Abstract: A fuel cell oxidation reduction reaction catalyst comprising a carbon substrate, an amorphous metal oxide intermediate layer on the substrate, and an intertwined matrix of platinum and elemental niobium arranged to form a surface metal layer covering the intermediate layer such that upon oxidation, the niobium binds with oxygen resulting in strengthened bonds between the platinum and the intermediate layer.

Abstract: A fuel cell system includes a plurality of fuel cells. Each of the fuel cells may include a current bypass device that is configured to flow a current responsive to an anode potential exceeding a cathode potential to prevent carbon corrosion within the fuel cell.

Abstract: A fuel cell system includes a plurality of fuel cells. Each of the fuel cells may include a current bypass device that is configured to flow a current responsive to an anode potential exceeding a cathode potential to prevent carbon corrosion within the fuel cell.

Abstract: A method of forming a fuel cell catalyst layer. The method includes spinning a composition including a base polymer, a solvent, and a catalyst precursor into a non-woven fiber mat having the catalyst precursor embedded therein. The method further includes carbonizing the non-woven fiber mat to form a carbon fiber substrate. The method also includes reacting the catalyst precursor to form a plurality of individual catalyst particles embedded in the carbon fiber substrate.

Abstract: According to one aspect of the present invention, there is provided a catalyst assembly. In one embodiment, the catalyst assembly includes a two-dimension (2-D) extensive catalyst including one or more precious catalytic metals and having a catalyst crystal plane; and a substrate supporting the 2-D extensive catalyst, the substrate including one or more non-precious catalytic metals and having a substrate crystal plane in substantial alignment with the catalyst crystal plane.

Abstract: A fuel cell oxidation reduction reaction catalyst comprising a carbon substrate, an amorphous metal oxide intermediate layer on the substrate, and an intertwined matrix of platinum and elemental niobium arranged to form a surface metal layer covering the intermediate layer such that upon oxidation, the niobium binds with oxygen resulting in strengthened bonds between the platinum and the intermediate layer.

Abstract: Fuel cell catalyst layers and methods of making the same are disclosed. The fuel cell catalyst layer may include a catalyst substrate including a non-woven mat of carbon nanofibers, each having a surface portion and a bulk portion bounded by the surface portion. A plurality of catalyst particles may be included in the catalyst layer, at least a first portion of which are fully embedded within the bulk portion of each of the carbon nanofibers. The method may include spinning a composition including a base polymer, a solvent, and a catalyst precursor into a non-woven fiber mat having the catalyst precursor embedded therein. The mat may then be carbonized to form a carbon fiber substrate and the catalyst precursor may be reacted to form catalyst particles embedded in the substrate. Embedding the catalyst particles may anchor them within the substrate and inhibit them from migrating during fuel cell operation.

Abstract: In one embodiment, the catalyst assembly includes a two-dimension (2-D) extensive catalyst having a catalyst crystal plane; and a substrate supporting the 2-D extensive catalyst and having a substrate crystal plane in substantial alignment with the catalyst crystal plane. In certain instances, the catalyst crystal plane includes first and second adjacent catalyst atoms defining a catalyst atomic distance, the substrate crystal plane includes first and second adjacent substrate atoms defining a substrate atomic distance, a percent difference between the catalyst and substrate atomic distances is less than 10 percent.

Abstract: A fuel cell assembly includes an anode with a catalyst layer and a gas inlet end, and a cathode with a catalyst layer and a gas inlet end. The assembly comprises a catalyst layer including a first and second set of catalyst segment pairs spaced apart respectively with first and second distances, a first ratio of an average segment width of the first set of catalyst segment pairs relative to the first distance being different from a second ratio of an average segment width of the second set of catalyst segment pairs relative to the second distance.

Abstract: In at least one embodiment, an oxygen reduction reaction catalyst (ORR) and a method for making the catalyst are provided. The method may include depositing a metal oxide on a graphitized carbon or graphene substrate. A platinum catalyst may then be deposited over the metal oxide to provide an ORR catalyst for use in, for example, a PEMFC. The metal oxide may be niobium oxide and may have an amorphous structure. The platinum catalyst may form a thin, electrically interconnected network structure overlaying the metal oxide. The ORR catalyst may be prepared by alternating the deposition of the metal oxide and the platinum catalyst, for example, using physical vapor deposition. The ORR catalyst may have a specific activity of at least 1,000 ?A/cm2 Pt and may approach or achieve bulk Pt activity.

Abstract: In at least one embodiment, a fuel cell is provided comprising a positive electrode including a first gas diffusion layer and a first catalyst layer, a negative electrode including a second gas diffusion layer and a second catalyst layer, a proton exchange membrane (PEM) disposed between the positive and negative electrodes, and a microporous layer of carbon and binder disposed between at least one of the first gas diffusion layer and the first catalyst layer and the second gas diffusion layer and the second catalyst layer. The microporous layer may have defined therein a plurality of pores with a diameter of 0.05 to 2.0 ?m and a plurality of bores having a diameter of 1 to 100 ?m. The bores may be laser perforated and comprise from 0.1 to 5 percent of a total porosity of the microporous layer.

Abstract: A fuel cell system may have at least one sensor including a pair of electrodes disposed on a substrate. The sensor may be configured to produce an output signal having a magnitude that is proportional to a relative humidity in a vicinity of the sensor and, if liquid water is on the sensor, proportional to an amount of the liquid water on the sensor.

Abstract: In at least one embodiment, an oxygen reduction reaction catalyst (ORR) and a method for making the catalyst are provided. The method may include depositing a metal oxide on a graphitized carbon or graphene substrate. A platinum catalyst may then be deposited over the metal oxide to provide an ORR catalyst for use in, for example, a PEMFC. The metal oxide may be niobium oxide and may have an amorphous structure. The platinum catalyst may form a thin, electrically interconnected network structure overlaying the metal oxide. The ORR catalyst may be prepared by alternating the deposition of the metal oxide and the platinum catalyst, for example, using physical vapor deposition. The ORR catalyst may have a specific activity of at least 1,000 ?A/cm2 Pt and may approach or achieve bulk Pt activity.

Abstract: A microporous layer forming a portion of a gas diffusion layer assembly positioned adjacent to a catalyst layer within a fuel cell electrode. The microporous includes a first carbon-based material layer comprising a plurality of hydrophobic pores with a diameter of 0.05 to 0.2 ?m and a plurality of bores with a diameter of 1 to 20 ?m. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.

Abstract: A spinning electrode fuel cell is disclosed. The spinning electrode fuel cell includes a housing and a stacked disk assembly which is rotatably mounted in the housing. The stacked disk assembly includes multiple electrochemical cells connected to each other. A motor engages the stacked disk assembly for rotating the stacked disk assembly in the housing. A fuel flow pathway is provided in the housing for distributing a fuel to the electrochemical cells. An oxidant flow pathway is provided in the housing and physically separated from the fuel flow pathway for distributing an oxidant to the electrochemical cells. A method of fabricating a fuel cell is also disclosed.

Abstract: In at least one embodiment, a microporous layer configured to be disposed between a catalyst layer and a gas diffusion layer of a fuel cell electrode assembly is provided. The microporous layer may have defined therein a plurality of hydrophilic pores, a plurality of hydrophobic pores with a diameter of 0.02 to 0.5 ?m, and a plurality of bores with a diameter of 0.5 to 100 ?m. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.

Abstract: A fuel cell includes a cathode having a first gas diffusion layer and a first catalyst layer, an anode including a second gas diffusion layer and a second catalyst layer and a proton exchange membrane disposed between the cathode and anode. A microporous layer is disposed between the first gas diffusion layer and the first catalyst layer. The microporous layer defines a plurality of domains extending between opposite surfaces of the microporous layer. Under freezing conditions the microporous layer is arranged to concentrate ice formation within the domains to reduce an amount of frozen water within the catalyst layer.

Abstract: A fuel cell assembly includes an anode with a catalyst layer and a gas inlet end, and a cathode with a catalyst layer and a gas inlet end. The assembly comprises a catalyst layer including a first and second set of catalyst segment pairs spaced apart respectively with first and second distances, a first ratio of an average segment width of the first set of catalyst segment pairs relative to the first distance being different from a second ratio of an average segment width of the second set of catalyst segment pairs relative to the second distance.

Abstract: In at least one embodiment, a microporous layer configured to be disposed between a catalyst layer and a gas diffusion layer of a fuel cell electrode assembly is provided. The microporous layer may have defined therein a plurality of hydrophilic pores, a plurality of hydrophobic pores with a diameter of 0.02 to 0.5 ?m, and a plurality of bores with a diameter of 0.5 to 100 ?m. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.

Abstract: In at least one embodiment, a fuel cell is provided comprising a positive electrode including a first gas diffusion layer and a first catalyst layer, a negative electrode including a second gas diffusion layer and a second catalyst layer, a proton exchange membrane (PEM) disposed between the positive and negative electrodes, and a microporous layer of carbon and binder disposed between at least one of the first gas diffusion layer and the first catalyst layer and the second gas diffusion layer and the second catalyst layer. The microporous layer may have defined therein a plurality of pores with a diameter of 0.05 to 2.0 ?m and a plurality of bores having a diameter of 1 to 100 ?m. The bores may be laser perforated and comprise from 0.1 to 5 percent of a total porosity of the microporous layer.