Abstract: A method for fabricating a fuel cell component includes the steps of providing a mask having a plurality of radiation transparent apertures, a radiation-sensitive material having a sensitivity to the plurality of radiation beams, and a flow field layer. The radiation-sensitive material is disposed on the flow field layer. The radiation-sensitive material is then exposed to the plurality of radiation beams through the radiation transparent apertures in the mask to form a diffusion medium layer with a micro-truss structure.

Abstract: A fuel cell system is provided including a fuel cell stack having a first end and second end. The fuel cell stack includes at least one fuel cell having a membrane-electrode assembly disposed between adjacent gas diffusion layers. The fuel cell system further includes a compression retention system having a plurality of compliant straps adapted to apply a compressive force to the fuel cell stack. The plurality of compliant straps are further adapted to accommodate an expansion of the fuel cell stack during an operation thereof and maintain the compressive force within a desired range.

Abstract: A fuel cell system is provided including a fuel cell stack having a first end and second end. The fuel cell stack includes at least one fuel cell having a membrane-electrode assembly disposed between adjacent gas diffusion layers. The fuel cell system further includes a compression retention system having a plurality of compliant straps adapted to apply a compressive force to the fuel cell stack. The plurality of compliant straps are further adapted to accommodate an expansion of the fuel cell stack during an operation thereof and maintain the compressive force within a desired range.

Abstract: A fuel cell system includes a water vapor transport device having a wet flow field layer having a coarse microtruss structure disposed between a pair of fine microtruss structures. The coarse and fine microtruss structures of the wet flow field layer are formed from a radiation-sensitive material. A dry flow field layer has a coarse microtruss structure disposed between a pair of fine microtruss structures. The coarse and fine microtruss structures of the dry flow field layer are also formed from a radiation-sensitive material. A membrane is disposed between the wet flow field layer and the dry flow field layer and adapted to permit a transfer of water vapor therethrough from the wet fluid to the dry fluid to form a humidified fluid.

Abstract: A method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and a second radiation-sensitive material adjacent the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has the first sensitivity and a second sensitivity different from the first sensitivity. At least one mask is placed between at least one radiation source and the first and second radiation-sensitive materials. The mask has a plurality of substantially radiation-transparent apertures. The first and second radiation-sensitive materials are then exposed to a plurality of radiation beams through the radiation-transparent apertures in the mask to form a first construct in the first radiation-sensitive material and a second construct in the second radiation-sensitive material. The first construct and the second construct cooperate to form the radiation-cured structure.

Abstract: A fuel cell including an anode-side catalyst coated membrane and a cathode-side catalyst coated membrane. At least a portion of a reduced-permeability layer is disposed between the ionically conductive membrane and the anode-side and cathode-side gas diffusion media, wherein the reduced-permeability layer is formed of a material that has a permeability that is less than a permeability of the ionically conductive member. The reduced-permeability layer may also be formed of a material that is softer than the ionically conductive membrane.

Abstract: According to the present invention, a stacked electrochemical conversion assembly is provided with an electrically and thermally insulating plate within one or both of the end unit assemblies of the stack. For example, in accordance with one embodiment of the present invention, the electrochemical conversion assembly includes at least one end unit assembly comprising an electrically conductive terminal plate and an electrically insulating plate interposed between the terminal plate and an end unit plate of the end unit assembly. The electrically insulating plate comprises an array of thermally insulating regions defined therein.

Abstract: A system for fabricating a radiation-cured structure is provided. The system includes a radiation-sensitive material configured to at least one of initiate, polymerize, crosslink and dissociate with exposure to radiation. At least one radiation source is configured to project a radiation beam toward the radiation-sensitive material. A smart glass device is disposed between the radiation-sensitive material and the at least one radiation source. The smart glass device includes at least one switchable layer selectively operable from an active state to an inactive state. The smart glass device is configured to expose the radiation-sensitive material to a desired exposure pattern when in one of the active state and the inactive state. A method for fabricating the radiation-cured structure is also provided.

Abstract: A system for fabricating a radiation-cured component is provided. The system includes a radiation-sensitive material configured to at least one of initiate, polymerize, crosslink and dissociate with exposure to radiation, and at least one radiation source configured to project a radiation beam with a vector that does not intersect the radiation-sensitive material. The system further includes a radiation directing device that is selectively positionable to reflect the radiation beam in a desired direction and exposure the radiation-sensitive material to the radiation beam. A method for fabricating the radiation-cured components is also provided.

Abstract: A catalyst ink composition for a fuel cell electrode is provided. The catalyst ink composition includes a plurality of electrically conductive support particles; a catalyst formed from a finely divided precious metal, the catalyst supported by the conductive support particles; an ionomer; at least one solvent; and a reinforcing material configured to bridge and distribute stresses across the electrically conductive support particles of the ink composition upon a drying thereof. An electrode for a fuel cell and a method of fabricating the electrode with the catalyst ink composition are also provided.

Abstract: The invention comprises a device for expanding tubular members to a controlled diameter and its method of fabrication. The device includes an expandable bladder held in a convoluted form. After the device is inserted into a cylindrical tube to be evenly expanded, the bladder is expanded by hydraulic pressure to a controlled maximum diameter. It is then deflated so the device can then be moved to another location and reused. The bladder is formed from a flexible impervious material having integral reinforcing fibers. It is initially formed in a fully expanded configuration over a convoluted mandrel and a removable cylindrical shell. When the shell is removed vacuum or external pressure draws the bladder against the mandrel. The bladder is overmolded with a resilient cover to hold it in reduced form until pressurized. The bladder cover prevents the bladder from kinking during the expansion.

Abstract: A catalyst ink composition for a fuel cell electrode is provided. The catalyst ink composition includes a plurality of electrically conductive support particles; a catalyst formed from a finely divided precious metal, the catalyst supported by the conductive support particles; an ionomer; at least one solvent; and a reinforcing material configured to bridge and distribute stresses across the electrically conductive support particles of the ink composition upon a drying thereof. An electrode for a fuel cell and a method of fabricating the electrode with the catalyst ink composition are also provided.

Abstract: A fuel cell system is provided including a fuel cell stack having a plurality of fuel cells disposed between a first end unit and a second end unit. The fuel cell system includes a compression retention system comprising a first sheet coupled to the first end unit and a second sheet coupled to the second end unit. A plurality of springs is disposed between the first sheet and the second sheet and is adapted to apply a compressive force to the fuel cell stack. The claimed invention includes methods for assembling the fuel cell system.

Abstract: The present invention is directed to an electroconductive element within an electrochemical cell that improves water management. The electroconductive element comprises an impermeable electrically conductive element and a porous liquid distribution media disposed along a major surface of the conductive element. Preferably, the liquid distribution media is in direct contact and fluid communication with a fluid distribution layer disposed between the membrane electrode assembly (MEA) and the liquid distribution media, so that liquids are drawn from the MEA through the fluid distribution layer to and through the liquid distribution media. The liquid distribution media transports liquids away from the MEA in the fuel cell. Methods of fabricating and operating fuel cells and electroconductive elements according to the present invention are also contemplated.

Abstract: Method and apparatus for cooling a fuel cell stack. The cooling system uses vaporization cooling of the fuel stack and supersonic vapor compression of the vaporized coolant to significantly increase the temperature and pressure of the liquid coolant flowing through a heat exchanger. By increasing the heat rejection temperature of the coolant delivered to the heat exchanger, the heat transfer area of the heat exchanger can be reduced and the mass flow rate of coolant can also be reduced. The increased fluid pressure is used to circulate the coolant through the cooling system, thereby eliminating the circulation pump associated with conventional systems.

Abstract: A diffusion medium layer for a fuel cell, including an electrically conductive microtruss structure disposed between a pair of electrically conductive grids is provided. At least one of the microtruss structure and the grids is formed from a radiation-sensitive material. A fuel cell having the diffusion medium layer and a method for fabricating the diffusion medium layer is also provided.

Abstract: A separator plate for a fuel cell is provided, including a substrate having a radiation-cured first flow field layer disposed thereon. A method for fabricating the separator plate is also provided. The method includes the steps of providing a substrate; applying a first radiation-sensitive material to the substrate; placing a first mask between a first radiation source and the first radiation-sensitive material, the first mask having a plurality of substantially radiation-transparent apertures; and exposing the first radiation-sensitive material to a plurality of first radiation beams to form a radiation-cured first flow field layer adjacent the substrate. A fuel cell having the separator plate is also provided.

Abstract: A fuel cell system is provided including a fuel cell stack having a first end and second end; an upper end unit adjacent the first end of the fuel cell stack; a lower end unit adjacent the second end of the fuel cell stack; and a compression retention system disposed external to the fuel cell stack. The compression retention system includes at least one restraining member extending from the upper end unit to the lower end unit, fastening means disposed at opposite ends of the at least one restraining member, and compressive means interposed between at least one of the fastening means and the end units; wherein the fastening means and the compressive means urge the upper end unit toward the lower end unit, thereby applying compressive force to the fuel cell stack. Also provided is a method for assembling the fuel cell system.

Abstract: A bipolar plate for a fuel cell is provided that includes a pair of unipolar plates having a separator plate disposed therebetween. One of the unipolar plates is produced from a porous material to minimize cathode transport resistance at high current density. A fuel cell stack including a fuel cell and the bipolar plate is also provided.

Abstract: A combined subgasket and membrane support for a fuel cell is provided. The combined subgasket and membrane support includes a substantially fluid impermeable feed region circumscribing a porous membrane support region. The membrane support region is integrally formed with the feed region. At least one of the membrane support region and the feed region is at least partially formed by a radiation-cured structure. A method for fabricating the subgasket and membrane support for the fuel cell is also provided.