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: 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: One embodiment includes at least one of the anode and cathode of a fuel cell comprises a first layer and a second layer in intimate contact with each other. Both the first layer and the second layer comprise a catalyst capable of catalyzing an electrochemical reaction of a reactant gas. The second layer has a higher porosity than the first layer. A membrane electrode assembly (MEA) based on the layered electrode configuration and a process of making a fuel cell are also described.

Abstract: Combustion heaters having internal combustion chambers are located adjacent the end cells of a stack of fuel cells to directly, conductively heat the end cells during cold start-up of the stack. Similar heater(s) may also be located within the stack when cold starting under extremely cold conditions. A method of combustion thawing a fuel cell stack is described.

Abstract: A method of operating a fuel cell system is disclosed, the method including the steps of providing a fuel cell stack including a plurality of fuel cell assemblies, each fuel cell assembly having a proton exchange membrane disposed between a plurality of fuel cell plates, wherein water is purged from the fuel cell system during a shutdown operation, and a current is produced in the fuel cell system following the shutdown purge to produce product water to hydrate the proton exchange membrane.

Abstract: Systems of checking thermal-induced circulation of a coolant in a fuel cell stack are disclosed. The system includes coolant inlet and outlet lines extending from a fuel cell stack. A pump and a radiator are confluently connected to the coolant inlet and coolant outlet lines. In one embodiment, a valve (either check type or automatic type) is provided in the coolant outlet line at the bottom of the fuel cell stack to prevent the flow of cold coolant from the coolant outlet line into the fuel cell stack upon start-up of the fuel cell stack. In another embodiment, a valve (either one-way flow control type or automatic type) is provided in the coolant inlet line at the top of the fuel cell stack. A method of checking thermal-induced circulation of a coolant in a fuel cell stack is also disclosed.

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: One embodiment includes at least one of the anode and cathode of a fuel cell comprises a first layer and a second layer in intimate contact with each other. Both the first layer and the second layer comprise a catalyst capable of catalyzing an electrochemical reaction of a reactant gas. The second layer has a higher porosity than the first layer. A membrane electrode assembly (MEA) based on the layered electrode configuration and a process of making a fuel cell are also described.

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: Systems of checking thermal-induced circulation of a coolant in a fuel cell stack are disclosed. The system includes coolant inlet and outlet lines extending from a fuel cell stack. A pump and a radiator are confluently connected to the coolant inlet and coolant outlet lines. In one embodiment, a valve (either check type or automatic type) is provided in the coolant outlet line at the bottom of the fuel cell stack to prevent the flow of cold coolant from the coolant outlet line into the fuel cell stack upon start-up of the fuel cell stack. In another embodiment, a valve (either one-way flow control type or automatic type) is provided in the coolant inlet line at the top of the fuel cell stack. A method of checking thermal-induced circulation of a coolant in a fuel cell stack is also disclosed.

Abstract: Systems of checking thermal-induced circulation of a coolant in a fuel cell stack are disclosed. The system includes coolant inlet and outlet lines extending from a fuel cell stack. A pump and a radiator are confluently connected to the coolant inlet and coolant outlet lines. In one embodiment, a valve (either check type or automatic type) is provided in the coolant outlet line at the bottom of the fuel cell stack to prevent the flow of cold coolant from the coolant outlet line into the fuel cell stack upon start-up of the fuel cell stack. In another embodiment, a valve (either one-way flow control type or automatic type) is provided in the coolant inlet line at the top of the fuel cell stack. A method of checking thermal-induced circulation of a coolant in a fuel cell stack is also disclosed.

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 catalyst ink composition for a fuel cell electrode is provided. The catalyst ink composition includes: an ionomer; at least one solvent; a quantity of nanostructured thin film support cores; a catalyst formed from a precious metal, the catalyst coated onto the nanostructured thin film support cores; and a quantity of particles. The particles are configured to provide an electrode porosity that militates against excess water accumulation in the electrode formed from the ink composition upon a drying thereof. An electrode for a fuel cell and a method of fabricating the electrode with the catalyst ink composition are also provided.

Abstract: A gasket for a fuel cell, wherein the gasket includes the use of two or more different materials as the gasket. For example, ethylene propylene diene monomer (EPDM) and/or the like, or another more chemically inert gasket material, is located inside or on an inboard position and is the wetted material that is exposed to the fuel cell operating environment. Silicone and/or the like, or another potentially contaminating material with better cold temperature sealability, is located outside or on an outboard position and does not come in contact with the fuel cell internal environment. One method of constructing such a gasket would be two include two parallel bead traces of the gasket materials on a polyimide (e.g., KAPTON®) carrier, or the like.

Abstract: A method of operating a fuel cell system is disclosed, the method including the steps of providing a fuel cell stack including a plurality of fuel cell assemblies, each fuel cell assembly having a proton exchange membrane disposed between a plurality of fuel cell plates, wherein water is purged from the fuel cell system during a shutdown operation, and a current is produced in the fuel cell system following the shutdown purge to produce product water to hydrate the proton exchange membrane.

Abstract: A system and method for determining the internal temperature of a fuel cell stack during stack start-up so as to start a cooling fluid flow before the internal temperature of the stack rises above a temperature that might damage the fuel cells within the stack. The system and method include determining an initial temperature from either an ambient temperature sensor or a sensor in the cooling fluid manifold in the stack, measuring the voltage of the stack and the current from the stack, and from these values determining the waste heat from the stack to determine its temperature. If hydrogen is sent to the cathode side of the stack during the start-up, then the system and method also include determining the flow rate of the hydrogen.

Abstract: The present invention is directed to mitigating overuse of limited membrane regions in electrochemical conversion assemblies, particularly under cold start conditions. In accordance with one embodiment of the present invention, the anode and/or cathode flowfield plates of an electrochemical conversion assembly are configured such that the fluid header region defines an anode fluid header, a cathode fluid header, and a coolant fluid header configured such that a feed region of the plate defines an array of substantially linear fluid channels extending from an acutely angled header/feed interface defined on the plate to a feed/active interface defined across the entire active area of the plate.

Abstract: A gasket for a fuel cell, wherein the gasket includes the use of two or more different materials as the gasket. For example, ethylene propylene diene monomer (EPDM) and/or the like, or another more chemically inert gasket material, is located inside or on an inboard position and is the wetted material that is exposed to the fuel cell operating environment. Silicone and/or the like, or another potentially contaminating material with better cold temperature sealability, is located outside or on an outboard position and does not come in contact with the fuel cell internal environment. One method of constructing such a gasket would be two include two parallel bead traces of the gasket materials on a polyimide (e.g., KAPTON®) carrier, or the like.

Abstract: A method for starting a frozen fuel cell stack includes discontinuing reactant humidification before shutting down the fuel cell stack. The anode and cathode are purged with the dry reactants. The fuel cell stack is soaked at freezing temperatures. During subsequent startup, dry reactants are initially delivered. An outlet temperature of the anode and a current load of the fuel cell stack are measured. The dry reactants are shut off when the temperature of the anode outlet or the current load reach predetermined values. The open circuit voltage potential of the fuel cells is monitored and compared to a first voltage value. When the open circuit voltage exceeds the first value, the fuel cell stack begins supplying current load. The current load of the fuel cell stack is increased or decreased based on a difference between the minimum voltage and a second voltage value.