Abstract: A membrane electrode assembly includes an anode, a cathode, a membrane disposed between the anode and the cathode, a catalyzed layer in at least one position selected from the group consisting of between the cathode and the membrane and between the anode and the membrane, and an edge seal positioned along an edge of the membrane electrode assembly, wherein the membrane and the catalyzed layer extends into the edge seal.

Abstract: An illustrative example cell stack assembly includes a plurality of fuel cells that each include a cathode electrode, an anode electrode and a matrix for holding a liquid acid electrolyte. The electrodes have lateral outside edges that are generally coplanar. A plurality of separator plates are respectively between the cathode electrode of one of the fuel cells and the anode electrode of an adjacent one of the fuel cells. The separator plates have lateral outside edges that are generally coplanar with the lateral outside edges of the electrodes. A plurality of barriers along at least one of the lateral outside edges of respective ones of the separator plates extend outwardly beyond the lateral outside edges of the electrodes and separator plates. The barriers inhibit acid migration between one of the electrodes on one side of the barrier and one of the electrodes on an opposite side of the barrier.

Abstract: A stack (10) of fuel cells (11) is manufactured with barriers (32) to prevent migration of a liquid electrolyte (such as phosphoric acid) out of the cells (11). The barrier (32) is secured within a step (34) formed within a land region (28) of a separator plate assembly (18) and extends from an edge (30) of the separator plate assembly (18) all or a portion of a distance between the edge (30) and a flow channel (24) defined within the separator plate assembly (18). The barrier (32) also extends away from the edge (30) a distance of between 0.051 and about 2.0 millimeters (about 2 and about 80 mils. The barrier (32) includes a hydrophobic, polymeric film (36), a pressure sensitive adhesive (38) as an assembly aid, and a fluoroelastomer bonding agent (40).

Abstract: A membrane electrode assembly is provided which includes an anode; a cathode; a membrane between the anode and the cathode; and a protective layer between the membrane and at least one electrode of the anode and the cathode, the protective layer having a layer of ionomer material containing a catalyst, the layer having a porosity of between 0 and 10%, an ionomer content of between 50 and 80% vol., a catalyst content of between 10 and 50% vol., and an electrical connectivity between catalyst particles of between 35 and 75%. A configuration using a precipitation layer to prevent migration of catalyst ions is also provided.

Abstract: An illustrative example cell stack assembly includes a plurality of fuel cells that each include a cathode electrode, an anode electrode and a matrix for holding a liquid acid electrolyte. The electrodes have lateral outside edges that are generally coplanar. A plurality of separator plates are respectively between the cathode electrode of one of the fuel cells and the anode electrode of an adjacent one of the fuel cells. The separator plates have lateral outside edges that are generally coplanar with the lateral outside edges of the electrodes. A plurality of barriers along at least one of the lateral outside edges of respective ones of the separator plates extend outwardly beyond the lateral outside edges of the electrodes and separator plates. The barriers inhibit acid migration between one of the electrodes on one side of the barrier and one of the electrodes on an opposite side of the barrier.

Abstract: A stack (10) of fuel cells (11) is provided with barriers (32) to prevent migration of a liquid electrolyte (such as phosphoric acid) out of the cells (11). The barrier (32) is secured within a step (34) defined within a land region (28) of a separator plate assembly (18) and extends from an edge (30) of the separator plate assembly (18) all or a portion of a distance between the edge (30) and a flow channel (24) defined within the separator plate assembly (18). The barrier (32) also extends away from the edge (30) a distance of between 0.051 and 2.0 millimeters (2 and 80 mils). The barrier (32) includes a hydrophobic, polymeric film (36), a pressure sensitive adhesive (38), as an assembly aid, and a fluoroelastomer bonding agent (40).

Abstract: A membrane electrode assembly includes an anode including a hydrogen oxidation catalyst; a cathode; a membrane disposed between the anode and the cathode; and a peroxide decomposition catalyst positioned in at least one position selected from the group consisting of a layer between the anode and the membrane and a layer between the cathode and the membrane wherein the peroxide decomposition catalyst has selectivity when exposed to hydrogen peroxide toward reactions which form benign products from the hydrogen peroxide. The peroxide decomposition catalyst can also be positioned within the membrane. Also disclosed is a power-generating fuel cell system including such a membrane electrode assembly, and a process for operating such a fuel cell system. The assembly components contain ionomer material which can be perfluorinated or non-perfluorinated, high temperature, hydrocarbon, and the like.

Abstract: An example fuel cell device includes an electrode assembly having two gas diffusion layers (GDLs). One GDL is adjacent to the anode electrode and the other GDL is adjacent to the cathode electrode. Seals on the periphery of the GDLs are configured to block reactant gases from direct mixing within the GDLs. Sealing the perimeter of the GDLs blocks liquid-water flow from exiting the gas diffusion layer. The disclosed example provides an opening in the seal near a fluid exit area of the fuel cell that provides a path for communicating water from the active area through a perimeter portion of the GDL. An example method of managing fluid in a fuel cell includes providing an opening in a perimeter seal of a GDL of the fuel cell. The method communicates a fluid through a channel in the plate and moves water through the opening using the fluid.

Abstract: An electrode for a phosphoric acid fuel cell includes a phosphoric acid electrode; catalyst particles on the phosphoric acid electrode; and a fluoropolymer on the catalyst particles. Methods for making such electrodes using soluble fluoropolymer are also provided.

Abstract: A membrane electrode assembly includes an anode including a hydrogen oxidation catalyst; a cathode; a membrane disposed between the anode and the cathode; and a peroxide decomposition catalyst positioned in at least one position selected from the group consisting of a layer between the anode and the membrane and a layer between the cathode and the membrane wherein the peroxide decomposition catalyst has selectivity when exposed to hydrogen peroxide toward reactions which form benign products from the hydrogen peroxide. The peroxide decomposition catalyst can also be positioned within the membrane. Also disclosed is a power-generating fuel cell system including such a membrane electrode assembly, and a process for operating such a fuel cell system. The assembly components contain ionomer material which can be perfluorinated or non-perfluorinated, high temperature, hydrocarbon, and the like.

Abstract: A membrane electrode assembly is provided which includes an anode; a cathode; a membrane between the anode and the cathode; and a protective layer between the membrane and at least one electrode of the anode and the cathode, the protective layer having a layer of ionomer material containing a catalyst, the layer having a porosity of between 0 and 10%, an ionomer content of between 50 and 80% vol., a catalyst content of between 10 and 50% vol., and an electrical connectivity between catalyst particles of between 35 and 75%. A configuration using a precipitation layer to prevent migration of catalyst ions is also provided.

Abstract: A membrane electrode assembly includes an anode including a hydrogen oxidation catalyst; a cathode; a membrane disposed between the anode and the cathode; and a peroxide decomposition catalyst positioned in at least one position selected from the group consisting of a layer between the anode and the membrane and a layer between the cathode and the membrane wherein the peroxide decomposition catalyst has selectivity when exposed to hydrogen peroxide toward reactions which form benign products from the hydrogen peroxide. The peroxide decomposition catalyst can also be positioned within the membrane. Also disclosed is a power-generating fuel cell system including such a membrane electrode assembly, and a process for operating such a fuel cell system. The assembly components contain ionomer material which can be perfluorinated or non-perfluorinated, high temperature, hydrocarbon, and the like.

Abstract: A membrane electrode assembly is provided which includes an anode; a cathode; a membrane between the anode and the cathode; and a protective layer between the membrane and at least one electrode of the anode and the cathode, the protective layer having a layer of ionomer material containing a catalyst, the layer having a porosity of between 0 and 10%, an ionomer content of between 50 and 80% vol., a catalyst content of between 10 and 50% vol., and an electrical connectivity between catalyst particles of between 35 and 75%. A configuration using a precipitation layer to prevent migration of catalyst ions is also provided.

Abstract: An exemplary method of treating a material such as carbon or graphite to render at least some surfaces of the material hydrophilic includes coating at least a portion of the at least some surfaces with an oxygenated element and controlling a rate of a breakdown of the oxygenated element to leave a corresponding elemental oxide on the surfaces. In one example, the material is treated before being incorporated into an article comprising the material. Another example method includes treating an article comprising the material. Disclosed examples include precipitation or decomposition as the breakdown of the oxygenated element.

Abstract: A proton exchange material includes perfluorinated carbon backbone chains and side chains extending off of the perfluorinated carbon backbone chains. The perfluorinated side chains include cross-link chains that have multiple sulfonimide groups, —SO2—NH—SO2—.

Abstract: An example fuel cell device includes an electrode assembly having two gas diffusion layers (GDLs). One GDL is adjacent to the anode electrode and the other GDL is adjacent to the cathode electrode. Seals on the periphery of the GDLs are configured to block reactant gases from direct mixing within the GDLs. Sealing the perimeter of the GDLs blocks liquid-water flow from exiting the gas diffusion layer. The disclosed example provides an opening in the seal near a fluid exit area of the fuel cell that provides a path for communicating water from the active area through a perimeter portion of the GDL. An example method of managing fluid in a fuel cell includes providing an opening in a perimeter seal of a GDL of the fuel cell. The method communicates a fluid through a channel in the plate and moves water through the opening using the fluid.

Abstract: A stack (10) of fuel cells (11) is manufactured with barriers (32) to prevent migration of a liquid electrolyte (such as phosphoric acid) out of the cells (11). The barrier (32) is secured within a step (34) formed within a land region (28) of a separator plate assembly (18) and extends from an edge (30) of the separator plate assembly (18) all or a portion of a distance between the edge (30) and a flow channel (24) defined within the separator plate assembly (18). The barrier (32) also extends away from the edge (30) a distance of between 0.051 and about 2.0 millimeters (about 2 and about 80 mils. The barrier (32) includes a hydrophobic, polymeric film (36), a pressure sensitive adhesive (38) as an assembly aid, and a fluoroelastomer bonding agent (40).

Abstract: A stack (10) of fuel cells (11) is provided with barriers (32) to prevent migration of a liquid electrolyte (such as phosphoric acid) out of the cells (11). The barrier (32) is secured within a step (34) defined within a land region (28) of a separator plate assembly (18) and extends from an edge (30) of the separator plate assembly (18) all or a portion of a distance between the edge (30) and a flow channel (24) defined within the separator plate assembly (18). The barrier (32) also extends away from the edge (30) a distance of between 0.051 and 2.0 millimeters (2 and 80 mils). The barrier (32) includes a hydrophobic, polymeric film (36), a pressure sensitive adhesive (38), as an assembly aid, and a fluoroelastomer bonding agent (40).

Abstract: An exemplary method of treating a material such as carbon or graphite to render at least some surfaces of the material hydrophilic includes coating at least a portion of the at least some surfaces with an oxygenated element and controlling a rate of a breakdown of the oxygenated element to leave a corresponding elemental oxide on the surfaces. In one example, the material is treated before being incorporated into an article comprising the material. Another example method includes treating an article comprising the material. Disclosed examples include precipitation or decomposition as the breakdown of the oxygenated element.

Abstract: A fuel cell includes an electrode assembly having an electrolyte between a cathode catalyst and an anode catalyst, and a flow field plate having a channel for delivering a reactant gas to the electrode assembly. The flow field plate includes a channel having a channel inlet. A porous diffusion layer is located between the electrode assembly and the flow field plate. The porous diffusion layer includes a first region near the channel inlet and a second region downstream from the first region relative to the channel inlet. The first region includes a filler material that partially blocks pores of the first region such that the first region has a first porosity and the second region has a second porosity that is greater than the first porosity.