Abstract: A fluid manifold assembly for an array of electrochemical fuel cell stacks has a substantially fluid impermeable housing. Inlet passages are formed within the housing for introducing at least one inlet fluid stream to each of the fuel cell stacks. Outlet passages are formed within the housing for exhausting at least one outlet fluid stream from each of the fuel cell stacks.

Abstract: A catalytic hydrocarbon reformer operates at lower temperature and pressure relative to conventional reformers. Convective heat transfer between the hot combustion gas stream and the reactor tube is enhanced through use of a narrow gap heat transfer area, which induces turbulent flow of the combustion gas stream across the reactor tube. The reactor tube includes a catalyst fines collection tube to accumulate and retain catalyst particles or fines entrained in the reformate gas stream.

Abstract: An electrochemical fuel cell stack has a first end plate, a second end plate, and fuel cell assemblies interposed therebetween. Each fuel cell assembly includes a membrane electrode assembly having at least one manifold header opening formed in the assembly for directing at least one of a fluid fuel stream, a fluid oxidant stream and a fluid coolant stream through the assembly. A tie rod extends within the opening and through each of the first and second end plates. Fastening means are disposed at opposite ends of the tie rod. Compressive means are interposed between at least one of the fastening means and at least one of the first and second end plates. In operation, the fastening means and the compressive means urge the first end plate toward the second end plate, thereby applying compressive force to the fuel cell assemblies.

Abstract: A method and apparatus selectively oxidizes, within the fuel cell assembly, the carbon monoxide present in a fuel stream fed to the assembly. A quantity of catalyst is contained within at least a portion of a fuel stream passageway within the stack. The carbon monoxide is selectively oxidized by the catalyst to carbon dioxide, and carbon monoxide produced by the reverse water-shift reaction is also oxidized.

Abstract: An electrochemical fuel cell assembly includes a membrane electrode assembly which comprises an anode, a cathode having a surface thereof exposed to ambient air, and an ion exchange membrane interposed between the anode and the cathode. A seal forms a gas-impermeable barrier around the anode to which a gaseous fuel stream is supplied. The assembly further includes a thermally conductive plate having a plurality of thermally conductive members or fins extending from a major surface of the plate. The thermally conductive members contact portions of the exposed cathode surface. Adjacent thermally conductive members cooperate with the plate and the exposed cathode surface to form air conducting channels. Heat generated exothermically in the membrane electrode assembly is dissipated to the atmosphere through the thermally conductive members.

Abstract: A gasketed membrane electrode assembly for electrochemical fuel cells employs gasketing material at the periphery of the ion exchange membrane, rather than the membrane itself, as a gasket. The gasketing material may be formed from an elastomeric material suitable for cold bonding or bonding by heat and pressure. A nonhydrophilic thermoplastic elastomer is the preferred gasketing material. The gasketed membrane electrode assembly provides a seal between the electrically conductive separator plates that is more effective and economical than assemblies employing the membrane itself as the gasketing material. In an alternative embodiment, a gasketed membrane assembly for use in the humidification portion of a fuel cell employs gasketing material at the periphery of a water permeable membrane.

Abstract: A method and apparatus are provided for reducing the concentration of carbon monoxide in a gaseous reactant stream comprising carbon monoxide and water vapor. The catalyst bed of a water gas shift reactor is preferably divided into two sections. Alternatively, an assembly which includes two sequential reactors can be employed. The first section or reactor operates in an adiabatic fashion whereas the second section or reactor is cooled, thereby facilitating the further conversion of carbon monoxide in the second section or reactor. The gaseous reactant stream exiting the second section or reactor typically has a carbon monoxide concentration in the range from about 0.06% to about 0.14% by volume.

Abstract: A method and apparatus is provided for removing water accumulated at the cathode of an electrochemical fuel cell incorporating a solid polymer ion exchange membrane. Liquid water accumulated at the cathode can be removed by maintaining a partial pressure of water vapor in the hydrogen-containing gas supply below the saturation pressure of water vapor therein such that water accumulated at the cathode is drawn by a concentration gradient toward the anode across the membrane and is absorbed as water vapor into the hydrogen-containing gas supply between the inlet and the outlet. In one embodiment, the partial pressure of water vapor in the hydrogen-containing gas supply is maintained below the saturation pressure of water vapor therein by imparting a pressure drop between the inlet and the outlet sufficient to draw water accumulated at the cathode toward the anode.

Abstract: An electric power generation system has a regulated vacuum ejector for recirculating the fluid fuel stream. The system includes a fuel cell stack, a pressurized fuel supply having a pressure control valve for regulating the pressure of the fuel supply, a vacuum ejector interposed between the fuel supply and the stack fuel stream inlet, a pressure transducer interposed between the ejector discharge outlet and the stack fuel stream inlet, and a pressurized oxidant supply with a pressure transducer. The ejector suction inlet is fluidly connected to the fuel stream outlet of the fuel cell stack. The fuel stream pressure transducer transmits a signal to the pressure control valve to adjust the pressure of the fuel supply when the detected pressure of the fuel stream deviates from a predetermined value. The oxidant stream pressure transducer transmits a signal to the pressure control valve to adjust the pressure of the fuel supply when the detected pressure of the oxidant stream changes.

Abstract: A method and apparatus oxidizes the carbon monoxide present in an incoming reactant fuel stream and/or carbon monoxide produced by the reverse water-shift reaction to carbon dioxide in a reactant stream introduced to an electrochemical fuel cell. The reactant stream comprises hydrogen, carbon dioxide and carbon monoxide. A first oxygen-containing gas stream is introduced into the reactant stream through a first port disposed between the reactant stream inlet and the reactant stream outlet. A further oxygen-containing gas stream is introduced into the reactant stream through at least one secondary port located between the first port and the reactant stream outlet.

Abstract: Polymeric compositions are derived from copolymers of .alpha.,.beta.,.beta.-trifluorostyrene with a variety of substituted .alpha.,.beta.,.beta.-trifluorostyrenes. These compositions are suitable for use as membranes, particularly as ion-exchange membranes, and most particularly as solid polymer electrolytes in electrochemical applications, such as, for example, electrochemical fuel cells.

Abstract: An electrochemical fuel cell stack has a humidification section located upstream from the electrochemically active section. The inlet fuel and oxidant streams are introduced into the humidification section without first being directed through the electrochemically active section. The upstream location of the humidification section in the stack enables the number of manifold openings in the active section to be reduced, thereby increasing the area available for the electrochemical reaction.

Abstract: A method and apparatus for providing a substantially constant output voltage from a fuel cell, notwithstanding output current variations, is disclosed. The voltage and secondarily the current of the cell is determined at least periodically. The pressure of the reactant gas in the fuel cell is then regulated so substantially the nominal voltage is maintained. The temperature in the fuel cell may also be regulated to maintain the nominal output voltage. Also, a method and apparatus for minimizing the parasitic power drain in a electric power generation system is disclosed. The fuel cell is fed with an reactant gas by a compressor driven by parasitic power drawn from the fuel cell.

Abstract: A solid polymer fuel cell electric power generation system removes a substantial portion of water accumulated at the cathode in the outlet fuel stream of the anode. The system permits the operation of a hydrogen/oxygen fuel cell in a dead-ended mode where substantially pure oxygen is employed as the oxidant supply or using low oxygen stoichiometry where a dilute oxidant source, such as oxygen-containing air, is employed as the oxidant supply. The system thereby eliminates the need for an oxygen recirculation pump in systems operating on substantially pure oxygen, and substantially reduces the parasitic load to pressurize the oxidant stream in systems operating on dilute oxidant streams.

Abstract: A power plant system produces utility grade electrical AC power from gaseous or liquid hydrocarbon fuels using a fuel cell stack employing ion exchange membranes. The fuel is desulfurized, mixed with water, heated and vaporized before being introduced into a reformer. The reformer produces a hydrogen-rich gas which is then directed through a series of heat exchangers, shift converters and a selective oxidizer. The processed fuel stream is combined in the fuel cell stack with a pressurized oxidant stream to generate DC power. Oxidant pressure is supplied by compressors driven by turbines using heated system exhaust gases. The DC power is converted into utility grade AC power using an inverter augmented by a battery peaking unit for rapid load following. The water generated in the fuel cell stack is recycled and used to cool the fuel cell stack and to humidify the fuel stream and oxidant stream prior to their introduction to the fuel cell stack.

Abstract: A method and apparatus for selectively oxidizing the carbon monoxide present in a mixture of gases, including hydrogen, to carbon dioxide is disclosed. Oxygen or an oxygen-containing gas mixture is introduced at locations along the latter portion of the reaction chamber in an isothermal reactor to selectively oxidize the carbon monoxide to carbon dioxide and to suppress the reverse water-shift reaction, which produces carbon monoxide and water from carbon dioxide and hydrogen.

Abstract: A laminated fluid flow field assembly for an electrochemical fuel cell comprises a separator layer and a stencil layer. The separator layer is formed of electrically conductive, substantially fluid impermeable sheet material. The stencil layer is formed of electrically conductive sheet material, and has a fluid inlet and at least one opening extending between its major surfaces and in fluid communication with the fluid inlet. The separator layer and the stencil layer are consolidated along one of their major surfaces. In operation, the separator layer and the stencil layer cooperate to form an open-faced channel for conducting pressurized fluid introduced at the fluid inlet.

Abstract: A membrane electrode and seal assembly for an electrochemical fuel cell comprises first and second layers of porous electrically conductive sheet material, such as carbon fiber paper. The sheet material layers have a solid polymer ion exchange membrane interposed therebetween. The sheet material layers cover and support the membrane over substantially its entire surface area. The sheet material layers are coated with a catalyst to render them electrochemically active, and are bonded together with the membrane to form a consolidated assembly. Openings are formed in the layers of sheet material and the membrane to accommodate the passage of fluids through the assembly. Channels formed in the layers of sheet material generally circumscribe the openings and the electrochemically active region of the sheet material. Solid preformed gaskets are disposed in the channels. The gasketing technique can also be applied to the membrane and seal assemblies of the humidification portion of fuel cell stacks.

Abstract: A method and apparatus is provided for removing water accumulated at the cathode of an electrochemical fuel cell incorporating a solid polymer ion exchange membrane. Liquid water accumulated at the cathode can be removed by maintaining a partial pressure of water vapor in the hydrogen-containing gas supply below the saturation pressure of water vapor therein such that water accumulated at the cathode is drawn by a concentration gradient toward the anode across the membrane and is absorbed as water vapor into the hydrogen-containing gas supply between the inlet and the outlet. In one embodiment, the partial pressure of water vapor in the hydrogen-containing gas supply is maintained below the saturation pressure of water vapor therein by imparting a pressure drop between the inlet and the outlet sufficient to draw water accumulated at the cathode toward the anode.

Abstract: An electrochemical fuel cell is provided for converting a fuel reactant stream and an oxidant reactant stream to a reaction product stream and electrical energy. The fuel cell includes a membrane electrode assembly interposed between two separator layers. The separator layers are formed of thin electrically conductive sheet material which is substantially impermeable to the fuel and oxidant reactant streams. The membrane electrode assembly comprises first and second electrode layers formed of porous electrically conductive sheet material. The electrode layers have a catalyst associated therewith, and an ion exchange membrane is interposed between the first and second electrode layers. The electrode layers include passages, such as the interstitial spaces within the electrode material or grooves formed in the surface of the electrode material, for flowing a reactant stream between an inlet and outlet within the electrode layer.