Abstract: A fuel cell system and associated method of operation includes assembling a fuel cell stack including an exhaust valve, flowing a premixed gas containing carbon monoxide therethrough; and closing the exhaust valve, including prior to storage. Subsequently, the exhaust valve may be opened and a refresh operation may be executed to purge the carbon monoxide from the fuel cell stack.

Abstract: A method for forming a caged electrocatalyst particles for fuel cell applications include a step of forming modified particles having a porous SiO2 shell on a surface of platinum-containing particles. The modified particles are subjected to acid treatment or electrochemical oxidation to remove a portion of the platinum-containing particle thereby creating caged electrocatalyst particles having a gap between the platinum-containing particles and their SiO2 shell.

Abstract: A method of forming a catalyst-containing electrode layer for a polymer electrolyte membrane (PEM) fuel involves permeating an electrode layer with a liquid additive composition that comprises an ionic liquid additive and a carrier solvent. The electrode layer is then dried to remove the carrier solvent and deposit the ionic liquid additive within the electrode layer. The ionic liquid additive may be an organic cation of an ionic liquid, an organic anion of an ionic liquid, or both an organic cation and an organic anion of an ionic liquid. Once the electrode layer with its internal loading of the ionic liquid additive has been formed, a polymer electrolyte membrane fuel cell may be assembled such that the electrode layer constitutes either an anode layer or a cathode layer of the PEM fuel cell.

Abstract: A method of making a fuel cell including the following steps: comprising: (a) mixing carbon nanotubes (CNT) with an initial dispersion, wherein the initial dispersion includes an ionomer; (b) heating and stirring the initial dispersion to form a CNT-ionomer composite suspension; (c) after forming the CNT-ionomer composite suspension, mixing the CNT-ionomer composite suspension with an electrode catalyst solution to form an electrode ink, wherein the electrode catalyst solution includes a carbon black powder and a catalyst supported by the carbon black powder; and (d) coating a proton exchange membrane with the electrode ink to form the fuel cell electrode.

Abstract: A method for forming a corrosion-resistant catalyst for fuel cell catalyst layers is provided. The method includes a step of depositing a conformal Pt or platinum alloy thin layer on NbO2 substrate particles to form Pt-coated NbO2. The Pt-coated NbO2 particles are then incorporated into a fuel cell catalyst layer.

Abstract: A method of making a fuel cell including the following steps: comprising: (a) mixing carbon nanotubes (CNT) with an initial dispersion, wherein the initial dispersion includes an ionomer; (b) heating and stirring the initial dispersion to form a CNT-ionomer composite suspension; (c) after forming the CNT-ionomer composite suspension, mixing the CNT-ionomer composite suspension with an electrode catalyst solution to form an electrode ink, wherein the electrode catalyst solution includes a carbon black powder and a catalyst supported by the carbon black powder; and (d) coating a proton exchange membrane with the electrode ink to form the fuel cell electrode.

Abstract: A coated substrate for forming fuel cell catalyst layers includes a plurality of substrate particles, an adhesion layer disposed over the substrate particles, and a precious metal layer disposed over the adhesion layer. The substrate particles may be carbon powders, carbon nanorods, carbon nanotubes and combinations thereof; with a preferred aspect ratio from 10:1 to 25:1. The adhesion layer includes a tungsten metal layer and may be formed into a heterogeneous layer comprising a lattice-interrupting layer interposed between two tungsten metal layers. The lattice-interrupting layer reduces mechanical stress to the adhesion layer with extended thickness that may develop when it experiences changing environments, and can be any layer other than the metal layer, for example, Al2O3, Al, or WOx, where x is 1.5 to 3.0. Characteristically, the coated substrate is used in fuel cell applications such as providing the catalyst particles used in the cathode and/or anode catalyst layers.

Abstract: A method for forming a carbon supported catalyst includes a step of providing a first carbon supported catalyst having a platinum-group metal supported on a first carbon support. Characteristically, the first carbon support has a first average micropore diameter and a first average carbon surface area. The first carbon supported catalyst is contacted with an oxygen-containing gas at a temperature less than about 450° C. for a predetermined period of time to form a second carbon supported catalyst, wherein the first carbon support or the second carbon supported catalyst is acid leached.

Abstract: A method for forming a carbon supported catalyst includes a step of providing a first carbon supported catalyst having a platinum-group metal supported on a first carbon support. Characteristically, the first carbon support has a first average micropore diameter and a first average carbon surface area. The first carbon supported catalyst is contacted with an oxygen-containing gas at a temperature less than about 450° C. for a predetermined period of time to form a second carbon supported catalyst, wherein the first carbon support or the second carbon supported catalyst is acid leached.

Abstract: A method for forming a fuel cell catalyst includes a step of forming an ionomer-containing layer including carbon particles and an ionomer. Tungsten-nickel alloy particles are formed on the carbon particles. At least a portion of the nickel in the tungsten-nickel alloy particles is replaced with palladium to form palladium-coated particles. The palladium-coated particles include a palladium shell covering the tungsten-nickel alloy particles. The palladium-coated particles are coated with platinum to form an electrode layer including core shell catalysts distributed therein.

Abstract: A method for making tungsten-alloy nanoparticles that are useful for fuel cell applications includes a step of combining a solvent system and a surfactant to form a first mixture. A tungsten precursor is introduced into the first mixture to form a tungsten precursor suspension. The tungsten precursor suspension is heated to form tungsten nanoparticles. The tungsten nanoparticles are combined with carbon particles to form carbon-nanoparticle composite particles. The carbon-nanoparticle composite particles are combined with a metal salt to form carbon-nanoparticle composite particles with adhered metal salt, the metal salt including a metal other than tungsten. The third solvent system is then removed. A two-stage heat treatment is applied to the carbon-nanoparticle composite particles with adhered metal salt to form carbon supported tungsten-alloy nanoparticles. A method for making carbon supported tungsten alloys by reducing a tungsten salt and a metal salt is also provided.

Abstract: One embodiment includes a method of forming a hydrophilic particle containing electrode including providing a catalyst; providing hydrophilic particles suspended in a liquid to form a liquid suspension; contacting said catalyst with said liquid suspension; and, drying said liquid suspension contacting said catalyst to leave said hydrophilic particles attached to said catalyst.

Abstract: A method for forming a corrosion-resistant catalyst for fuel cell catalyst layers is provided. The method includes a step of depositing a conformal Pt or platinum alloy thin layer on NbO2 substrate particles to form Pt-coated NbO2. The Pt-coated NbO2 particles are then incorporated into a fuel cell catalyst layer.

Abstract: A carbon supported catalyst includes a carbon support having an average micropore diameter is less than about 70 angstroms and a platinum-group metal being disposed over the carbon support. A method for making the carbon supported catalyst includes a step of providing a first carbon supported catalyst having a platinum-group metal supported on a carbon support. The first carbon supported catalyst has a first average micropore diameter, and a first average surface area. The first carbon supported catalyst is contacted with an oxygen-containing gas at a temperature less than about 250° C. for a predetermined period of time to form a second carbon supported catalyst. The second carbon supported catalyst has a second average pore diameter and a second average surface area. Characteristically, the second average pore diameter is greater than the first average pore diameter, and the second average surface area is less than the first average surface area.

Abstract: A method for forming a fuel cell catalyst includes a step of forming an ionomer-containing layer including carbon particles and an ionomer. Tungsten-nickel alloy particles are formed on the carbon particles. At least a portion of the nickel in the tungsten-nickel alloy particles is replaced with palladium to form palladium-coated particles. The palladium-coated particles include a palladium shell covering the tungsten-nickel alloy particles. The palladium-coated particles are coated with platinum to form an electrode layer including core shell catalysts distributed therein.

Abstract: A method for preparing hollow platinum or platinum-alloy catalysts includes a step of forming a plurality of low-melting-point metal nanoparticles. A platinum or platinum-alloy coating is then deposited onto the low-melting-point metal nanoparticles to form platinum or platinum-alloy coated particles. The low-melting-point metal nanoparticles are then removed to form a plurality of hollow platinum or platinum-alloy particles.

Abstract: A method for forming a caged electrocatalyst particles for fuel cell applications include a step of forming modified particles having a porous SiO2 shell on a surface of platinum-containing particles. The modified particles are subjected to acid treatment or electrochemical oxidation to remove a portion of the platinum-containing particle thereby creating caged electrocatalyst particles having a gap between the platinum-containing particles and their SiO2 shell.

Abstract: One embodiment includes a method of forming a hydrophilic particle containing electrode including providing a catalyst; providing hydrophilic particles suspended in a liquid to form a liquid suspension; contacting said catalyst with said liquid suspension; and, drying said liquid suspension contacting said catalyst to leave said hydrophilic particles attached to said catalyst.

Abstract: A fuel cell including at least one of a hydrophilic interlayer and a flow field treated to impart hydrophilic properties is disclosed, wherein the hydrophilic interlayer and the treated flow field militate against water accumulation in ultrathin electrodes of the fuel cell, particularly for cool-start operating conditions (i.e. about 0° C. to about 60° C.).

Abstract: A method for making tungsten-alloy nanoparticles that are useful for fuel cell applications includes a step of combining a solvent system and a surfactant to form a first mixture. A tungsten precursor is introduced into the first mixture to form a tungsten precursor suspension. The tungsten precursor suspension is heated to form tungsten nanoparticles. The tungsten nanoparticles are combined with carbon particles to form carbon-nanoparticle composite particles. The carbon-nanoparticle composite particles are combined with a metal salt to form carbon-nanoparticle composite particles with adhered metal salt, the metal salt including a metal other than tungsten. The third solvent system is then removed. A two-stage heat treatment is applied to the carbon-nanoparticle composite particles with adhered metal salt to form carbon supported tungsten-alloy nanoparticles. A method for making carbon supported tungsten alloys by reducing a tungsten salt and a metal salt is also provided.