Abstract: Disclosed are processes for producing a fuel cell electrode and a membrane electrode assembly. In one preferred embodiment, the process comprises (a) preparing a suspension of catalyst particles dispersed in a liquid medium containing a polymer dissolved or dispersed therein; (b) dispensing the suspension onto a primary surface of a substrate selected from an electronically conductive catalyst-backing layer (gas diffuser plate) or a solid electrolyte membrane; and (c) removing the liquid medium to form the electrode that is connected to or integral with the substrate, wherein the polymer is both ion-conductive and electron-conductive with an electronic conductivity no less than 10?4 S/cm and ionic conductivity no less than 10?5 S/cm and the polymer forms a coating in physical contact with the catalyst particles or coated on the catalyst particles.

Abstract: The present invention provides a light-weight, compact fuel cell that is well-suited to powering portable electronic devices and vehicles, particularly light-duty vehicles such as golf carts, forklifts, wheelchairs, motor bikes, and scooters. The fuel cell comprises the following major components: (a) a fuel anode; (b) an oxidant cathode comprising an alcohol-tolerant oxidant reduction catalyst; and (c) a liquid electrolyte in ionic contact with the anode and the cathode with the electrolyte comprising a solution and an alcohol fuel dissolved in the solution. The presently invented dissolved-fuel direct alcohol fuel cell eliminates the use of expensive polymer electrolyte membranes and, in general, do not require the use of expensive platinum as a catalyst material at the cathode and/or at the anode. The alcohol fuel may be selected from methanol, ethanol, propanol, isopropanol, formic acid, or a combination thereof. The electrolyte may comprise an acid or an alkaline solution.

Abstract: Disclosed is a process for exfoliating a layered material to produce nano-scaled platelets having a thickness smaller than 100 nm, typically smaller than 10 nm, and often between 0.34 nm and 1.02 nm. The process comprises: (a) subjecting a layered material to a gaseous environment at a first temperature and first pressure sufficient to cause gas species to penetrate between layers of the layered material, forming a gas-intercalated layered material; and (b) subjecting the gas-intercalated layered material to a second pressure, or a second pressure and a second temperature, allowing gas species to partially or completely escape from the layered material and thereby exfoliating the layered material to produce partially delaminated or totally separated platelets. The gaseous environment preferably contains only environmentally benign gases that are reactive (e.g., oxygen) or non-reactive (e.g., noble gases) with the layered material.

Abstract: Disclosed is a hybrid fiber tow that comprises multiple continuous filaments and nanoscale fillers embedded in the interstitial spaces between continuous filaments. Nanoscale fillers may be selected from a nanoscale graphene plate, non-graphite platelet, carbon nano-tube, nano-rod, carbon nano-fiber, non-carbon nano-fiber, or a combination thereof. Also disclosed are a hybrid fiber tow impregnated with a matrix material and a composite structure fabricated from a hybrid fiber tow. The composite exhibits improved physical properties (e.g., thermal conductivity) in a direction transverse to the continuous fiber axis. A roll-to-roll process for producing a continuous fiber tow or matrix-impregnated fiber tow and an automated process for producing composite structures containing both continuous filaments and nanoscale fillers are also provided.

Abstract: A controlled-release fuel cell comprising (a) a proton exchange membrane having a first surface and a second surface, a fuel electrode or anode being coupled to the first surface, and an oxidant electrode or cathode being coupled to the second surface; (b) a fuel flow field plate having surface channels positioned in front of the anode with the channels containing therein a controlled-release material that retains a liquid fuel at or below an ambient temperature, but releases the fuel at a temperature higher than an activation temperature to deliver a fuel vapor to the anode; (c) heating means in heat-supplying relation to the controlled-release material to activate fuel vapor release on demand at a desired rate; and (d) fuel supply means that feeds the liquid fuel to the controlled-release material. The invented fuel cell is compact and lightweight, with significantly reduced fuel crossover and improved fuel utilization efficiency.

Abstract: Disclosed is a nano-composite material comprising fully separated nano-scaled graphene platelets (NGPs) dispersed in a matrix material, wherein each of the platelets comprises a sheet of graphite plane or multiple sheets of graphite plane and has a thickness no greater than 100 nm and the platelets have an average length, width, or diameter no greater than 500 nm. The graphene plates are present in an amount no less than 15% by weight based on the total weight of the platelets and the matrix material combined. Typically, the nanocomposite is electrically conductive with a bulk conductivity no less than 10 S/cm and more typically no less than 100 S/cm. Highly conductive NGP nanocomposites are particularly useful for fuel cell flow field plate (bipolar plate) and battery electrode applications. Nanocomposites with high NGP proportions can be used in automotive friction plates and aircraft brake components.

Abstract: Disclosed are a nano-composite composition and a method of making such a composite that is composed of a matrix material and dispersed reinforcement nano-scaled graphene plates (NGPs) that are substantially aligned along at least one specified direction or axis. The method comprises: (a) providing a mixture of nano-scaled graphene plates (NGPs) and a matrix material in a fluent state; (b) extruding the mixture to form a filament wherein NGPs are aligned along a filament axis; (c) aligning a plurality of segments of the filament in a first direction, or moving the filament back and forth along a first direction and its opposite direction, to form a NGP-matrix filament preform; and (d) consolidating the preform to form the nanocomposite material. Also disclosed is a method of making a nano-composite fiber.

Abstract: A self-humidifying proton exchange membrane (PEM) composition, a membrane-electrode assembly, and a fuel cell. The PEM composition comprises (a) a proton-conducting polymer; (b) a catalyst that promotes the chemical reaction between hydrogen and oxygen molecules to generate water in the membrane, and (c) a deliquescent material dispersed in this polymer. The amount of catalyst is preferably 0.01%-50% by weight on the basis of the polymer weight. The catalyst is preferably a metal catalyst selected from the group consisting of platinum, gold, palladium, rhodium, iridium, ruthenium, and mixtures and alloys thereof. Suitable deliquescent materials include, but are not limited to, calcium chloride, calcium bromide, potassium biphosphate, potassium acetate and combinations thereof. A deliquescent material absorbs and retains an essentially constant amount of moisture to keep the proton mobile in the PEM structure.

Abstract: A fuel cell including primarily (a) a membrane electrode assembly, which comprises (i) a proton exchange membrane having a front face and a rear face, (ii) an anode being coupled to the front face, and (iii) a cathode being coupled to the rear face; (b) a fuel permeation-controlling member positioned in front of the anode; the member being substantially impermeable to an organic fuel or water at an ambient temperature or below, but being permeable at a temperature higher than an activation temperature; (c) heating means in control relation to the fuel permeation-controlling member to activate fuel permeation through the member on demand. The invented fuel cell is compact and lightweight, with significantly reduced fuel crossover and improved fuel utilization efficiency. The fuel cell is particularly useful for powering small vehicles and portable devices such as a notebook computer, a personal digital assistant, a mobile phone, and a digital camera.

Abstract: A hydrogen generator apparatus that delivers a hydrogen stream at a controlled rate to a fuel cell. The apparatus comprises a fuel tank, a wicking material in the fuel tank, a fluid retained in the wicking material, a first disc bounding the wicking material and comprising a hydrophilic membrane for receiving the fluid from the wicking material by a wicking pressure to form a fluid-wetted surface, a second disc having a porous surface area with the second disc being in contact with the first disc with the two discs moveable relative to each other, a catalyst on the porous surface to form a catalyst-coated surface, and hydrogen generated by hydrolyzation of the fluid contacting the catalyst due to a relative motion between the first disc and the second disc.

Abstract: An inorganic proton-conducting membrane and a fuel cell comprising this membrane. The fuel cell comprises a fuel anode, an oxidant cathode, and an inorganic proton-conducting membrane disposed between the anode and the cathode. The membrane is composed of a nano-structured network of proton-exchange inorganic particles. The particles form a sufficiently high density of proton-conducting nanometer-scaled channels with at least one dimension smaller than 100 nanometers so that ionic conductivity of the membrane is no less than 10?6 S/cm (mostly greater than 10?4 S/cm ) at 25° C. or no less than 10?4 S/cm (mostly greater than 10?2 S/cm) at 200° C. This inorganic membrane allows a hydrogen-oxygen fuel cell to operate at a higher temperature without the need (or with a reduced need) to maintain the membrane in a highly hydrated state. A higher operating temperature also implies a fast electro-catalytic reaction of a fuel (e.g.