchanging fluid flows through the heat exchanging channel thereby cooling fluid within the cavity. The heat exchanging fluid never contacts the fluid within the cavity. In various embodiments, the heat exchanging channel has a single or stacked layer when viewed along a cross section. The heat exchanging channel has a spherical, cylindrical, or rectangular shape. In one embodiment, an insulative layer is disposed between layers of the heat exchanging channel.

Abstract: An exchange membrane includes, for example, a first layer membrane having a first thickness, a second layer membrane having a thickness less than the first thickness, and the second layer membrane containing a catalyst, a catalyst content in the second layer membrane being greater than a catalyst content in the first layer membrane, and the exchange membrane having an interface between the first layer membrane and the second layer membrane. In some embodiments, the membrane electrode assembly (MEA) includes the first layer membrane without a catalyst, and/or the exchange membrane includes a bi-layer exchange membrane.

Abstract: Method for forming a membrane electrode assembly, include for example, providing a first layer membrane, a second layer membrane, an anode electrode, and a cathode electrode. The first layer membrane has a first thickness, the second layer membrane has a thickness less than the first thickness, and the second layer membrane contains a catalyst content that is greater than a catalyst content in the first layer membrane. The first layer membrane, the second layer membrane, the anode electrode, and the cathode electrode are formed into a membrane electrode assembly (MEA) comprising an exchange membrane having an interface between the first layer membrane and the second layer membrane. In some embodiments, may include a first and second lamination process, a single laminating process, a roll-to-roll process, and/or a casting process.

Abstract: A fuel cell system includes a first fluid flow plate including a first plurality of first channels for flow of an oxidant or a fuel. The plurality of first channel has first channel cross-sectional flow areas. A second fluid flow plate includes a second plurality of second channels for flow of an oxidant or a fuel. The plurality of second channels has second channel cross-sectional flow areas. A membrane electrode assembly is located between the first plate and the second plate. The first flow plate includes a passage for a flow of a fluid entirely on a seam side of the first flow plate as the first plurality of first channels. The passage has a cross-sectional area for flow of the fluid smaller than the first channel cross-sectional flow area.

Abstract: A fuel cell stack includes an endplate assembly having a structural endplate. An insulator plate has a second exterior surface contacting a first interior surface of the structural endplate and a second interior surface on an opposite side of the insulator plate. A third plate has a third exterior surface contacting the second interior surface and a third interior surface on an opposite side of the third plate relative to the insulator plate. The third interior surface and third exterior surface are substantially flat. The second interior surface and the third exterior surface contact each other substantially continuously in a longitudinal direction and a lateral direction, and are flat and substantially parallel to each other. The second exterior surface is contoured such that the second exterior surface is not flat and is substantially non-parallel relative to the third interior surface.

Abstract: A fuel cell system includes a first fluid flow plate including a first plurality of first channels for flow of an oxidant or a fuel. The plurality of first channel has first channel cross-sectional flow areas. A second fluid flow plate includes a second plurality of second channels for flow of an oxidant or a fuel. The plurality of second channels has second channel cross-sectional flow areas. A membrane electrode assembly is located between the first plate and the second plate. The first flow plate includes a passage for a flow of a fluid entirely on a seam side of the first flow plate as the first plurality of first channels. The passage has a cross-sectional area for flow of the fluid smaller than the first channel cross-sectional flow area.

Abstract: Method and system for electrochemically compressing hydrogen. In one embodiment, the system includes a membrane electrode assembly (MEA) that includes a polymer electrolyte membrane (PEM), an anode, and a cathode. First and second gas diffusion media are positioned adjacent the cathode and anode, respectively. A humidifying membrane is positioned next to the second gas diffusion medium on a side opposite the anode. A water supply is connected to the humidifying membrane, and a hydrogen gas supply is connected to the second gas diffusion medium. A hydrogen gas collector including a back pressure regulator is connected to the first gas diffusion medium. Separators, positioned on opposite sides of the MEA, are connected to a power source. In use, hydrogen is electrochemically pumped across the MEA and collected in the hydrogen gas collector. The PEM is kept properly humidified by the humidifying membrane, which releases water into the second gas diffusion medium.

Abstract: An anode catalyst suitable for use in an electrolyzer. The anode catalyst includes a support and a plurality of catalyst particles disposed on the support. The support may include a plurality of metal oxide or doped metal oxide particles. The catalyst particles, which may be iridium, iridium oxide, ruthenium, ruthenium oxide, platinum, and/or platinum black particles, may be arranged to form one or more aggregations of catalyst particles on the support. Each of the aggregations of catalyst particles may include at least 10 particles, wherein each of the at least 10 particles is in physical contact with at least one other particle. The support particles and their associated catalyst particles may be dispersed in a binder.

Abstract: A fuel cell system includes a first plurality of fuel cells having a cathode and an anode. The plurality of fuel cells is configured to produce electrical power having a current and a voltage output. The plurality of fuel cells includes a first conductive plate and a second conductive plate. A shunt is electrically connected to the first conductive plate and the second conductive plate for shunting voltage output between the cathode and the anode. The shunt is mounted to, and supported by, the plurality of fuel cells. The shunt is connected to a control mechanism to control a shorting of one or more fuel cells of the plurality of fuel cells. The control mechanism is mounted to, and supported by, the plurality of fuel cells.

Abstract: A fuel cell system includes a first fluid flow plate including a first plurality of first channels for flow of an oxidant or a fuel. The plurality of first channel has first channel cross-sectional flow areas. A second fluid flow plate includes a second plurality of second channels for flow of an oxidant or a fuel. The plurality of second channels has second channel cross-sectional flow areas. A membrane electrode assembly is located between the first plate and the second plate. The first flow plate includes a passage for a flow of a fluid entirely on a seam side of the first flow plate as the first plurality of first channels. The passage has a cross-sectional area for flow of the fluid smaller than the first channel cross-sectional flow area.

Abstract: A fuel cell system includes a first plurality of fuel cells having a cathode and an anode. The plurality of fuel cells is configured to produce electrical power having a current and a voltage output. The plurality of fuel cells includes a first conductive plate and a second conductive plate. A shunt is electrically connected to the first conductive plate and the second conductive plate for shunting voltage output between the cathode and the anode. The shunt is mounted to, and supported by, the plurality of fuel cells. The shunt is connected to a control mechanism to control a shorting of one or more fuel cells of the plurality of fuel cells. The control mechanism is mounted to, and supported by, the plurality of fuel cells.

Abstract: A fuel cell stack includes an endplate assembly having a structural endplate. An insulator plate has a second exterior surface contacting a first interior surface of the structural endplate and a second interior surface on an opposite side of the insulator plate. A third plate has a third exterior surface contacting the second interior surface and a third interior surface on an opposite side of the third plate relative to the insulator plate. The third interior surface and third exterior surface are substantially flat. The second interior surface and the third exterior surface contact each other substantially continuously in a longitudinal direction and a lateral direction, and are flat and substantially parallel to each other. The second exterior surface is contoured such that the second exterior surface is not flat and is substantially non-parallel relative to the third interior surface.

Abstract: A fuel cell stack includes an endplate assembly having a structural endplate. An insulator plate has a second exterior surface contacting a first interior surface of the structural endplate and a second interior surface on an opposite side of the insulator plate. A third plate has a third exterior surface contacting the second interior surface and a third interior surface on an opposite side of the third plate relative to the insulator plate. The third interior surface and third exterior surface are substantially flat. The second interior surface and the third exterior surface contact each other substantially continuously in a longitudinal direction and a lateral direction, and are flat and substantially parallel to each other. The second exterior surface is contoured such that the second exterior surface is not flat and is substantially non-parallel relative to the third interior surface.

Abstract: A fuel cell stack includes a structural endplate having an exterior surface. An insulator plate contacts an interior surface of the structural endplate located on an opposite surface of the endplate relative to the exterior surface. A collector plate contacts the insulator plate on an opposite side of the insulator plate relative to the structural endplate. A pocket plate is located on an interior side of the collector plate located on an opposite side of the insulator plate relative to the structural endplate. The collective plate is received in a pocket of an exterior side of the pocket plate. The exterior side is adjacent the collector plate and closer to the structural endplate than an opposite side of the pocket plate.

Abstract: A fuel cell stack includes an endplate assembly of a fuel cell system which includes a structural endplate having a first exterior surface and a first interior surface located on an opposite side of the endplate relative to the first exterior surface. An insulator plate has a second exterior surface contacting the first interior surface of the structural endplate and second interior surface on an opposite side of the insulator plate relative to the second exterior surface. A third plate has a third exterior surface contacting the second interior surface and a third interior surface on an opposite side of the third plate relative to the insulator plate. The third interior surface and third exterior surface are substantially flat such that third interior surface and the third exterior surface are about parallel to each other.

Abstract: A fuel cell stack includes a fluid flow plate at an outer end, a sealing member contacting the fluid flow plate and a gas diffusion layer, and a catalyst layer inside the gas diffusion layer. A membrane is located at a central location between the catalyst layer and a second catalyst layer. The fluid flow plate includes a channel for receiving a portion of a perimeter of the gas diffusion layer.

Abstract: A fuel cell stack includes a fluid flow plate at an outer end, a sealing member contacting the fluid flow plate and a gas diffusion layer, and a catalyst layer inside the gas diffusion layer. A membrane is located at a central location between the catalyst layer and a second catalyst layer. The fluid flow plate includes a channel for receiving a portion of a perimeter of the gas diffusion layer.

Abstract: A fuel cell stack includes a structural endplate having an exterior surface. An insulator plate contacts an interior surface of the structural endplate located on an opposite surface of the endplate relative to the exterior surface. A collector plate contacts the insulator plate on an opposite side of the insulator plate relative to the structural endplate. A pocket plate is located on an interior side of the collector plate located on an opposite side of the insulator plate relative to the structural endplate. The collective plate is received in a pocket of an exterior side of the pocket plate. The exterior side is adjacent the collector plate and closer to the structural endplate than an opposite side of the pocket plate.

Abstract: A method for operating a fuel cell system includes electrically coupling a fuel cell stack to an energy storage device and an electrical demand by a load device. A controller is coupled to the fuel cell stack, the energy storage device, and the load device via a communications connection. The controller obtains information relative to an operation of at least one of the fuel cell stack and the energy storage device and the controller controls an operation of the load device based on the information.