Abstract: An illustrative example fuel cell device includes a cell stack assembly of a plurality of fuel cells that each include an anode and a cathode. A pressure plate is situated near one end of the cell stack assembly. An intermediate component is situated between the end of the cell stack assembly and the pressure plate. The intermediate component includes a porous material in at least two fluid reservoirs and a barrier between the two fluid reservoirs to prevent fluid communication between the reservoirs.

Abstract: An illustrative example fuel cell assembly includes at least one cooler and a plurality of fuel cells each having an anode and a cathode. Each of the anodes includes an anode flow plate configured to allow fuel to flow through the anode. The anode flow plates have a respective flow resistance that varies among at least some of the anodes based on a distance between the corresponding anode and the cooler.

Abstract: An illustrative example fuel cell cooler plate includes a first side configured to be received adjacent a fuel cell component and a second side facing opposite the first side. The first side defines a first surface area of the plate. An edge is transverse to the first side and the second side. The edge has a surface area that is less than the first surface area. A first coolant passage within the plate is closer to the second side than the first side. A second coolant passage is between the first side and the first coolant passage. The second coolant passage is in a heat exchange relationship with the first coolant passage.

Abstract: An illustrative example fuel cell assembly includes a plurality of cells respectively including at least an electrolyte layer, an anode flow plate on one side of the electrolyte layer, and a cathode flow plate on an opposite side of the electrolyte layer. At least one cooler is situated adjacent a first one of the cells. The cooler is closer to that first one of the cells than it is to a second one of the cells. The cathode flow plates respectively include a plurality of flow channels and the anode flow plates respectively include a plurality of flow channels. The anode flow plates respectively include some of the flow channels in a condensation zone of the fuel cell assembly. The flow channels of the anode flow plate in the condensation zone of the first one of the cells have a first flow capacity. The flow channels of the anode flow plate of the second one of the cells that are in the condensation zone have a second flow capacity. The second flow capacity is greater than the first flow capacity.

Abstract: An illustrative example fuel cell power plant includes a cell stack assembly, a single stage convertor configured to couple the cell stack assembly to a power network, and a controller that is configured to determine whether the fuel cell power plant has a DC voltage brownout condition during an islanded mode of operation. The controller dynamically adjusts the frequency droop gain of the power plant using an offset while satisfying at least three criteria of a set of criteria consisting of (i) avoiding overloading other fuel cell power plants of the power network, (ii) avoiding exceeding a maximum load step-up capability of the power network, (iii) avoiding exceeding a maximum load step-up capability of the fuel cell power plant, (iv) maintaining a system frequency within an acceptable frequency range, and (v) avoiding repeating the DC voltage brownout condition.

Abstract: An illustrative example fuel cell manifold assembly includes a metal manifold pan. A polymer material liner that is self-supporting includes a primary wall situated adjacent an interior of the manifold pan. The liner has a channel around a periphery of the liner and a portion of the manifold is received in the channel. A reactant conduit adapter is received through respective openings in the manifold pan and the liner. The reactant conduit adaptor includes a flange that is received against an interior surface on the primary wall of the liner with an interface between the flange and the interior surface being sealed. Another portion of the reactant conduit adaptor is adjacent an exterior of the manifold pan that faces in an opposite direction from the interior surface on the primary wall.

Abstract: An illustrative example fuel cell device includes a cell stack assembly of a plurality of fuel cells that each include an anode and a cathode. A pressure plate is situated near one end of the cell stack assembly. A spacer between the end of the cell stack assembly and the pressure plate has a length, a width, and a height. The height of the spacer defines a spacing between the pressure plate and the end of the cell stack assembly. The spacer has a plurality of ribs that define at least two fluid reservoirs. At least one of the ribs separates the fluid reservoirs so that fluid in one of the reservoirs is isolated from fluid in the other.

Abstract: An illustrative example reformer includes a housing having an inlet plenum, a reforming section, and an outlet. The inlet plenum includes a catalyst situated where a source fluid passing through the inlet plenum will be exposed to the catalyst prior to entering the reforming section.

Abstract: An illustrated example method of making a porous carbon composite includes mixing a carbon-based material, a binder and pore former particles to establish a mixture. The mixture is placed into a mold where it is subjected to pressure at an ambient temperature to form a compacted body. Subsequently, the compacted body is heated to a temperature that causes at least partial removal of the pore former particles to establish pores in place of at least some of the pore former particles.

Abstract: An illustrative example system includes at least one fuel cell that is configured to generate electricity based on an electrochemical reaction. The fuel cell includes an exhaust. A heat pump includes an evaporator, a condenser, a compressor, and an expansion valve. A coolant loop is external to the at least one fuel cell. The coolant loop has a first portion associated with the exhaust such that heat from the exhaust increases a temperature of coolant fluid in the first portion. The coolant loop has a second portion downstream of the first portion. The second portion of the coolant loop is associated with the evaporator such that heat from the coolant fluid in the second portion increases the temperature of the evaporator.

Abstract: A composite plate (26) is formed in a mold (8) by placing one of two preforms (15, 23) of between about 80 wt. % and about 85 wt. % flake graphite, balance polymer binder, into the mold and disposing a coolant tube array (18) thereon, depositing a powder (21) of the flake/polymer around the tube array, placing a second preform on the powder and a mold plunger (27) on the second preform, heating the mold to the melting temperature of the polymer under a pressure of 625 psi (4311 kPa), cooling the mold to the solidification temperature of the polymer while still under pressure, cooling the mold further, disassembling the mold, and removing the composite plate. The composite plate has reactant gas flow field channels (31, 32) in major surfaces thereof, is devoid of any acid edge protection layer or film and is devoid of any acid impervious separator plate between either of the fuel cell reactant gas flow fields and the coolant tube array.

Abstract: An illustrative example enclosure includes a support frame having longitudinal beams and lateral channel members that define an outward facing flow passage. A first roof panel and a second roof panel respectively include lateral edges aligned with the channel members. The lateral edge of the first roof panel is situated adjacent the lateral edge of the second roof panel. An interface between the lateral edge of the first roof panel and the lateral edge of the second roof panel is situated above or within the flow passage of one of the channel members. At least one seal engages the first roof panel and the second roof panel. The seal is received in the flow passage of the channel member in sealing engagement with the channel member.

Abstract: A cloud tower (11) receives microscopic particles (18) impelled by an inert gas (17) for deposition on a porous substrate (29) having vacuum (34) disposed on opposite side. To alter the size and/or shape of the deposition field without changing the entire tower structure, a pair of flaps (43, 44) are hinged (47, 48) on one side or on a pair of opposed sides of the cloud primary tower. Another embodiment places selectable tower inserts (36, 38) within the primary tower structure, fitting therein and sealing thereto.

Abstract: An illustrative example cell stack assembly includes a plurality of fuel cells that each include a cathode electrode, an anode electrode and a matrix for holding a liquid acid electrolyte. The electrodes have lateral outside edges that are generally coplanar. A plurality of separator plates are respectively between the cathode electrode of one of the fuel cells and the anode electrode of an adjacent one of the fuel cells. The separator plates have lateral outside edges that are generally coplanar with the lateral outside edges of the electrodes. A plurality of barriers along at least one of the lateral outside edges of respective ones of the separator plates extend outwardly beyond the lateral outside edges of the electrodes and separator plates. The barriers inhibit acid migration between one of the electrodes on one side of the barrier and one of the electrodes on an opposite side of the barrier.

Abstract: A stack (10) of fuel cells (11) is manufactured with barriers (32) to prevent migration of a liquid electrolyte (such as phosphoric acid) out of the cells (11). The barrier (32) is secured within a step (34) formed within a land region (28) of a separator plate assembly (18) and extends from an edge (30) of the separator plate assembly (18) all or a portion of a distance between the edge (30) and a flow channel (24) defined within the separator plate assembly (18). The barrier (32) also extends away from the edge (30) a distance of between 0.051 and about 2.0 millimeters (about 2 and about 80 mils. The barrier (32) includes a hydrophobic, polymeric film (36), a pressure sensitive adhesive (38) as an assembly aid, and a fluoroelastomer bonding agent (40).

Abstract: The thermal profile of one or more fuel cells (10) cooled by coolant flowing in coolant flow passageways (30, 31, 33, 34, 37-41, 45-50) is tailored by providing selected material (65, 68) adjacent a portion (33b) of the coolant passageway; the selected material has a different thermal transfer characteristic than material surrounding other portions of the coolant passageway. The material may be more insulative or more conductive. The material may be wrapping (65), such as shrink wrap, about a coolant tube, or it may be altered material (68) in a molding material.

Abstract: An illustrative example embodiment of a fuel cell includes a cathode electrode, an anode electrode, and a porous matrix layer between the electrodes. The porous matrix layer includes pores and solids. The solids comprises at least 90% boron phosphate. A phosphoric acid electrolyte is within the pores of the matrix layer.

Abstract: According to an example embodiment, a method of making a fuel cell component includes permeating at least a portion of a component layer with a polymer. The portion of the component layer is adjacent an edge of the component layer. Some of the polymer is allowed to extend beyond the edge to thereby establish a flap beyond the edge of the component layer. A fuel cell component includes a component layer having a portion adjacent an edge of the layer that is impregnated with a polymer material and a flap of the polymer material extending beyond the edge.

Abstract: According to an example embodiment, a method of making a phosphoric acid fuel cell component includes situating at least one polymer film layer against a permeable component layer. The polymer film layer comprises a polymer that is chemically resistant to phosphoric acid. The polymer film layer is melted. The permeable component layer is impregnated with the melted polymer to thereby establish a region on the component layer that is impermeable to phosphoric acid. The impregnated region also provides a seal against reactant leakage from the component.

Abstract: A cylindrical shift converter (4) is disposed within an annular heat exchanger (28, 24) which has an outer wall (5). A plurality of spiral rods (90) create a plurality of spiral gas passages (26a) between the outer wall and a thin shell (92). The outer diameter of the thin shell is at least about 3/16 inch (about 4 mm) less than the inner diameter of an inner wall (20) of an annular hydrodesulfurizer (10), to facilitate inserting the shift converter and heat exchanger into the hydrodesulfurizer to form a unitized assembly (2). The spiral passages open into the hydrodesulfurizer.