Abstract: A membrane electrode assembly comprises an anode electrode comprising an anode gas diffusion layer and an anode catalyst layer; a cathode electrode comprising a cathode gas diffusion layer and a cathode catalyst layer; and a polymer electrolyte membrane interposed between the anode catalyst layer and the cathode catalyst layer; wherein the cathode catalyst layer comprises: a first cathode catalyst sublayer adjacent the polymer electrolyte membrane, the first cathode catalyst sublayer comprising a first catalyst supported on a first carbonaceous support and a second catalyst supported on a second carbonaceous support; and a second cathode catalyst sublayer adjacent the cathode gas diffusion layer, the second cathode catalyst sublayer comprising a third catalyst supported on a third carbonaceous support; wherein the first carbonaceous support is carbon black and the second and third carbonaceous supports are graphitized carbon.

Abstract: A method for removing contaminants in a fuel cell comprises: supplying a hydrogen-based fuel to the anode; supplying a first oxidant to the cathode, wherein the first oxidant comprises at least some sulfur dioxide; drawing a primary load from the fuel cell stack while supplying the hydrogen-based fuel to the anode and the air to the cathode; shutting down the fuel cell when a voltage of the fuel cell is equal to or less than a threshold voltage at which sulfur crosses over from the cathode to the anode, wherein shutting down the fuel cell comprises: performing at least one oxidant starvation while drawing the primary load, removing the primary load after performing the at least one oxidant starvation, and bringing the anode to a high potential after removing the primary load; and thereafter, restarting the fuel cell.

Abstract: A method for removing contaminants in a fuel cell comprises: supplying a hydrogen-based fuel to the anode; supplying a first oxidant to the cathode, wherein the first oxidant comprises at least some sulfur dioxide; drawing a primary load from the fuel cell stack while supplying the hydrogen-based fuel to the anode and the air to the cathode; shutting down the fuel cell when a voltage of the fuel cell is equal to or less than a threshold voltage at which sulfur crosses over from the cathode to the anode, wherein shutting down the fuel cell comprises: performing at least one oxidant starvation while drawing the primary load, removing the primary load after performing the at least one oxidant starvation, and bringing the anode to a high potential after removing the primary load; and thereafter, restarting the fuel cell.

Abstract: The present invention is related to methods of making membrane electrode assembly components. The methods include transferring a catalyst layer to a polymer electrolyte membrane or a gas diffusion layer. Methods of making membrane electrode assemblies with these components are also disclosed.

Abstract: A system and method for starting up a fuel cell system are disclosed. Briefly described, an embodiment for starting an electrochemical reaction between a fuel and an oxidant during a start-up process includes a fuel cell stack operable to output a nominal voltage during a normal operating condition and operable to output a reduced start-up voltage during the start-up process, and includes at least one balance of plant (BOP) device that supports operation of the fuel cell stack, operable at a nominal output when sourced by the fuel cell stack at the nominal voltage, and operable at a reduced output when sourced by the fuel cell stack at the reduced start-up voltage.

Abstract: Improved water distribution can be obtained within the cells of a fuel cell series stack by maintaining a suitable temperature difference between the cathode and anode sides of each cell in the stack during shutdown. A method of shutting down a fuel cell stack having at least two fuel cells stacked in series, each fuel cell having a cathode side and an anode side, the method comprising: stopped the generation of electricity from the stack; allowing the stack to cool over a cooldown period; and maintaining a temperature difference between the cathode side and the anode side of each fuel cell during the cooldown period, wherein the direction of the temperature difference in each fuel cell is the same. The fuel cell stack may comprise coolant channels, Peltier devices and anode and cathode reactant flow fields.

Abstract: Improved water distribution can be obtained within the cells of a fuel cell series stack by maintaining a suitable temperature difference between the cathode and anode sides of each cell in the stack during shutdown. This can be accomplished by thermally insulating the “hot” end and sides of the stack and by providing a thermal mass adjacent to the “hot” end.

Abstract: A membrane exchange humidifier employs a water permeable membrane comprising a microporous polymer and a hydrophilic additive. In operation, the membrane preferably has favorable water transmission properties and resists transmission of reactant gas or other components. The membrane is suitable for use even when permeable in its dry condition to the wet or dry gases in the humidifier, and/or when the wet and dry gases are of different composition. By wetting the membrane, the presence of an amount of liquid water in the wet gas can reduce gas transmission through the membrane to an acceptable level. The humidifier is useful in fuel cell systems in which a reactant gas supply stream, such as the oxidant supply stream, is humidified primarily using water vapor from a fuel cell reactant exhaust stream. The humidifier is particularly suitable for use in conjunction with solid polymer fuel cell systems. The improved mechanical and welding properties of the membrane allow for a simpler humidifier configuration.

Abstract: An anode catalyst layer for a fuel cell is presented having first and second catalyst compositions and a hydrophobic binder. The first catalyst composition includes a noble metal, other than Ru, on a corrosion-resistant support material; the second catalyst composition contains a single-phase solid solution of a metal oxide containing Ru. The through-plane concentration of ionomer in the catalyst layer decreases as a function of distance from the membrane interface. Gas diffusion electrodes, catalyst-coated membranes, MEAs and fuel cells having the foregoing anode catalyst layer are also described.

Abstract: A water insoluble additive for improving the performance of an ion-exchange membrane, such as in the context of the high temperature operation of electrochemical fuel cells. The insoluble additive comprises a metal oxide cross-linked matrix having acid groups covalently attached to the matrix through linkers. In one embodiment, the metal is silicon and the cross-linked matrix is a siloxane cross-linked matrix containing silicon atoms cross-linked by multiple disiloxy bonds and having acid groups covalently attached to the silicon atoms through alkanediyl linkers.

Abstract: A significant problem in PEM fuel cell durability is in premature failure of the ion-exchange membrane and in particular by the degradation of the ion-exchange membrane by reactive hydrogen peroxide species. Such degradation can be reduced or eliminated by the presence of an additive in the anode, cathode or ion-exchange membrane. The additive may be a radical scavenger, a membrane cross-linker, a hydrogen peroxide decomposition catalyst and/or a hydrogen peroxide stabilizer. The presence of the additive in the membrane electrode assembly (MEA) may however result in reduced performance of the PEM fuel cell. Accordingly, it may be desirable to restrict the location of the additive to locations of increased susceptibility to membrane degradation such as the inlet and/or outlet regions of the MEA.

Abstract: An electric power generation system has elements that improve the cold start capability and freeze tolerance of a constituent fuel cell stack cooperate to reduce the amount of water remaining within the passages of the stack. The system includes a purge system that is connectable to the oxidant supply, fuel supply and/or coolant passages upstream of the stack. When the stack is shut down, the stack is disconnected from an external circuit, and purge fluid is transmitted by the purge system through the stack before the stack falls below the freezing point of water. In systems where fuel and/or oxidant streams are humidified prior to entry into the stack, a humidifier bypass system may be provided in place of the purge system. The humidifier bypass system transmits reactant fluid to the stack in fluid isolation from the humidifier, so that the inlet reactant streams are unhumidified.

Abstract: The invention relates to an ion-conductive polymer membrane for a fuel cell, whereby the polymer membrane is configured from a polymer-forming hydrocarbon material and to a method for producing the same. The membrane also has a metal-containing gel which has been hydrolysed and/or condensed from a metal alkoxide starting material and which is deposited in the polymer and/or is chemically bonded to the polymer. The proportion of metal alkoxide by weight, in relation to the membrane, lies between 25% and 1%.