Abstract: A fuel cell cathode catalyst is provided comprising nanostructured elements comprising microstructured support whiskers bearing nanoscopic catalyst particles; wherein the catalyst comprises platinum and manganese and at least one other metal selected from the group consisting of Group VIb metals, Group VIIb metals and Group VIIIb metals other than platinum and manganese; wherein the volume ratio of platinum to the sum of all other metals in the catalyst is between about 1 and about 4 and wherein the Mn content is equal to or greater than about 5 micrograms/cm2 areal density. Typically, the volume ratio of manganese to the at least one other metal is between 10:90 and 90:10. Typically, the at least one other metal is Ni or Co. In addition, a fuel cell MBA comprising the present cathode catalyst is provided. In addition, methods of making the present cathode catalyst are provided.

Abstract: The present invention is a microlayer for use with an electrically conductive porous substrate of a gas diffusion layer. The microlayer includes carbon particles and a polymeric composition of first highly-fluorinated polymers that are non-melt processable and second highly-fluorinated polymers that are melt processable.

Abstract: A method is presented for preconditioning fuel cell membrane electrode assemblies for use in fuel cell systems which includes exposure to saturated steam at superatmospheric pressures, typically for at least 10 minutes and more typically at least 25 minutes. Typically, the preconditioning method according to the present invention results in reduction of the start up or conditioning time required when the MEA's are first installed in a fuel cell system and improvement of overall performance, as reflected in the achievement of high current density at relatively high voltage. The method may additionally include the step of enclosing the fuel cell membrane electrode assembly in a container which is substantially impervious to water before the fuel cell membrane electrode assembly returns to ambient temperature.

Abstract: The invention provides protective articles comprising a backing that comprises a fluorinated polymer and a curable adhesive on at least one layer of the backing. The protective articles of the invention may be used to provide substrates or articles of the invention having a fluorinated surface. The invention also provides methods of preparing such articles, methods of repairing appliqués, and methods of edge sealing appliqués.

Abstract: Fuel cell membrane electrode assemblies and fuel cell polymer electrolyte membranes are provided comprising bound anionic functional groups and polyvalent cations, such as Mn or Ru cations, which demonstrate increased durability. Methods of making same are also provided.

Abstract: A method is provided for automated converting of a web of a thin patterned catalyst-coated membrane to separate membrane sheets for fuel cell assembly. The membrane typically has a thickness of about one thousandth of an inch. Automated web converting involves transporting, with use of a movable vacuum, an end portion of the membrane web from a first location to a second location. With use of respective first and second vacuums at the first and second locations, and after removal of the movable vacuum, the end portion of the membrane web is releasably secured at the first and second locations. The membrane web is cut within a gap defined between a single catalyst pattern of the membrane web end portion and an adjacent catalyst pattern to produce a membrane sheet. The membrane sheet is precisely positioned to a desired orientation to facilitate subsequent processing of the membrane sheet.

Abstract: The present invention provides a method of making a gasketed fuel cell membrane electrode assembly by simultaneously binding together the parts of the MEA, impregnating uncured elastomeric gasket material into the outer edge portions of each fluid transport layer, and substantially curing the uncured elastomeric gasket material so as to form anode-side and cathode-side gaskets. In order to form a raised-ridge microstructured contact pattern on the contact face of each gasket, patterning plates bearing a negative relief of a raised-ridge microstructured contact pattern may be positioned between the press platens and the uncured elastomeric gasket material.

Abstract: An electrolyte membrane is formed by an acidic polymer and a low-volatility acid that is fluorinated, substantially free of basic groups, and is either oligomeric or non-polymeric.

Abstract: A method of making a crosslinked polymer is provided as well as the polymer so made, the method comprising the steps of: providing a highly fluorinated fluoropolymer, typically a perfluorinated fluoropolymer, comprising pendent groups which include a group according to the formula —SO2X, where X is F, Cl, Br, OH, or —O?M+, where M+ is a monovalent cation, and exposing said fluoropolymer to electron beam radiation so as to result in the formation of crosslinks. Typically, the method according to the present invention additionally comprises the step of: forming said fluoropolymer into a membrane, typically having a thickness of 90 microns or less, more typically 60 microns or less, and most typically 30 microns or less.

Abstract: An article bearing a flow field such as a distribution plate for use in a fuel cell is provided. The active portion of the article, i.e., the portion of the article bearing the flow field, comprises at least two subsections; a first central subsection and a second peripheral subsection; wherein channels within the first subsection have a cross-sectional profile that differs from that of channels within the second subsection. Typically, channels of the first subsection have lesser depth, greater draft or greater ratio of draft to depth. In addition, an article bearing a flow field is provided where the flow field comprises at least two channel segments which differ in draft. In addition, an article bearing a flow field is provided where the flow field comprises at least one channel segment comprising first and second channel walls which differ in draft.

Abstract: A method is provided for making a crosslinked polymer electrolyte, typically in the form of a membrane for use as a polymer electrolyte membrane in an electrolytic cell such as a fuel cell, by trimerization of nitrile groups contained on groups pendant from the polymer. The resulting polymer electrolyte membrane comprises a highly fluorinated polymer comprising: a perfluorinated backbone, first pendent groups which comprise sulfonic acid groups, and crosslinks comprising trivalent groups according to the formula: The first pendent groups are typically according to the formula: —R1—SO3H, where R1 is a branched or unbranched perfluoroalkyl or perfluoroether group comprising 1-15 carbon atoms and 0-4 oxygen atoms, most typically —O—CF2—CF2—CF2—CF2—SO3H or —O—CF2—CF(CF3)—O—CF2—CF2—SO3H.

Abstract: Components for the manufacture of polymer electrolyte membrane fuel cells are provided, as well as apparatus and automatable methods for their manufacture by rotary die cutting and by lamination of various layers to form membrane electrode assemblies.

Abstract: A fuel cell cathode catalyst is provided which comprises nanostructured elements comprising microstructured support whiskers bearing nanoscopic catalyst particles. The nanoscopic catalyst particles are made by the alternating application of first and second layers, the first layer comprising platinum and the second layer being an alloy or intimate mixture of iron and a second metal selected from the group consisting of Group VIb metals, Group VIIb metals and Group VIIIb metals other than platinum and iron, where the atomic ratio of iron to the second metal in the second layer is between 0 and 10, where the planar equivalent thickness ratio of the first layer to the second layer is between 0.3 and 5, and wherein the average bilayer planar equivalent thickness of the first and second layers is less than 100 ?.

Abstract: A method is provided for making a reinforced polymer electrolyte membrane, such as may be used in electrolytic cells such as fuel cells, by mixing a sulfonate- or sulfonyl halide-functional polymer with a bisamidine compound and subsequently trimerizing the amidine groups of the bisamidine compound to form triazine linkages. The sulfonyl halide or sulfonate groups may then be converted to sulfonic acid groups, yielding a polymer electrolyte reinforced with a polytriazine.

Abstract: A polymer electrolyte membrane is provided having a thickness of 90 microns or less and comprising a polymer, said polymer comprising a highly fluorinated backbone and recurring pendant groups according to the formula: YOSO2—CF2—CF2—CF2—CF2—O-[polymer backbone]??(I) where Y is H+ or a monovalent cation such as an alkali metal cation. Typically, the membrane is a cast membrane. Typically, the polymer has a hydration product of greater than 22,000. Typically, the polymer has an equivalent weight of 800-1200.

Abstract: A method is provided for making a crosslinked polymer by direct fluorination of a non-perfluorinated polymer comprising first pendent groups which comprise sulfonyl halide groups or by direct fluorination of a polymer mixture of a first polymer which is a non-perfluorinated polymer and a second polymer which comprises first pendent groups which comprise sulfonyl halide groups. Such crosslinked polymers or polymer mixtures may be used to make polymer electrolyte membranes (PEM's) that may be used in electrolytic cells such as fuel cells and which should demonstrate increased durability in fuel cell use.

Abstract: A method is provided for making a crosslinked polymer electrolyte, typically in the form of a membrane for use as a polymer electrolyte membrane in an electrolytic cell such as a fuel cell, as well as the polymer so made, the method comprising application of electron beam radiation to a highly fluorinated fluoropolymer comprising: a backbone derived in part from tetrafluoro-ethylene monomer, first pendent groups which include a group according to the formula —SO2X, where X is F, Cl, Br, OH or —O?M+, where M+ is a monovalent cation, and second pendent groups which include Br, Cl or I. Typically, the membrane has a thickness of 90 microns or less, more typically 60 or less, and most typically 30 microns or less.

Abstract: A method is provided for making a reinforced polymer electrolyte membrane, such as may be used in electrolytic cells such as fuel cells, by mixing a sulfonate- or sulfonyl halide-functional polymer with a bisamidine compound and subsequently trimerizing the amidine groups of the bisamidine compound to form triazine linkages. The sulfonyl halide or sulfonate groups may then be converted to sulfonic acid groups, yielding a polymer electrolyte reinforced with a polytriazine.

Abstract: The invention describes a method of curing a polymerizable material containing ethylenically unsaturated bonds at a temperature of 60° C. or less, comprising the steps of (a) providing a curative comprising an effective amount of a light-stable isomer of a 2,4,5-triarylimidazolyl dimer, such as bilophine; (b) activating said curative by application of an activator selected from the group consisting of solvent and friction; and (c) combining the activated curative with the polymerizable material. Articles comprising an adhesive having a detackified surface, such as adhesive bandages, a detackifying solution, a two-part adhesive system, and a fastening system are also provided.

Abstract: An electronic device adapted for performing molecular biological processes. The device includes a flexible polymeric substrate having a first surface and a second surface. A plurality of microlocations interrupt the first surface, and each of said microlocations include an electrode disposed on the second surface of the flexible substrate. A hydrophilic matrix is positioned on the first surface of the flexible substrate and is capable of electrical contact with the electrode.