Abstract: A fuel cell system having an integral electrical conduction system is provided for the transmission of electrical energy created from a fuel cell stack. The electrical conduction system conducts electricity to a positive and a negative pole, each disposed at a common end of the fuel cell stack for reducing the amount of external wiring needed for connecting multiple fuel cell stacks together. The fuel cell stack and electrical system are both disposed in a housing.

Abstract: An integrated hybrid electrochemical device comprising a nickel-metal hydride battery and an alkaline H2—O2/air fuel cell together sharing a common alkali metal electrolyte in a housing common to both. In one embodiment, the NiMH battery and alkaline fuel cell electrodes share only the same electrolyte. According to another embodiment, the battery and fuel cell electrodes not only share the same electrolyte, but also share common reactant supply plenums as well. In another embodiment, the battery and fuel cell electrodes share a common electrolyte, common reactant (i.e. H2 and O2 or air) supply plenums, and common current collectors.

Abstract: A method is disclosed for producing a casting mold for an engine block, the casting mold includes a mold seat for a cast-in-place cylinder bore liner, the seat having a surface disposed at an angle relative to a longitudinal axis of the cylinder bore liner, wherein the cylinder bore liner becomes slightly unseated upon thermal expansion.

Abstract: A hydrogen distribution valve for alternately distributing gaseous and liquid hydrogen from a tank is disclosed. The hydrogen distribution valve includes a valve housing having a gaseous hydrogen inlet, a liquid hydrogen inlet, a hydrogen outlet and a reference pressure port for receiving a reference hydrogen pressure. A rocker valve is provided in the valve housing for alternately sealing the gaseous hydrogen inlet and the liquid hydrogen inlet. A bias mechanism engages the rocker valve for biasing the rocker valve in sealing engagement with said liquid hydrogen inlet. A valve membrane is provided in fluid communication with the reference pressure port and engages the valve head for biasing the valve head in sealing engagement with the gaseous hydrogen inlet.

Abstract: A fuel cell stack comprising a plurality of fuel cells which are connected together. Each cell has an anode, a cathode, and a membrane therebetween and which are each arranged between two bipolar plates. The anode sides of the individual fuel cells have flow fields for a gaseous fuel supplied to the fuel cells extending between an anode space arranged at the top in the fuel cell stack and an anode space arranged at the bottom of the fuel cell stack. A collecting container is provided in the anode space arranged at the bottom of the fuel cell stack for water which is produced during the electrochemical reaction and is present in the form of a liquid and the water which is collected there has an evaporation surface and serves for the humidification of the fuel fed to the fuel cell stack.

Abstract: The present invention discloses various methods in which a quality of a diffusion media for use in a fuel cell assembly can be qualitatively evaluated. The material constant, an internal contact angle, a ratio of high and low energy pores, and an external contact angle can be calculated for the diffusion media and compared to a predetermined standard to evaluate the quality of the diffusion media.

Abstract: A liquid hydrogen tank assembly that employs a level sensor inductively coupled through the tank walls so as to minimize one conductive heat path through the tank walls. The tank assembly includes an inner tank and an outer tank having a vacuum layer therebetween to maintain the liquid hydrogen within the inner tank under cryogenic temperatures. A capacitive level sensor is positioned within the inner tank and provides an electrical indication of the level of the liquid hydrogen within the inner tank. The level sensor is electrically coupled to an inner coil within the inner tank. An outer coil is provided proximate the outer tank wall and is electrically coupled to a signal processing and conditioning circuit.

Abstract: A fuel cell system with a proton exchange membrane. There is a cathode catalyst layer overlying the first face of the proton exchange membrane, and a cathode diffusion layer overlying the cathode catalyst layer. There is an anode catalyst layer overlying the second face of the proton exchange membrane, and an anode diffusion layer overlying the anode catalyst layer. The cathode diffusion layer has a water vapor permeance of less than about 3×10?4 g/(Pa s m2) at 80° C. and 1 atmosphere. The invention also relates to cathode diffusion layers for fuel cell systems.

Abstract: An integrated cell voltage unit for monitoring the voltage of each fuel cell in a fuel cell stack that is easily and reliably electrically coupled to the bipolar plates of the fuel cell stack. The bipolar plates of the fuel cell stack are equipped with a specialized tab connector that engages with a corresponding electrical connector on the cell voltage unit. Either the tab connectors on the bipolar plates or the corresponding connectors on the cell voltage unit include flexible members to provide a suitable electrical friction engagement. The cell voltage unit is attached to the bipolar plates and does not require its own separate housing. In one embodiment, the housing of the fuel cell stack includes a recessed portion in which the cell voltage unit is positioned.

Abstract: A method and apparatus is disclosed for forming a metal casting sprue for a lost foam casting process, the sprue formed in sand for receiving molten metal and directing the molten metal to a foam pattern in a mold cavity, wherein the sprue formation is facilitated by an insert having a plurality of apertures formed therein, the apertures facilitating an application of a coating to sand surrounding the insert prior to removal of the insert from the sand, and wherein the sprue facilitates a minimization of production costs and an optimization of material properties of the resultant casting.

Abstract: A cast-in-place cylinder bore liner (15) is disclosed for use in sand casting of engine cylinder blocks, the cylinder bore liner (15) having a protuberant portion (60) adjacent a first end (61) thereof, whereby accuracy in the positioning of cast-in-place bore liners (15) is maximized.

Abstract: A mold design is disclosed for sand casting of engine cylinder blocks, such as engine cylinder V-blocks, with cast-in-place cylinder bore liners, wherein a dimensional accuracy in the positioning of cast-in-place bore liners is maximized.

Abstract: A 3D Printing Rapid Prototyping process using Al/Mg particles coated with a metal (i.e. copper, nickel, zinc, or tin) that (1) prevents oxidation of the Al/Mg particles, and (2) either alone, or when alloyed with the aluminum or magnesium core metal, melts below the liquidus temperature of the core.

Abstract: A fuel cell system extracts water from the effluent of a fuel cell for supply to other components of the fuel cell system that require water. A preferred embodiment is a fuel cell system, for the production of electricity from hydrogen gas and an oxidant, comprising: (a) a fuel cell comprising an anode input for a hydrogen-containing anode supply stream, a cathode input for an oxidant-containing cathode supply stream, and a cathode output for cathode effluent comprising water produced by said fuel cell; and (b) a water transfer device, connected to said fuel cell, that transfers water from said cathode effluent to said anode supply stream.

Abstract: A method of addressing one MEA failure mode by controlling MEA catalyst layer overlap, and the apparatus formed thereby is disclosed. The present invention addresses a feature of membrane electrode assembly (MEA) architecture that is associated with field failures due to the loss of ionomer from the edges of the electrolyte. To address ionomer degradation, the present invention provides a MEA design in which the cathode catalyst edges are closer than the anode catalyst edges to the edges of the electrolyte.

Abstract: A method for detecting leaks in a fuel cell system that includes a hydrogen storage tank, a primary shut-off valve and a secondary shut-off valve in a supply line. At shut-down, the primary shut-off valve is closed and the stack is temporarily left operating. The pressure is measured in the supply line between the valves. When the measured pressure has reached a predetermined shut-down pressure, the secondary shut-off valve is closed. At the next system start-up, the pressure is measured before the shut-off valves are opened, and the measured pressure is compared with the stored pressure. If the current pressure measurement is lower than the stored pressure measurement, it is an indication that the supply line between the shut-off valves or the secondary valve leaks. If the measured pressure is higher than the stored pressure, it is an indication that the primary valve leaks.

Abstract: A casting mold for an engine block and method for manufacturing the casting mold. In one embodiment, the casting mold includes a mold seat with a double-curved surface, and a cast-in cylinder liner. The cylinder liner has an axis and an end surface. The end surface is in tangential contact with the double-curved surface in a seated position prior to any thermal expansion of the cylinder liner. In various embodiments, the cylinder liner becomes slightly unseated upon thermal expansion.

Abstract: A method and apparatus for controlling the dispersion of molten metal in a mold cavity is disclosed, the control facilitated by a localized densification of foam in a lost foam casting operation for producing metal castings, wherein the filling of regions of the mold cavity which do not lend themselves to castability is maximized, an amount of backfill and casting defects are minimized, and a flow pattern of molten metal and material properties of the resulting casting are optimized.

Abstract: A mold design is disclosed for precision sand casting of engine cylinder blocks, such as engine cylinder V-blocks, having chills disposed therein, wherein an expansion and contraction caused by changes in temperature during the casting operation are accommodated by the chills.

Abstract: A method for preparing engine block cylinder bore liners is disclosed, the method including preconditioning of the cylinder bore liners for use in sand casting of engine cylinder blocks, wherein an efficiency of the preconditioning process is maximized, a metal pour temperature is minimized, and material properties of the casting are optimized.