Abstract: In an electrochemical fuel cell, a sufficient quantity of catalyst, effective for promoting the reaction of reactant supplied to an electrode, is disposed within the volume of the electrode so that a reactant introduced at a first major surface of the electrode is substantially completely reacted upon contacting the second major surface. Crossover of reactant from one electrode to the other electrode through the electrolyte in an electrochemical fuel cell is thereby reduced.

Abstract: An embossed fluid flow field plate for electrochemical cells comprises two sheets of compressible, electrically conductive material. Each sheet has two oppositely facing major surfaces. At least one of the major surfaces has an embossed surface which has a fluid inlet formed therein. The embossed surface has at least one open-faced channel embossed therein extending from the fluid inlet for conducting pressurized fluid introduced at the fluid inlet. A metal sheet is interposed between each of the compressible sheets. The compressible, electrically conductive sheet preferably comprises graphite foil. A method of fabricating an embossed separator plate for use in conjunction with an electrochemical fuel cell comprises (1) providing two sheets of compressible, electrically conductive sheet material, (2) interposing a metal sheet between each of the compressible sheets, and (3) embossing an open-faced channel in at least one of the surfaces of the sheets facing away from the metal sheet.

Abstract: An embossed fluid flow field plate for electrochemical cells comprises two sheets of compressible, electrically conductive material. Each sheet has two oppositely facing major surfaces. At least one of the major surfaces has an embossed surface which has a fluid inlet formed therein. The embossed surface has at least one open-faced channel embossed therein extending from the fluid inlet for conducting pressurized fluid introduced at the fluid inlet. A metal sheet is interposed between each of the compressible sheets. The compressible, electrically conductive sheet preferably comprises graphite foil.

Abstract: A method and apparatus selectively oxidizes, within the fuel cell assembly, the carbon monoxide present in a fuel stream fed to the assembly. A quantity of catalyst is contained within at least a portion of a fuel stream passageway within the stack. The carbon monoxide is selectively oxidized by the catalyst to carbon dioxide, and carbon monoxide produced by the reverse water-shift reaction is also oxidized.

Abstract: An electrochemical fuel cell assembly includes a membrane electrode assembly which comprises an anode, a cathode having a surface thereof exposed to ambient air, and an ion exchange membrane interposed between the anode and the cathode. A seal forms a gas-impermeable barrier around the anode to which a gaseous fuel stream is supplied. The assembly further includes a thermally conductive plate having a plurality of thermally conductive members or fins extending from a major surface of the plate. The thermally conductive members contact portions of the exposed cathode surface. Adjacent thermally conductive members cooperate with the plate and the exposed cathode surface to form air conducting channels. Heat generated exothermically in the membrane electrode assembly is dissipated to the atmosphere through the thermally conductive members.

Abstract: A method and apparatus is provided for removing water accumulated at the cathode of an electrochemical fuel cell incorporating a solid polymer ion exchange membrane. Liquid water accumulated at the cathode can be removed by maintaining a partial pressure of water vapor in the hydrogen-containing gas supply below the saturation pressure of water vapor therein such that water accumulated at the cathode is drawn by a concentration gradient toward the anode across the membrane and is absorbed as water vapor into the hydrogen-containing gas supply between the inlet and the outlet. In one embodiment, the partial pressure of water vapor in the hydrogen-containing gas supply is maintained below the saturation pressure of water vapor therein by imparting a pressure drop between the inlet and the outlet sufficient to draw water accumulated at the cathode toward the anode.

Abstract: A method and apparatus oxidizes the carbon monoxide present in an incoming reactant fuel stream and/or carbon monoxide produced by the reverse water-shift reaction to carbon dioxide in a reactant stream introduced to an electrochemical fuel cell. The reactant stream comprises hydrogen, carbon dioxide and carbon monoxide. A first oxygen-containing gas stream is introduced into the reactant stream through a first port disposed between the reactant stream inlet and the reactant stream outlet. A further oxygen-containing gas stream is introduced into the reactant stream through at least one secondary port located between the first port and the reactant stream outlet.

Abstract: A solid polymer fuel cell electric power generation system removes a substantial portion of water accumulated at the cathode in the outlet fuel stream of the anode. The system permits the operation of a hydrogen/oxygen fuel cell in a dead-ended mode where substantially pure oxygen is employed as the oxidant supply or using low oxygen stoichiometry where a dilute oxidant source, such as oxygen-containing air, is employed as the oxidant supply. The system thereby eliminates the need for an oxygen recirculation pump in systems operating on substantially pure oxygen, and substantially reduces the parasitic load to pressurize the oxidant stream in systems operating on dilute oxidant streams.

Abstract: A laminated fluid flow field assembly for an electrochemical fuel cell comprises a separator layer and a stencil layer. The separator layer is formed of electrically conductive, substantially fluid impermeable sheet material. The stencil layer is formed of electrically conductive sheet material, and has a fluid inlet and at least one opening extending between its major surfaces and in fluid communication with the fluid inlet. The separator layer and the stencil layer are consolidated along one of their major surfaces. In operation, the separator layer and the stencil layer cooperate to form an open-faced channel for conducting pressurized fluid introduced at the fluid inlet.

Abstract: A method and apparatus is provided for removing water accumulated at the cathode of an electrochemical fuel cell incorporating a solid polymer ion exchange membrane. Liquid water accumulated at the cathode can be removed by maintaining a partial pressure of water vapor in the hydrogen-containing gas supply below the saturation pressure of water vapor therein such that water accumulated at the cathode is drawn by a concentration gradient toward the anode across the membrane and is absorbed as water vapor into the hydrogen-containing gas supply between the inlet and the outlet. In one embodiment, the partial pressure of water vapor in the hydrogen-containing gas supply is maintained below the saturation pressure of water vapor therein by imparting a pressure drop between the inlet and the outlet sufficient to draw water accumulated at the cathode toward the anode.

Abstract: An electrochemical fuel cell is provided for converting a fuel reactant stream and an oxidant reactant stream to a reaction product stream and electrical energy. The fuel cell includes a membrane electrode assembly interposed between two separator layers. The separator layers are formed of thin electrically conductive sheet material which is substantially impermeable to the fuel and oxidant reactant streams. The membrane electrode assembly comprises first and second electrode layers formed of porous electrically conductive sheet material. The electrode layers have a catalyst associated therewith, and an ion exchange membrane is interposed between the first and second electrode layers. The electrode layers include passages, such as the interstitial spaces within the electrode material or grooves formed in the surface of the electrode material, for flowing a reactant stream between an inlet and outlet within the electrode layer.

Abstract: A secondary electrochemical cell including a first electrode and a counteectrode each capable of reversibly incorporating an alkali metal, an alkali metal incorporated in at least one of the electrodes and an electrolyte solution containing an organic solvent, a salt of the alkali metal and at least one sequestering agent capable of complexing with the alkali moiety of the electrolyte salt, wherein the first electrode includes a carbon composition having a degree of graphitization greater than about 0.40.