Abstract: A bipolar plate assembly includes a first frame member, a second frame member, and a membrane electrode assembly. The first frame member has a first side and a second side. The first side has a first side protuberance. The second frame member includes a first side and a second side. The second side has a second side recess. The membrane electrode assembly has an anode plate and a cathode plate. A portion of the membrane electrode assembly is disposed between the first frame member and the second frame member. The portion of the membrane electrode assembly has a juxtaposition of the anode plate and the cathode plate. The first side protuberance of the first frame member deforms the portion of the membrane electrode assembly into the second side recess of the second frame member.

Abstract: A method for assembling a fuel cell humidifier can include steps of providing a first humidifier plate and a humidifier membrane. The first humidifier plate can have a first top plate surface. The humidifier membrane can have a bottom membrane surface. The bottom membrane surface of the humidifier membrane can be disposed on the first top plate surface of the first humidifier plate. The first humidifier plate can be partially melted. This can permit the first top plate surface of the first humidifier plate to permeate into the bottom membrane surface of the humidifier membrane. The first humidifier plate can be cooled, which can fuse the first top plate surface of the first humidifier plate with the bottom membrane surface of the humidifier membrane.

Abstract: A method for assembling a fuel cell humidifier can include steps of providing a first humidifier plate and a humidifier membrane. The first humidifier plate can have a first top plate surface. The humidifier membrane can have a bottom membrane surface. The bottom membrane surface of the humidifier membrane can be disposed on the first top plate surface of the first humidifier plate. The first humidifier plate can be partially melted. This can permit the first top plate surface of the first humidifier plate to permeate into the bottom membrane surface of the humidifier membrane. The first humidifier plate can be cooled, which can fuse the first top plate surface of the first humidifier plate with the bottom membrane surface of the humidifier membrane.

Abstract: A modular boost converter includes a fuel cell, a modular boost converter, a battery, a motor, and a capacitor. The modular boost converter includes a plurality of modules. Each of the plurality of modules include a boost system. Only one converter is necessary to utilize each of the fuel cell and the capacitor. The single converter can have a capacity to convert power greater than the energy of the fuel cell, but the total output power of the converter is less than the total energy provided by the fuel cell and the capacitor combined. The modular boost converter utilizes internal module switching to selectively draw energy from at least one of the fuel cell and the capacitor.

Abstract: A hybrid bipolar plate assembly for a fuel cell includes a formed cathode half plate and a stamped metal anode half plate. The stamped metal anode half plate is unnested with and affixed to the formed cathode half plate. Each of the half plates has a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures. The coolant side of the formed cathode half plate need not correspond with cathode flow channels formed on the opposite reactant side. The coolant side of the stamped metal anode half plate has lands corresponding with anode channels formed on the opposite oxidant side. The lands define a plurality of coolant channels on the coolant side of the stamped metal anode half plate and abut the coolant side of the formed cathode half plate.

Abstract: A modular boost converter includes a fuel cell, a modular boost converter, a battery, a motor, and a capacitor. The modular boost converter includes a plurality of modules. Each of the plurality of modules include a boost system. Only one converter is necessary to utilize each of the fuel cell and the capacitor. The single converter can have a capacity to convert power greater than the energy of the fuel cell, but the total output power of the converter is less than the total energy provided by the fuel cell and the capacitor combined. The modular boost converter utilizes internal module switching to selectively draw energy from at least one of the fuel cell and the capacitor.

Abstract: A method for assembling a fuel cell humidifier can include steps of providing a first humidifier plate and a humidifier membrane. The first humidifier plate can have a first top plate surface. The humidifier membrane can have a bottom membrane surface. The bottom membrane surface of the humidifier membrane can be disposed on the first top plate surface of the first humidifier plate. The first humidifier plate can be partially melted. This can permit the first top plate surface of the first humidifier plate to permeate into the bottom membrane surface of the humidifier membrane. The first humidifier plate can be cooled, which can fuse the first top plate surface of the first humidifier plate with the bottom membrane surface of the humidifier membrane.

Abstract: A bipolar plate assembly includes a first frame member, a second frame member, and a membrane electrode assembly. The first frame member has a first side and a second side. The first side has a first side protuberance. The second frame member includes a first side and a second side. The second side has a second side recess. The membrane electrode assembly has an anode plate and a cathode plate. A portion of the membrane electrode assembly is disposed between the first frame member and the second frame member. The portion of the membrane electrode assembly has a juxtaposition of the anode plate and the cathode plate. The first side protuberance of the first frame member deforms the portion of the membrane electrode assembly into the second side recess of the second frame member.

Abstract: A system for assembling a fuel cell stack can include a plurality of fuel cells, a dispenser, and a holder. The dispenser can be configured to successively transfer the fuel cells to the holder. The holder can be configured to successively receive the fuel cells. Each of the fuel cells can be received at a constant position along a first axis. The holder can also be configured to index each received fuel cell by a predetermined distance along the first axis, thereby forming the fuel cell stack. In addition, the holder can compress the fuel cell stack after the fuel cell stack is formed.

Abstract: A power conversion system includes a first voltage subsystem, a second voltage subsystem, a power conversion module, and a microcontroller module. The first voltage subsystem has a supply voltage and at least one first filter module. The supply voltage has a first portion and a second portion. The second voltage subsystem includes a converted voltage in series with the second portion of the supply voltage, and a plurality of second filter modules. The power conversion module is configured to convert the first portion of the supply voltage to the converted voltage. The microcontroller module is configured to control the power conversion module.

Abstract: A hybrid bipolar plate assembly for a fuel cell includes a formed cathode half plate and a stamped metal anode half plate. The stamped metal anode half plate is unnested with and affixed to the formed cathode half plate. Each of the half plates has a reactant side and a coolant side, a feed region, and a header with a plurality of header apertures. The coolant side of the formed cathode half plate need not correspond with cathode flow channels formed on the opposite reactant side. The coolant side of the stamped metal anode half plate has lands corresponding with anode channels formed on the opposite oxidant side. The lands define a plurality of coolant channels on the coolant side of the stamped metal anode half plate and abut the coolant side of the formed cathode half plate.

Abstract: A method for creating an oxygen depleted gas in a fuel cell system, including operating a fuel cell stack at a desired cathode stoichiometry at fuel cell system shutdown to displace a cathode exhaust gas with an oxygen depleted gas. The method further includes closing a cathode flow valve and turning off a compressor to stop the flow of cathode air.

Abstract: A system and method of producing electrical power from a solid waste stream is provided. The system includes a low tar gasification generator that receives a feedstock stream, such as a solid waste stream. The feedstock stream is gasified to produce a first gas stream that includes hydrogen, at least one contaminant and at least one diluent. At least one clean-up process is performed on the first gas stream to remove the at least one contaminant and generate a second gas stream. Electrical power is generated by a solid oxide fuel cell in response to receiving the second gas stream. The solid oxide fuel cell outputting an anode exhaust gas stream. A portion of the anode exhaust gas is vented to reduce the level of diluent in the second gas stream.

Abstract: A system and method of producing syngas from a solid waste stream is provided. The system includes a low tar gasification generator that gasifies the solid waste stream to produce a first gas stream. A process module cools the first gas stream and removes contaminants, such as metals, sulfur and carbon dioxide from the first gas stream to produce a second gas stream having hydrogen. The second gas stream is received by a power module that generates electrical power from the second gas stream. The process module may include one or more heat exchangers.

Abstract: A fuel cell system including a fuel cell stack having a plurality of fuel cells, each of the fuel cells including an electrolyte membrane disposed between an anode and a cathode, an anode supply manifold in fluid communication with the anodes of the fuel cells, the anode supply manifold providing fluid communication between a source of hydrogen and the anodes, an anode exhaust manifold in fluid communication with the anodes of the fuel cells, and a fan in fluid communication with the anodes of the fuel cells, wherein the fan controls a flow of fluid through the anodes of the fuel cells after the fuel cell system is shutdown.

Abstract: A system and method for reconditioning a fuel cell stack to recover stack voltage loss. The method includes first operating the fuel cell stack in a wet condition where the humidity level in the stack is above 100% to provide liquid water at the cell electrodes. The method then applies a low voltage potential to the stack that causes contaminants to be released from the catalyst surface of the cell electrodes. This step can include starving the cathode side of oxygen for a limited period of time. The method then causes water to flow through the stack so that the contaminants are flushed out of the stack. The process can be performed during vehicle operation where small amounts of voltage would be recovered or during vehicle service where a relatively large amount of voltage could be recovered.

Abstract: A method for creating an oxygen depleted gas in a fuel cell system, including operating a fuel cell stack at a desired cathode stoichiometry at fuel cell system shutdown to displace a cathode exhaust gas with an oxygen depleted gas. The method further includes closing a cathode flow valve and turning off a compressor to stop the flow of cathode air.

Abstract: A fuel cell system including a fuel cell stack having a plurality of fuel cells, the fuel cell stack including an anode supply manifold and an anode exhaust manifold, a first valve in fluid communication with at least one of the anode supply manifold and the anode exhaust manifold, wherein the first valve includes an inlet for receiving a fluid flow and an outlet for exhausting a fluid, a sensor for measuring at least a fluid pressure at the inlet and the outlet of the first valve, wherein the sensor generates a sensor signal representing the pressure measurement, and a processor for receiving the sensor signal, analyzing the sensor signal, and determining a composition of a fluid in the fuel cell system based upon the analysis of the sensor signal.

Abstract: A system and method for recovering fuel cell stack voltage loss through humidification control. The method includes determining a rate of contamination addition to a surface of a fuel cell electrode in the fuel cell stack and determining a rate of contamination removal from the surface of the fuel cell electrode. The method compares the rate of contamination addition to the rate of the contamination removal to determine whether contaminant surface coverage of the electrode is increasing or decreasing and, if increasing, determines whether the amount of contamination of the electrode is above a predetermined value, where, if so, stack reconditioning through wet stack operation may be performed.

Abstract: A fuel cell system is disclosed with a fuel cell stack having a plurality of fuel cells, the fuel cell stack including an external electrical circuit adapted to control current from the fuel cell stack, a sensor for measuring at least one of an environmental condition affecting the fuel cell stack and a characteristic of the fuel cell stack, wherein the sensor generates a sensor signal representing a measurement of the sensor, and a processor for receiving the sensor signal, analyzing the sensor signal, and controlling an adaptive load applied to the external electrical circuit based upon the analysis of the sensor signal.