Abstract: A cooler-humidifier plate for use in a proton exchange membrane (PEM) fuel cell stack assembly is provided. The cooler-humidifier plate combines functions of cooling and humidification within the fuel cell stack assembly, thereby providing a more compact structure, simpler manifolding, and reduced reject heat from the fuel cell. Coolant on the cooler side of the plate removes heat generated within the fuel cell assembly. Heat is also removed by the humidifier side of the plate for use in evaporating the humidification water. On the humidifier side of the plate, evaporating water humidifies reactant gas flowing over a moistened wick. After exiting the humidifier side of the plate, humidified reactant gas provides needed moisture to the proton exchange membranes used in the fuel cell stack assembly.

Abstract: A fluid flow passage bridgepiece for insertion into an open-face fluid flow channel of a fluid flow plate is provided. The bridgepiece provides a sealed passage from a columnar fluid flow manifold to the flow channel, thereby preventing undesirable leakage into and out of the columnar fluid flow manifold. When deployed in the various fluid flow plates that are used in a Proton Exchange Membrane (PEM) fuel cell, bridgepieces of this invention prevent mixing of reactant gases, leakage of coolant or humidification water, and occlusion of the fluid flow channel by gasket material. The invention also provides a fluid flow plate assembly including an insertable bridgepiece, a fluid flow plate adapted for use with an insertable bridgepiece, and a method of manufacturing a fluid flow plate with an insertable fluid flow passage bridgepiece.

Abstract: A fluid flow plate includes a generally porous portion and a generally non-porous portion which together form on a first surface of the plate, a flow channel having at least one turn for distributing a reactant gas in a fuel cell. The porous portion defines an outer lateral portion of the at least one turn. Such fluid flow plate(s) provide a water management scheme for a fuel cell and/or fuel cell assembly in which the turn(s) in a flow channel of the fluid flow plate(s) are used for multi-point per flow channel addition, removal, and/or redistribution of water for regulation of the humidity of a stream of reactant gas for membrane hydration and/or cooling. Desirably, for removal of water, the inertia of large water droplets moving along with the reactant gas through the flow channel impact the porous portion which forms the outer lateral portion of the turn(s).

Abstract: Fluid service and/or electrical conductivity for a fuel cell assembly is promoted. Open-faced flow channel(s) are formed in a flow field plate face, and extend in the flow field plate face between entry and exit fluid manifolds. A resilient gas diffusion layer is located between the flow field plate face and a membrane electrode assembly, fluidly serviced with the open-faced flow channel(s). The resilient gas diffusion layer is restrained against entering the open-faced flow channel(s) under a compressive force applied to the fuel cell assembly. In particular, a first side of a support member abuts the flow field plate face, and a second side of the support member abuts the resilient gas diffusion layer. The support member is formed with a plurality of openings extending between the first and second sides of the support member. In addition, a clamping pressure is maintained for an interface between the resilient gas diffusion layer and a portion of the membrane electrode assembly.

Abstract: A fuel cell assembly has a current conducting end plate with a conductive body formed integrally with isolating material. The conductive body has a first surface, a second surface opposite the first surface, and an electrical connector. The first surface has an exposed portion for conducting current between a working section of the fuel cell assembly and the electrical connector. The isolating material is positioned on at least a portion of the second surface. The conductive body can have support passage(s) extending therethrough for receiving structural member(s) of the fuel cell assembly. Isolating material can electrically isolate the conductive body from the structural member(s). The conductive body can have service passage(s) extending therethrough for servicing one or more fluids for the fuel cell assembly. Isolating material can chemically isolate the one or more fluids from the conductive body. The isolating material can also electrically isolate the conductive body from the one or more fluids.

Abstract: A hydration system includes fuel cell fluid flow plate(s) and injection port(s). Each plate has flow channel(s) with respective inlet(s) for receiving respective portion(s) of a given stream of reactant fluid for a fuel cell. Each injection port injects a portion of liquid water directly into its respective flow channel in order to mix its respective portion of liquid water with the corresponding portion of the stream. This serves to hydrate at least corresponding part(s) of a given membrane of the corresponding fuel cell(s). The hydration system may be augmented by a metering system including flow regulator(s). Each flow regulator meters an injecting at inlet(s) of each plate of respective portions of liquid into respective portion(s) of a given stream of fluid by corresponding injection port(s).

Abstract: An integrated system includes a fuel cell assembly for supplying electrical power to a building, a furnace having a heating chamber and a heat exchanger for supplying heat to the building, and a reformer for providing a supply of reformate directly to the furnace and the fuel cell assembly. The system may include a controller for apportioning the supply of reformate to the fuel cell assembly and to the furnace in response to heating and electrical power needs of the building. In another embodiment, an integrated system includes a fuel cell assembly for providing electrical power to a building, a reformer/furnace unit comprising a chamber and a heat exchanger for providing heat to a building, and wherein fuel is reformed/oxidized in a fuel-rich environment in said chamber to produce a supply of reformate for said fuel cell assembly, and in a fuel-lean environment in said chamber for releasing heat.

Abstract: A fluid flow plate includes first and second outward faces. Each of the outward faces has a flow channel thereon for carrying respective fluid. At least one of the fluids serves as reactant fluid for a fuel cell of a fuel cell assembly. One or more pockets are formed between the first and second outward faces for decreasing density of the fluid flow plate. A given flow channel can include one or more end sections and an intermediate section. An interposed member can be positioned between the outward faces at an interface between an intermediate section, of one of the outward faces, and an end section, of that outward face. The interposed member can serve to isolate the reactant fluid from the opposing outward face. The intermediate section(s) of flow channel(s) on an outward face are preferably formed as a folded expanse.

Abstract: A Proton Exchange Membrane (PEM) fuel cell stack is disclosed having multiple layers between a first end plate and a second end plate. The multiple layers define multiple fuel cell sub-stacks disposed in parallel and electrically isolated from each other intermediate the end plates. At the end plates, the fuel cell sub-stacks are electrically connected in series. At least some layers of the fuel cell stack comprise shared layers shared between multiple sub-stacks, and at least some layers of the multiple layers comprise dedicated layers for corresponding fuel cell sub-stacks. The shared layers include a fluid flow plate assembly and a membrane electrode assembly, while the dedicated layers comprise gas diffusion layers. The fluid flow plate assembly is fabricated of a non-conductive material and has multiple conductive fluid flow sub-plates, each of which aligns to a respective sub-stack of the fuel cell stack.

Abstract: Isolator(s) include isolating material and optionally gasketing material strategically positioned within a fuel cell assembly. The isolating material is disposed between a solid electrolyte and a metal flow field plate. Reactant fluid carried by flow field plate channel(s) forms a generally transverse electrochemical gradient. The isolator(s) serve to isolate electrochemically a portion of the flow field plate, for example, transversely outward from the channel(s), from the electrochemical gradient. Further, the isolator(s) serve to protect a portion of the solid electrolyte from metallic ions.

Abstract: The fuel cell stack includes sequential fuel cell membrane elements of polymer membrane with a cathode side and an anode side. The polymer membrane is held in place by an elastomeric gasket which includes flow channels leading to manifold passages which deliver hydrogen or other fuel gas to the anode side of the fuel cell membrane element and deliver air or oxygen to the cathode side of the fuel cell membrane assembly. The fuel cells are separated by fuel separator assemblies comprised of metallic foil with strips of porous graphite thereon. Cooling plates which receive cooling water are interspersed within the stack. The entire stack is held in place by a plastic resin shell. The various elements are compressed together by an upper platen with a limited range of travel which is urged toward the cell by air pressure, an air-filled bladder, an array of compression springs, or by similar methods.