Abstract: Disclosed herein are embodiments of an apparatus for preparing rotating disk electrodes. One such apparatus comprises a base, a plurality of disk mounts attached to the base, each configured to receive a respective rotating disk, a plurality of motors each coupled to a corresponding one of the plurality of disk mounts and configured to rotate the corresponding one of the plurality of disk mounts and a controller configured to individually operate each of the plurality of motors.

Abstract: Disclosed herein are catalyst degradation detection assemblies and methods of catalyst degradation detection that can be performed in-situ. One embodiment of an in-situ fuel cell catalyst degradation detection assembly comprises a humidified hydrogen supply configured to supply humidified hydrogen to an anode of a fuel cell, a humidified nitrogen supply configured to supply humidified nitrogen to a cathode of the fuel cell, a collection cell containing a liquid, the collection cell configured to receive either cathode exhaust from the fuel cell through a cathode exhaust line or anode exhaust from the fuel cell through an anode exhaust line and means for detecting a gas.

Abstract: Disclosed herein are systems and methods for recovering performance of fuel cells by recovering fuel cell catalyst activity. One system for recovering catalyst performance of a fuel cell stack made of one or more fuel cells in a vehicle comprises a sensor for detecting an EOL state of the fuel cell. A notification device notifies a user when the sensor detects the EOL state of the fuel cell. Means for drawing a steady-state load from the fuel cell stack is used to operate the fuel cell stack until the catalyst performance is recovered.

Abstract: Disclosed herein are processes for recovering performance of fuel cells by recovering fuel cell catalyst activity and methods of testing the durability and activity performance of fuel cells. One catalyst recovery process disclosed herein for a fuel cell having a membrane electrode assembly comprises operating the fuel cell for a first recovery cycle with fuel gas supplied to an anode of the fuel cell and an oxidant supplied to a cathode of the fuel cell while drawing a current from the fuel cell at steady state throughout the first recovery cycle, the first recovery cycle having a predetermined time period. The fuel cell has reached end of life due in part to intermittent use prior to operating the fuel cell for the first recovery cycle. A life of the fuel cell improves when the first recovery cycle is complete.

Abstract: Embodiments of suspension clamps for use in testing membrane samples used in fuel cells are provided. One example of a suspension clamp comprises a frame, a clamp member, a plurality of electrodes, and a suspension component. The clamp member is hingedly attached to one end of the frame. Each of the plurality of electrodes extends along a membrane-facing surface of at least one of the clamp member and the frame. A suspension component is attached to at least one of the clamp member and the frame and is configured to suspend the suspension clamp during testing of a membrane sample. The suspension clamp can be used to measure one or more of resistance, impedance, conductance, proton permeability and through-thickness of the membrane sample.

Abstract: Methods of fabricating gas diffusion electrodes and gas diffusion electrodes made from such methods are disclosed herein. One method of fabricating a gas diffusion electrode for a fuel cell comprises preparing a catalyst ink of a predetermined viscosity. Preparing the catalyst ink comprises mixing a catalyst solution comprising catalyst particles, an ionomer and a solvent at a first speed for a first period of time and homogenizing the catalyst solution at a second speed in a temperature controlled environment for a second period of time, wherein the second period of time is longer than the first period of time, the second period of time and the second speed selected to preserve a structure of the catalyst particles during homogenization. An active electrode layer is formed by spraying the catalyst ink directly on a gas diffusion layer in a single application and a uniform loading.

Abstract: Disclosed herein are systems and methods of diagnosing in situ the health of a fuel cell stack while it is in operation in a vehicle. One such system of diagnosing in situ the health of a fuel cell stack while it is in operation in a vehicle comprises at least one gas sensor configured to detect a gas in exhaust from the fuel cell stack and a control unit configured to receive data from the gas sensor. The control unit has baseline data particular to a catalyst of the fuel cell stack and is programmed to determine information from the baseline data and the data from the gas sensor, the information providing a condition of the fuel cell stack. A display unit is configured to display an indication of the condition.

Abstract: A water uptake measurement system for measuring uptake of a fluid by a sample includes a sample chamber, a suspension component and a supply interface. A suspension aperture is located at a first end of the sample chamber and extends from an outer surface of the sample chamber to an inner surface of the sample chamber. The suspension component passes through the suspension aperture and is configured to support the sample within the internal cavity such that the sample is spaced apart from the inner surface of the sample chamber. The supply interface is configured to deliver the fluid to the internal cavity of the sample chamber.

Abstract: Disclosed herein are embodiments of an apparatus for analysis of electrochemical dissolution. One embodiment comprises a working electrode submerged in a first reaction chamber containing liquid electrolyte, a counter electrode submerged in a second reaction chamber containing liquid electrolyte, a reference electrode submerged in a third reaction chamber and electrolytically connected to the working electrode and an ion conductor electrolytically connecting the first reaction chamber and the second reaction chamber while physically separating the first reaction chamber and the second reaction chamber.

Abstract: Disclosed herein are embodiments of an apparatus for preparing rotating disk electrodes. One such apparatus comprises a base, a plurality of disk mounts attached to the base, each configured to receive a respective rotating disk, a plurality of motors each coupled to a corresponding one of the plurality of disk mounts and configured to rotate the corresponding one of the plurality of disk mounts and a controller configured to individually operate each of the plurality of motors.

Abstract: Disclosed herein are methods and devices for evaluating ex-situ chemical degradation of fuel cell membranes. One embodiment of a method for evaluating ex-situ chemical degradation of a membrane comprises submerging a membrane in Fenton solution in a reaction vessel with a non-reactive weight configured to maximize exposure of the membrane to the Fenton solution, sealing the reaction vessel, heating the reaction vessel at a fixed rate to a predetermined temperature, holding the reaction vessel at the predetermined temperature for a predetermined test period, cooling the reaction vessel to room temperature, removing the membrane and analyzing the Fenton solution for fluoride ions.

Abstract: Disclosed herein are fluid distribution methods and assemblies for supplying fluid to test assemblies. One embodiment of a fluid distribution assembly comprises at least two input lines each configured to supply a fluid. A source selection component is connected to the input lines and configured to receive the fluid of the input lines and select from the fluids a target fluid. A range selection component is configured to receive the target fluid and to select a flow range of the target fluid, outputting the target fluid to a flow component comprising a first flow adjustment component having a first flow rate resolution and a second flow adjustment component having a second flow rate resolution. The range selection component is configured to selectively output the target fluid to one of the first flow adjustment component and the second flow adjustment component based on the selected flow range.

Abstract: Disclosed herein are systems and methods of diagnosing in situ the health of a fuel cell stack while it is in operation in a vehicle. One such system of diagnosing in situ the health of a fuel cell stack while it is in operation in a vehicle comprises at least one gas sensor configured to detect a gas in exhaust from the fuel cell stack and a control unit configured to receive data from the gas sensor. The control unit has baseline data particular to a catalyst of the fuel cell stack and is programmed to determine information from the baseline data and the data from the gas sensor, the information providing a condition of the fuel cell stack. A display unit is configured to display an indication of the condition.

Abstract: Disclosed herein are methods and devices for evaluating ex-situ chemical degradation of fuel cell membranes. One embodiment of a method for evaluating ex-situ chemical degradation of a membrane comprises submerging a membrane in Fenton solution in a reaction vessel with a non-reactive weight configured to maximize exposure of the membrane to the Fenton solution, sealing the reaction vessel, heating the reaction vessel at a fixed rate to a predetermined temperature, holding the reaction vessel at the predetermined temperature for a predetermined test period, cooling the reaction vessel to room temperature, removing the membrane and analyzing the Fenton solution for fluoride ions.

Abstract: Disclosed herein are catalyst degradation detection assemblies and methods of catalyst degradation detection that can be performed in-situ. One embodiment of an in-situ fuel cell catalyst degradation detection assembly comprises a humidified hydrogen supply configured to supply humidified hydrogen to an anode of a fuel cell, a humidified nitrogen supply configured to supply humidified nitrogen to a cathode of the fuel cell, a collection cell containing a liquid, the collection cell configured to receive either cathode exhaust from the fuel cell through a cathode exhaust line or anode exhaust from the fuel cell through an anode exhaust line and means for detecting a gas.

Abstract: Disclosed herein are methods of making a membrane electrode assembly for a fuel cell. One method disclosed herein comprises preparing a catalyst ink of a predetermined viscosity, masking an electrode substrate having a first surface and a second surface on the first surface with a magnetic mask, spraying the catalyst ink on the first surface of the electrode substrate, and drying the catalyst ink by heating the electrode substrate and the magnetic mask in an oven at a predetermined temperature for a predetermined period of time.

Abstract: Embodiments of suspension clamps for use in testing membrane samples used in fuel cells are provided. One example of a suspension clamp comprises a frame, a clamp member, a plurality of electrodes, and a suspension component. The clamp member is hingedly attached to one end of the frame. Each of the plurality of electrodes extends along a membrane-facing surface of at least one of the clamp member and the frame. A suspension component is attached to at least one of the clamp member and the frame and is configured to suspend the suspension clamp during testing of a membrane sample. The suspension clamp can be used to measure one or more of resistance, impedance, conductance, proton permeability and through-thickness of the membrane sample.

Abstract: Disclosed herein are systems and methods for recovering performance of fuel cells by recovering fuel cell catalyst activity. One system for recovering catalyst performance of a fuel cell stack made of one or more fuel cells in a vehicle comprises a sensor for detecting an EOL state of the fuel cell. A notification device notifies a user when the sensor detects the EOL state of the fuel cell. Means for drawing a steady-state load from the fuel cell stack is used to operate the fuel cell stack until the catalyst performance is recovered.

Abstract: Disclosed herein are processes for recovering performance of fuel cells by recovering fuel cell catalyst activity and methods of testing the durability and activity performance of fuel cells. One catalyst recovery process disclosed herein for a fuel cell having a membrane electrode assembly comprises operating the fuel cell for a first recovery cycle with fuel gas supplied to an anode of the fuel cell and an oxidant supplied to a cathode of the fuel cell while drawing a current from the fuel cell at steady state throughout the first recovery cycle, the first recovery cycle having a predetermined time period. The fuel cell has reached end of life due in part to intermittent use prior to operating the fuel cell for the first recovery cycle. A life of the fuel cell improves when the first recovery cycle is complete.

Abstract: Methods of fabricating gas diffusion electrodes and gas diffusion electrodes made from such methods are disclosed herein. One method of fabricating a gas diffusion electrode for a fuel cell comprises preparing a catalyst ink of a predetermined viscosity. Preparing the catalyst ink comprises mixing a catalyst solution comprising catalyst particles, an ionomer and a solvent at a first speed for a first period of time and homogenizing the catalyst solution at a second speed in a temperature controlled environment for a second period of time, wherein the second period of time is longer than the first period of time, the second period of time and the second speed selected to preserve a structure of the catalyst particles during homogenization. An active electrode layer is formed by spraying the catalyst ink directly on a gas diffusion layer in a single application and a uniform loading.