Abstract: The present invention provides, among other things, membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more external manifolds which deliver reagents and/or coolant to one or more reactant or coolant flow fields of the membrane cassettes. In particular, the present invention describes the insert molding method, whereby the plenums of the external manifolds are created during the stack encapsulation step. The invention describes several methods for creating the manifold runner geometry via insert-molding, machining, or with separate components.

Abstract: The present invention provides, among other things, membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more external manifolds which deliver reagents and/or coolant to one or more reactant or coolant flow fields of the membrane cassettes. In particular, the present invention describes the insert molding method, whereby the plenums of the external manifolds are created during the stack encapsulation step. The invention describes several methods for creating the manifold runner geometry via insert-molding, machining, or with separate components.

Abstract: The present invention provides membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more external manifolds which deliver reagents and/or coolant to one or more reactant or coolant flow fields of the membrane cassettes. In particular, the present invention describes the insert molding method, whereby the plenums of the external manifolds are created during the stack encapsulation step. The invention describes several methods for creating the manifold runner geometry via insert-molding, machining, or with separate components.

Abstract: Various aspects of invention provide portable power manager operating methods. One aspect of the invention provides a method for operating a power manager having a plurality of device ports for connecting with external power devices and a power bus for connecting with each device port. The method includes: disconnecting each device port from the power bus when no external power device is connected to the device port; accessing information from newly connected external power devices; determining if the newly connected external power devices can be connected to the power bus without power conversion; if not, determining if the newly connected external power devices can be connected to the power bus over an available power converter; and if so, configuring the available power converter for suitable power conversion.

Abstract: Various aspects of the invention provide power manager enclosures. One aspect of the invention provides a power manager enclosure including: a sealed housing comprising opposing substantially rectangular top and bottom faces, opposing substantially rectangular longitudinal front and back faces and opposing substantially rectangular transverse left and right side faces; and a plurality of device ports for operably connecting external power devices to the power manger disposed on one or more of the left and right side faces and on only one of the front and back faces.

Abstract: An elongated fuel processor assembly is coupled to a fuel cell stack for producing a reformate for consumption by the fuel cell stack. The elongated fuel processor assembly includes an annular core having a thermal conduction mass for conducting heat, an annular reformer surrounding and supported by the annular core, and a vaporizer surrounding and supported by the annular core.

Abstract: A Solid Oxide Fuel Cell (SOFC) system having a hot zone with a center cathode air feed tube for improved reactant distribution, a CPOX reactor attached at the anode feed end of the hot zone with a tail gas combustor at the opposing end for more uniform heat distribution, and a counter-flow heat exchanger for efficient heat retention.

Abstract: The present invention provides membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more composite membrane electrode assemblies which have a peripheral gasket where the gasket has at least one groove or channel for introducing and distributing a sealant about the cassette. In certain preferred embodiments, the invention provides cassettes and stacks which are suitable for use in fuel cell applications.

Abstract: The present invention provides membrane cassettes and stacks thereof which are suitable for a use in a variety of electrochemical applications. The invention further provides membrane cassettes which comprise one or more bipolar plates which have one or two reactant or coolant flow fields consisting of at least one groove in opposing surfaces of the bipolar plate. In certain preferred embodiments, the invention provides cassettes and stacks which are suitable for use in fuel cell applications. Particularly preferred embodiments of the invention include design improvements which enhance the performance and reliability of certain components of the fuel cell stack.

Abstract: A gas separation unit 102, 200, 300 for permeating a gas out from a pressurized feed mixture includes an input manifold 104, 204, an exhaust manifold, 106, 206 and a permeate assembly 108, 208, 303. The permeate assembly supports one or more permselective foils 130, 132, 218, 232, 318 over a hollow cavity 134, 272, 306 supported by a microscreen element 142, 144, 228, 230, 326. The microscreen element includes non-porous perimeter walls 190, 192, 278 supported on a frame surface and a porous central area 194, 280 supported over the hollow cavity. A porous spacer 138, 140, 174, 234 disposed inside the hollow cavity structurally supports the entire microscreen surface spanning the hollow cavity while also providing a void volume for receiving fluid passing through the porous central area and for conveying the fluid through the hollow cavity.

Abstract: A pump includes a housing with an inlet and an outlet, and a stator that generates a rotating magnetic field and defines a pumping chamber. A rotor mounted for axial rotation within the pumping chamber has salient poles to interact with the field. The rotor mounts eccentrically such that a gap between the rotor body and stator varies circumferentially. The rotor defines hollows intermediate the salient poles with cylindrical rollers for free radial movement therein. Fluid-filled volumes are formed between the housing, the rotor and the rollers. On each side of a plane passing through the rotor axis and the housing axis, the pumping chamber is in fluid communication with the inlet or outlet, respectively. The volume expands on one side of the plane and contracts on the other. As the rotor spins, the expanding volume draws fluid from the inlet and the contracting volume expels fluid from the outlet.

Abstract: A pump includes a housing with an inlet and an outlet, and a stator that generates a rotating magnetic field. A pressure boundary assembly defines a pumping chamber. A rotor mounted for axial rotation within the pumping chamber has salient poles to interact with the field. The rotor mounts eccentrically such that a gap between the rotor body and stator varies circumferentially. The rotor defines hollows intermediate the salient poles with cylindrical rollers for free radial movement therein. Fluid-filled volumes are formed between the housing, the rotor and the rollers. On each side of a plane passing through the rotor axis and the housing axis, the pumping chamber is in fluid communication with the inlet or outlet, respectively. As the rotor spins, expanding volume draws fluid from the inlet and contracting volume expels fluid from the outlet.

Abstract: A device for recovering liquid droplets from a fluid flow stream including a rotatable element comprising wall elements configured to partially enclose a volume with an annular perimeter wall that includes an inside surface radially offset from and facing an axial center, a fixed base wall supports the rotatable element about the axial center, an input fluid conduit delivers the fluid flow stream into the fluid volume, means for rotating the rotatable element for generating a centrifugal force capable of forming a layer of liquid held by the centrifugal force against the inside surface, and an output liquid conduit disposed to collect liquid from the layer of liquid, wherein the layer of liquid rotates with the inside surface with a tangential velocity vector and the collection aperture is fixed in position opposed to the tangential velocity vector such that liquid in the layer of liquid enters the collection aperture.

Abstract: A solid oxide fuel cell system including a main plate, an inner cylinder attached to the main plate, an intermediate cylinder attached to the main plate such that the intermediate cylinder contains a cathode air stream, and an outer cylinder attached to the main plate. An exhaust annular gap is formed between the intermediate and outer cylinders such that hot exhaust gases flow through the exhaust annular gap and heat is transferred from the hot exhaust gases to the cathode air stream. The solid oxide fuel cell system may also include a two-stage tail gas combustor.

Abstract: An interconnect for electrically connecting a first and second cell of a tubular fuel cell bundle having a body with an anode contact and a cathode contact extending therefrom. The anode contact is formed to follow a contour of an anode portion of the first cell. The cathode contact is formed to follow a contour of a cathode portion of the second cell. A contact aid may be applied to the anode contact and/or cathode contact for securing the contact to the respective portion of the fuel cell bundle. The interconnect preferably completes a series connection between the first and second cells.

Abstract: An improved electrochemical polymer electrolyte membrane cell stack is provided that includes one or more individual fuel cell cassettes, each fuel cell cassette having at least one membrane electrode assembly, fuel flow field and oxidant flow field. Within each fuel cell cassette, each membrane electrode assembly has at least one manifold opening for the passage of reactant manifolds through the cassette, all of which are bonded about the perimeter by a sealant, and each flow field has at least one manifold opening and any manifold openings on the flow fields which do not correspond to a manifold providing reactant for distribution to such flow field is bonded about its perimeter by a sealant. Each fuel cell cassette may also contain other typical components of a electrochemical polymer electrolyte membrane cell stack, such as separator plates or coolant flow fields, which also have manifold openings which may or may not be bonded about the perimeter.

Abstract: A self-contained portable fuel cell system is described capable of economically generating a nominal 12 V of DC electrical power.

Abstract: The invention provides a fuel cell stack including a layer of encapsulating material disposed about the separator plate, MEA, and reactant manifold, wherein the reactant manifold is bounded at least in part by the encapsulating material. The fuel cell stack also includes a first opening through the plate body to the first face from the second face, and an open channel in the second face extending from the opening toward a periphery of the plate. The invention also provides a fuel cell stack having a first face including an opening for passage of a reactant therethrough, a first reactant flow field defined thereon, and a first raised surface formed thereon substantially surrounding the opening. The first raised surface is configured and adapted to mate with a second surface on a face of an adjacent plate to create a flow obstruction for encapsulating material.

Abstract: The invention provides a fuel cell stack including a layer of encapsulating material disposed about the separator plate, MEA, and reactant manifold, wherein the reactant manifold is bounded at least in part by the encapsulating material. The fuel cell stack also includes a first opening through the plate body to the first face from the second face, and an open channel in the second face extending from the opening toward a periphery of the plate. The invention also provides a fuel cell stack having a first face including an opening for passage of a reactant therethrough, a first reactant flow field defined thereon, and a first raised surface formed thereon substantially surrounding the opening. The first raised surface is configured and adapted to mate with a second surface on a face of an adjacent plate to create a flow obstruction for encapsulating material.

Abstract: A fuel processor assembly for producing a hydrogen rich stream for a fuel cell includes a reformer, a vaporizer adjacent the reformer, a heat transfer block around at least a portion of the reformer and the vaporizer and a heating element coupled to the heat transfer block for providing heat to the block during start up. To cold start the fuel processor, the heating element is activated to heat the heat transfer block. When a temperature of the heat transfer block reaches operational for the reformer, the heating element is turned off and an alternative source of heat is utilized for the endothermic reaction.