Abstract: The present invention is directed to addressing performance issues attributable to membrane electrode assemblies, and the components thereof, in electrochemical conversion cells. In accordance with one embodiment of the present invention, a device comprising at least one electrochemical conversion cell is provided. The cell is configured to convert first and second reactants to electrical energy and comprises a membrane electrode assembly and at least one membrane reinforcement layer. The combination of elastic modulus and thickness of the reinforcement layer and the bond between the reinforcement layer and the membrane electrode assembly are sufficient to enhance the structural integrity of the membrane electrode assembly beyond the operational degradation threshold of the assembly.

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 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 method for preventing a fuel cell voltage potential reversal including determining a relationship between the cell resistance and the current of a fuel cell stack at which a fuel cell voltage potential reversal will occur, operating the fuel cell stack according to a power demand requested, and determining the maximum cell resistance of the fuel cells in the stack. If the maximum cell resistance exceeds a threshold value for the current at which the fuel cell stack is being operated, the operation of the fuel cell stack is restricted to prevent the fuel cell voltage potential from reversing.

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: According to one embodiment of the present invention, a fuel cell life counter is configured to determine membrane degradation using fuel cell cycling data and S-N curve data for the membrane. According to another embodiment of the present invention, a method of managing remaining fuel cell life is provided where variables like membrane dehydration rate, water content, temperature, and heating/cooling rate are controlled as a function of the remaining life of the fuel cell. Additional embodiments are provided where fuel cell life counters and methods of managing remaining life are independent of S-N curve data and the use of fatigue life contour plots.

Abstract: In accordance with one embodiment of the present invention, a method of operating an electrochemical conversion cell is provided wherein the method comprises the steps of (i) initiating a membrane dehydration sequence when the membrane is characterized by an initial membrane hydration ?WET and (ii) maintaining the membrane dehydration sequence until the membrane is characterized by a target membrane hydration ?DRY. According to the method, the membrane dehydration sequence is characterized by a drying rate that varies in a manner that substantially corresponds to a fatigue life contour map of the membrane. Additional methods and corresponding systems are contemplated.

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 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 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: The present invention provides for a construction for a bipolar plate for a fuel cell stack that enables the bipolar plate to be a more compliant member in the fuel cell stack. The bipolar plate can be configured to provide varying levels of compliance, as demanded by the design of the fuel cell stack. The bipolar plate can be more compliant than the diffusion media members and the active elements used to form the individual fuel cells. The compliant nature of the individual bipolar plates enables localized dimensional changes that occur within the fuel cell stack to be compensated by a localized deformation of the portions of the bipolar plate within that region. The bipolar plate has an internal coolant flow field where some opposing pairs of lands are spaced apart with a gap therebetween while other opposing pairs of lands are in contact with one another.

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 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: 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 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.

Abstract: A method of producing a fuel cell stack is disclosed, the method including the steps of compressing the fuel cell stack at a first pressure and compressing the fuel cell stack at a second pressure higher than the first pressure, wherein a shorting resistance of fuel cells in the fuel cell stack is maximized and a durability of the fuel cell stack is maximized.

Abstract: An electrically conductive element and a related assembly are provided for use in an electrochemical cell. The electrically conductive separator plate has an upper boundary and a lower boundary. The upper boundary has at least one land formed therein, where the land has a surface defining a first plane and the lower boundary defines a second plane. The first plane extends towards said second plane, so as to intersect with said second plane at an angle greater than zero. An assembly further comprises a compliant layer which substantially conforms to the angled land surfaces, thereby enhancing contact pressure between and across a plurality of components in the compliant layer. A method of assembling such a separator assembly in a fuel cell is also provided.

Abstract: A method of operating an electrochemical conversion assembly is provided. According to the method, an assembly warm-up operation is executed by increasing the temperature TSTACK of the membrane electrode assembly. Next, stoichiometry-based control of the relative humidity (RH) of one of the reactant flowfields is initiated when the temperature TSTACK exceeds a threshold temperature T0. The stoichiometry-based RH control comprises a reduction in the relative humidity from a value RHWET exceeding 100% relative humidity to a value RHDRY less than 100% relative humidity. The relative humidity value RHDRY is sufficiently low to permit reduction of an initial membrane hydration ?WET in the membrane electrode assembly.

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 diffusion media for use in a PEM fuel cell which includes a relieved edge region relative to the interior region of the diffusion media. The outer perimeter or portion of the diffusion media that will interface with a sealing gasket is pre-compressed. The pre-compressed diffusion media lowers the compression stress on the MEA at the gasket interfaces, enabling a more uniform compression on the entirety of the MEA surfaces during the build, compression, and later operation of a fuel cell stack.