Abstract: A fuel cell component is provided, including a substrate disposed adjacent at least one radiation-cured flow field layer. The flow field layer is one of disposed between the substrate and a diffusion medium layer, and disposed on the diffusion medium layer opposite the substrate. The flow field layer has at least one of a plurality of reactant flow channels and a plurality of coolant channels for the fuel cell. The fuel cell component may be assembled as part of a repeating unit for a fuel cell stack. A method for fabricating the fuel cell component and the associated repeating unit for the fuel cell is also provided.

Abstract: A method for fabricating a radiation-cured structure is provided. The method includes the steps of providing a first radiation-sensitive material and applying a second radiation-sensitive material to the first radiation-sensitive material. The first radiation-sensitive material has a first sensitivity. The second radiation-sensitive material has 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: The present invention isolates the fluid streams flowing into and out of a fuel cell stack from the terminal plates so that the fluid streams and terminal plates do not come into contact with one another. The prevention of the fluid streams from contacting the terminal plate eliminates corrosion concerns associated with the terminal plate. The present invention accomplishes this isolation through the use of headers having fluid passageways therein that route the fluid streams in and/or out of the fuel cell stack while preventing contact between the fluid streams and the terminal plate.

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 seal structure is disclosed for forming a substantially fluid tight seal between a UEA and a plate of a fuel cell system, the seal structure including a sealing member formed in one fuel cell plate, a seal support adapted to span feed area channels in an adjacent fuel cell plate, and a seal adapted to cooperate with a UEA disposed between the fuel cell plates, the sealing member, and the seal support to form a substantially fluid tight seal between the UEA and the one fuel cell plate. The seal structure militates against a leakage of fluids from the fuel cell system, facilitates the maintenance of a velocity of a reactant flow in the fuel cell system, and a cost thereof is minimized.

Abstract: An interlockable bead seal for a bipolar plate is provided. The interlockable bead seal includes a first elongate bead formed on a first plate and a second elongate bead formed on a second plate. The first elongate bead has a sealing surface and the second elongate bead has a trough. An interlockable bipolar plate having the interlockable bead seals, and a fuel cell stack formed from a plurality of the interlockable bipolar plates, are also provided. A lateral slippage between components of the fuel cell stack is militated against by the interlockable bipolar plates.

Abstract: A fuel cell of the type having a membrane electrode assembly (MEA) interdisposed between a pair of bipolar plate assemblies. The MEA may have a convoluted configuration to maximize the effective surface area of the MEA for a given planar area. Each bipolar plate assembly includes a gas distribution layer of open cell conductive foam material which is divided into a plurality of generally parallel segments to define a plurality of generally parallel porous reactant paths. The segments are defined by selectively varying the porosity of the foam material and/or selectively varying the thickness of the foam material. The foam material may be a conductive graphite foam media or a conductive metallic foam media. Each bipolar plate assembly further includes a non-porous, conductive separator plate. The bipolar plate assembly distributes the reactant gases delivered via a manifold structure across the face of the MEA.

Abstract: A bead seal structure is disclosed for sealing between plates of a fuel cell system, wherein the bead seal structure militates against a leakage of fluids from the fuel cell system and a cost thereof is minimized.

Abstract: A gasket for a fuel cell, wherein the gasket includes the use of two or more different materials as the gasket. For example, ethylene propylene diene monomer (EPDM) and/or the like, or another more chemically inert gasket material, is located inside or on an inboard position and is the wetted material that is exposed to the fuel cell operating environment. Silicone and/or the like, or another potentially contaminating material with better cold temperature sealability, is located outside or on an outboard position and does not come in contact with the fuel cell internal environment. One method of constructing such a gasket would be two include two parallel bead traces of the gasket materials on a polyimide (e.g., KAPTON®) carrier, or the like.

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 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: 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: 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 fuel cell comprising: a first layer comprising a first ionomer and an additive, the additive comprising a metal oxide comprising an oxide at least one of of Ce, Mn, V, Pt, Ru, Zr, Ni, Cr, W, Co, Mo, or Sn, and wherein the additive is present in at least 0.1 weight percent of the ionomer is disclosed as one embodiment of the invention, and performance and durability are advantaged wherein one or all of the metal oxide consists essentially nanoparticles.

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 gasket for a fuel cell, wherein the gasket includes the use of two or more different materials as the gasket. For example, ethylene propylene diene monomer (EPDM) and/or the like, or another more chemically inert gasket material, is located inside or on an inboard position and is the wetted material that is exposed to the fuel cell operating environment. Silicone and/or the like, or another potentially contaminating material with better cold temperature sealability, is located outside or on an outboard position and does not come in contact with the fuel cell internal environment. One method of constructing such a gasket would be two include two parallel bead traces of the gasket materials on a polyimide (e.g., KAPTON®) carrier, or the like.

Abstract: An electroconductive porous substrate such as carbon fiber paper with an electroconductive polymer deposited on the carbon fibers of the paper is used as a wicking material or diffusion medium in a fuel cell. The polymer may be deposited from a solution of monomers by electrochemical polymerization.

Abstract: A thermal management system of an electrochemical engine comprises a radiator provided with a wicking mechanism, a coolant pump fluidly connected to the radiator, a water tank, and a water pump. The water tank is located in the void spaces around fuel storage tanks, and may be filled directly or with reclaimed water from a vapor by-product of the electrochemical engine. The water pump is operable to supply water from the water tank to the wicking mechanism during peak power and/or hot day conditions. Moisture in the vapor by-product may be condensed with the excess cooling capacity of the radiator under less severe cooling conditions. Under freezing conditions, exhaust or coolant from the electrochemical engine may be used to unfreeze water in the tank and wicking mechanism supply lines.

Abstract: A bipolar plate for use with a fuel cell is provided including an electrically conductive foam as a coolant layer between thin metal foil layers. The thin metal foil layers are provided with serpentine flow field patterns on a surface thereof.

Abstract: 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.