Abstract: Provided herein are methods for making a crystalline form of N-((4,6-dimethyl-2-oxo-1,2-dihydropyridin-3-yl)methyl)-5-(ethyl (tetrahydro-2H-pyran-4-yl)amino)-4-methyl-4?-(morpholinomethyl)-[1,1?-biphenyl]-3-carboxamide hydrobromide and related products, compositions and treatment methods.

Abstract: A method of manufacturing a flow field plate includes mixing graphite and resin materials to provide a mixture. The mixture is formed into a continuous flow field plate, for example, by ram extrusion or one or more press belts. The continuous flow field plate is separated into discrete flow field plates. Flow field channels are provided in one of the continuous flow field plate and the discrete flow field plates.

Abstract: A method of manufacturing a flow field plate includes mixing graphite and resin materials to provide a mixture. The mixture is formed into a continuous flow field plate, for example, by ram extrusion or one or more press belts. The continuous flow field plate is separated into discrete flow field plates. Flow field channels are provided in one of the continuous flow field plate and the discrete flow field plates.

Abstract: A fuel cell assembly (20) has an extended operational life, in part, because of unique startup and shutdown procedures used for operating the fuel cell assembly. In disclosed examples, a purge gas mixture of hydrogen and nitrogen includes less than 2% hydrogen for selectively purging portions of the assembly during a startup or shutdown procedure. In a disclosed example, the hydrogen-nitrogen mixture contains less than 0.1% hydrogen.

Abstract: A fuel cell separator plate assembly (20) includes a separator plate layer (22) and flow field layers (24, 26). In one disclosed example, the separator plate layer (22) comprises graphite and a hydrophobic resin. The hydrophobic resin of the separator plate layer (22) serves to secure the separator plate layer to flow field layers on opposite sides of the separator plate layer. In one example, at least one of the flow field layers (24, 26) comprises graphite and a hydrophobic resin such that the flow field layer is hydrophobic and nonporous. In another example, two graphite and hydrophobic resin flow field layers are used on opposite sides of a separator plate layer. One disclosed example includes all three layers comprising graphite and a hydrophobic resin.

Abstract: A fuel cell assembly (20) includes an electrochemically active portion (40) that operates at an average operating temperature within a temperature range that is selected based upon an expected life cycle of the fuel cell assembly (20). In a disclosed example, the average operating temperature range for the electrochemically active portion is between about 340° F. (171° C.) and about 360° F. (182° C.). Maximum and minimum operating temperatures of the electrochemically active portion may be outside of the average operating temperature range. In one example, the electrochemically active portion is maintained at a temperature of at least 300° F. (149° C.) and less than 400° F. (204° C.).

Abstract: A fuel cell 12 has a liquid electrolyte 20, a cathode electrode 28, and an anode electrode 26. The fuel cell includes an electrolyte condensation zone 58 extending from an edge 56 of a first catalyst layer 36 on the cathode electrode to an outer edge 48 of an edge seals 52 and 49. An anode electrode has an anode catalyst layer 30 with an end substantially coinciding with an inner edge 53 of the edge seals. The acid condensation zone is located near the reactant exit, so that electrolyte that has evaporated into the reactant stream can condense out before leaving the fuel cell for re-absorption back into the fuel cell.

Abstract: In a fuel cell for a fuel cell power plant having a PEM (9), a cathode comprising at least a catalyst (10) and a support substrate (17), possibly with a diffusion layer (16), on one side of the PEM, and an anode comprising at least an anode support substrate (14) and an anode catalyst (11) on the opposite side of the PEM, and a porous water transport plate having reactant gas flow field channels (31, 32) (21, 28) adjacent to each of said support substrates as well as water flow channels (22) in at least one of said water transport plates, the thermal conductance of the cathode is less than about one-half of the thermal conductance of the anode, and preferably less than one-quarter of the thermal conductance of the anode, to promote flow of water from the cathode to the anode and to the adjacent water transport plate, obviating the need, in some cases, for water or reactant pressure pumps.

Abstract: A system and method for building a program (e.g., a control program) for execution by a programmable controller from a source program. The source program, which includes instructions in a high-level programming language (e.g., structured text, C++, Pascal or graphics oriented languages), is separately converted into a first and second processor-executable programs. The first and second processor-executable programs are then compared, and if the first and second processor-executable programs are substantially the same, then one of them is sent to the programmable controller. If they are not substantially the same one of them is corrupt and the conversion process is aborted. In variations, the source program is simultaneously converted into the first and second processor-executable programs using a diversified collection of hardware and software components.

Abstract: A vacuum fuel cell system (10) and procedure provide for starting up a fuel cell (12) with a rapid fuel purge of an anode flow field (38) to minimize corrosion of a carbon catalyst support layer (26) by a reverse current mechanism produced by movement of a fuel-air front through the anode flow field (38). A vacuum source (90) applies a vacuum to the anode flow field (38) while the fuel cell (12) is shut down and while a fuel inlet valve (70) and a fuel exhaust valve (74) are closed. The resulting vacuum within the anode flow field (38) produces rapid purge of the fuel through the anode flow field (38) upon start up, and a strong vacuum will get rid of essentially all of the air within the anode flow field (38) to virtually eliminate movement of the fuel-air front.

Abstract: The plant (60) includes at least one fuel cell (10, 62) having a wetproofed anode support (20) and a cathode support (24) for directing reactant streams adjacent catalysts (14, 16). A porous anode cooler plate (26) has its fuel channels (28A, 28B, 28C, 28D) secured adjacent the anode support (20). A porous cathode water management plate (38) has its oxidant channels (40A, 40B, 40C, 40D) secured adjacent the cathode support (24). A direct antifreeze solution passes only through coolant channels (32A, 32B, 32C, 32D) of the anode cooler plate (26) so the solution cannot poison the catalysts (14, 16), while fuel cell product water flows passively through the water management plate (38) and water management channels (44A, 44B, 44C, 44D) defined in the plate (38) to humidify reactant streams and be discharged from the fuel cell (62).

Abstract: A stack (11) of fuel cells have water flow channels receiving water through a pump (33) from an accumulator (29) having double walls (63, 66) with vacuum insulation panels (VIPs) (65, 68) therebetween, auxiliary DC power source (80) (battery or supercapacitor) is disposed in a container (43) having double walls (81, 86) with VIPs (65, 68) encapsulated therebetween. A keep-warm heater (51) keeps the source warm enough for at least half power capacity, the source driving its own heater as well as a keep-warm heater (50) in the accumulator to keep the accumulator above freezing. A microwave heater (58) disposed in the accumulator distributes energy to melt ice using fuel cell stack power upon startup.

Abstract: A freeze tolerant fuel cell power plant (10) includes at least one fuel cell (12), a coolant loop (42) having a porous water transport plate (44) secured in a heat and mass exchange relationship with the fuel cell (12) and a coolant pump (46) for circulating a coolant through the plate (44) and for transferring water into or out of the plate (44) with the coolant. A coolant heat exchanger (52) removes heat from the coolant, and an accumulator (66) stores the coolant and fuel cell product water and directs the product water out of the accumulator (66). The coolant is a two-component mixed coolant liquid circulating through the coolant loop (42) consisting of between 80 and 95 volume percent of a low freezing temperature water immiscible fluid component and between 5 and 20 volume percent of a water component.

Abstract: A fuel cell stack (10) includes a reaction portion (20) having an end cell (12) secured adjacent to a current collector (30). The collector (30) has a sensible heat no greater than a sensible heat of the end cell (12) and an electrical resistivity no greater than 100 micro-ohms centimeters. An insulator (40) is secured adjacent the collector (30) and has a thermal conductivity that is no greater than 0.500 Watts per meter per degree Kelvin. Because of the low sensible heat of the current collector (30) and low rate of heat transfer of the insulator (40), heat does not readily leave the end cell (12) resulting in a rapid heating of the end cell (12), thereby avoiding freezing and accumulation of product water in the end cell (12) during start up in subfreezing conditions.

Abstract: The reactant gas manifolds (12-15) of a PEM fuel cell are modified to provide insulated manifolds (14a) having inner and outer walls (30, 31) closed off by a peripheral wall (35) to provide a chamber (36) which may be filled with a vacuum, a low thermal conductivity gas, a VIP (59) or a GFP (63). Single walled manifolds (14d, 14e) may have VIPs or GFPs inside or outside thereof. An insulation panel (40) similarly has inner and outer walls (42, 43) closed with a peripheral wall (45) so as to form a chamber (46) that may contain a vacuum, a low thermal conductivity gas, a VIP or a GFP. The tie rods 9a may be recessed 50 into the pressure plate 11a of the fuel cell stack to allow a flush surface for the insulation panel 40.

Abstract: Water transfer means (86) transfers fuel cell product water from a cathode water transport plate (34) to an anode water transport plate (23) of the same or a different fuel cell, wholly within a fuel cell stack (50), (disposed within each fuel cell of a fuel cell stack (50)). The water transfer means may be a very high permeability proton exchange membrane (21a), a water transfer band (90) such as silicon carbide particles, a porous water transfer zone (107), with or without a flow restrictor (109), internal water manifolds (112, 113) which extend through an entire fuel cell stack, or internal manifolds (112a, 112b, 112c, 112d, 113a, 113b, 113c, 113d) which extend only through groups of cells between solid plates (71).

Abstract: A fuel cell system having a stack of proton exchange membrane fuel cells is operated in sub-freezing temperatures by draining any liquid water from the fuel cell water flow passages upon or after the previous shut-down of the stack before freezing can occur, and, thereafter a) starting-up the stack by directing fuel and oxidant reactants into the cell and connecting a load to the stack; b) using heat produced by the stack to increase the operating temperature of the stack to melt ice within the stack; and, c) upon the stack operating temperature reaching at least 0° C., circulating anti-freeze through stack coolers to maintain the temperature of the stack low enough to maintain a sufficiently low water vapor pressure within the cells to prevent cell dry out for at least as long as there is insufficient liquid water to circulate through the water flow passages.

Abstract: To evaporatively cool fuel cells, the pressure in steam carrying channels on one side of a hydrophobic porous liquid/vapor barrier layer disposed between adjacent fuel cells is reduced to below the vapor pressure of liquid water passing through liquid water carrying channels on the other side of the barrier layer, such as by using a vacuum pump. This causes some of the liquid water to boil and change to steam. The steam passes through the barrier layer into the steam channels and is carried out of the cells. The operating temperature of the fuel cell is adjusted by controlling the pressure within the steam channels, such as by controlling the amount of heat removed from the steam after it leaves the steam channels.

Abstract: A fuel cell stack (50) includes fuel cells (16, 18, 19) with anode and cathode water transport plates (23, 31, 34, 37) having porosity of at least 50%, thereby to significantly increase the amount of water stored within the water transport plates when the stack is shut down, which doubles the heat of fusion as the ice in the pores melts during a startup following freeze. This extends the period of time before the water in the pores reaches a hard freeze at ?20° C. from 180 hours to 280 hours. A controller (60) controls the bypass (55) of a heat exchanger (54) to cause the temperature of the stack to reach a temperature sufficient to raise the sensible heat of the stack by 20%-40% above what it is with the fuel cell power plant operating steady state, prior to being shut down, thereby increasing the hours required for the fuel cell to cool down to 0° C. in ?20° C. environment from 60 hours to 90 hours, allowing easier startups when shut down for less than 90 hours.

Abstract: A fuel cell power plant system includes the ability to operate an enthalpy recovery device even under cold conditions. A bypass arrangement allows for selectively bypassing one or more portions of the enthalpy recovery device under selected conditions. In one example, the enthalpy recovery device is completely bypassed under selected temperature conditions to allow the device to freeze and then later to be used under more favorable temperature conditions. In another example, the enthalpy recovery device is selectively bypassed during a system startup operation. One example includes a heater associated with the enthalpy recovery device. Another example includes preheating oxidant supplied to one portion of the enthalpy recovery device.