Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) coating a hydrophobic microporous layer across the substrate; (3) coating a catalyst layer onto the hydrophobic microporous layer in the AA region; (4) coating a first fuel cell membrane ionomer layer onto the catalyst layer in the AA region and onto the hydrophobic microporous layer in the WVT region; (5) optionally applying a membrane support layer to the first fuel cell membrane ionomer layer in the AA region and the WVT region; (6) optionally applying a coating of second fuel cell membrane ionomer layer thereby forming a coated substrate; and (7) assembling the coated substrate to a companion coated substrate.

Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) simultaneously coating a microporous layer, a catalyst layer, and a first membrane ionomer layer onto the substrate; (3) applying an optional membrane support layer to the first membrane ionomer layer in the AA region and the WVT region; (4) applying an optional second membrane ionomer layer; (5) heating treating a coated substrate; and (6) assembling the coated substrate to a companion coated substrate.

Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) simultaneously coating a microporous layer, a catalyst layer, and a first membrane ionomer layer onto the substrate; (3) applying an optional membrane support layer to the first membrane ionomer layer in the AA region and the WVT region; (4) applying an optional second membrane ionomer layer; (5) heating treating a coated substrate; and (6) assembling the coated substrate to a companion coated substrate.

Abstract: The present disclosure provides a method for manufacturing an integrated MEA, the method includes the following steps: (1) providing a substrate having an AA region and a WVT region; (2) coating a hydrophobic microporous layer across the substrate; (3) coating a catalyst layer onto the hydrophobic microporous layer in the AA region; (4) coating a first fuel cell membrane ionomer layer onto the catalyst layer in the AA region and onto the hydrophobic microporous layer in the WVT region; (5) optionally applying a membrane support layer to the first fuel cell membrane ionomer layer in the AA region and the WVT region; (6) optionally applying a coating of second fuel cell membrane ionomer layer thereby forming a coated substrate; and (7) assembling the coated substrate to a companion coated substrate.

Abstract: The present disclosure provides an integrated fuel cell having a water vapor transfer region wherein the integrated fuel cell includes a first bipolar plate, a second bipolar plate, and a membrane electrode assembly (MEA) disposed between the first and second bipolar plates. The membrane electrode assembly further includes a water vapor transfer portion and at least one active area portion configured to generate electricity and provide a water byproduct upon facilitating a reaction involving an input stream containing hydrogen and an input stream containing oxygen.

Abstract: Systems and methods are disclosed that provide for a fuel cell stack assembly including stack end cells that facilitate improved diagnostic and detection capabilities. In certain embodiments, an anode side of a FC stack end cell consistent with embodiments disclosed herein may be configured to have a lower anode gas flow rate than other cells in the FC stack. The cathode side of a FC stack end cell consistent with embodiments disclosed herein may be further configured to have a higher gas flow rate than other cells in the FC stack. Embodiments of the disclosed FC stack end cells may, among other things, allow for detection of adverse conditions and/or events in a FC stack assembly prior to such conditions and/or events negatively affecting other cells in the FC stack.

Abstract: The present invention is directed to an electroconductive element within an electrochemical cell that improves water management. The electroconductive element comprises an impermeable electrically conductive element and a porous liquid distribution media disposed along a major surface of the conductive element. Preferably, the liquid distribution media is in direct contact and fluid communication with a fluid distribution layer disposed between the membrane electrode assembly (MEA) and the liquid distribution media, so that liquids are drawn from the MEA through the fluid distribution layer to and through the liquid distribution media. The liquid distribution media transports liquids away from the MEA in the fuel cell. Methods of fabricating and operating fuel cells and electroconductive elements according to the present invention are also contemplated.

Abstract: A diffusion media is provided for implementation with a PEM fuel cell. The diffusion media is a permeable sheet that is rigid along a transverse axis, flexible along a lateral axis and has a substantially incompressible thickness. The diffusion media is able to be mass produced in large sheets and rolled along the lateral axis for transport and storage. The rigidity of the transverse axis is provided by either inclusion of larger fibers or metallic strips aligned in the transverse direction and prevents tenting of the diffusion media into flow channels of the PEM fuel cell. The diffusion media is water and gas permeable and electrically conductive.

Abstract: A porous diffusion media according to the present invention is positioned against a catalyst layer of the membrane electrode assembly, the porous matrix comprises carbon paper, and the water transfer particles comprise carbon fibers or powders. Relatively high and relatively low water transfer particle density regions alternate across the porous diffusion media. A first major face of the media may be collectively more hydrophilic than the second major face and the second major face may be collectively more hydrophobic than the first major face. The diffusion media is positioned against the catalyst layer along the first major face of the diffusion media and against a flow field of the fuel cell along the second major face of the diffusion media. The porous diffusion media comprises hydrophobic material disposed along the second major face of the diffusion media.

Abstract: Gas diffusion media for use in fuel cells are provided that contain a pattern of deposited hydrophobic polymer such that less than 100% of the surface of the diffusion media is covered with hydrophobic polymer. The media are made by first wetting a sheet of carbon fiber paper in an aqueous emulsion of the hydrophobic polymer. The wetted sheet is contacted with a pattern member containing one or more openings oriented to correspond to a predetermined or desired pattern of hydrophobic polymer deposition. While still in contact with the pattern member, the sheet is heated or otherwise treated to cause evaporation of the water from the sheet. Evaporation while in contact with the pattern member takes place in such a way that hydrophobic polymer is concentrated in the sheet at the openings of the pattern member by the process of evaporation.

Abstract: Favorable performance of diffusion media in fuel cells has found to be correlated to a parameter (the C/F ratio) that relates to a spatial and thickness distribution of the hydrophobic fluoropolymer on the carbon fiber substrate structure of the medium. Suitable diffusion media may be chosen from among commercially coated diffusion media by measuring the C/F ratio by means of energy dispersive spectroscopy, and choosing the diffusion media if the value of the C/F ratio is within the preferred range. Alternatively, the diffusion media may be manufactured with an improved process that consistently yields values of C/F ratio in the desired range.

Abstract: Specially prepared gas diffusion media improve the performance of PEM fuel cells. The media are made by first dipping an electrically conductive porous material such as carbon fiber paper into a suspension of hydrophobic polymer and drying the paper to create a desired deposition pattern of hydrophobic polymer on the substrate. Then a paste containing a fluorocarbon polymer and carbon particles is applied to a desired side of the substrate, and thereafter the paste and hydrophobic polymer are sintered together at high temperature on the paper. In particular, nonionic surfactants remain on the carbon fiber paper after the initial hydrophobic polymer is applied to the electrically conductive porous material. When the paste is coated on the dried paper, the paste is in contact with a hydrophilic surface.

Abstract: A low humidification and durable fuel cell membrane is provided with water adsorbing material embedded therein in order to adsorb water under wet conditions and provide a reservoir of water to keep the membrane irrigated under dry conditions. A hydrogen oxidation catalyst is provided on the water adsorbing material which will catalyze the reaction of hydrogen and oxygen that are crossing through the membrane and will serve to irrigate the membrane and keep the water adsorbing material full of water. Accordingly, the humidification requirements to a fuel cell stack in an operating system are reduced.

Abstract: A porous diffusion media according to the present invention is positioned against a catalyst layer of the membrane electrode assembly, the porous matrix comprises carbon paper, and the water transfer particles comprise carbon fibers or powders. Relatively high and relatively low water transfer particle density regions alternate across the porous diffusion media. A first major face of the media may be collectively more hydrophilic than the second major face and the second major face may be collectively more hydrophobic than the first major face. The diffusion media is positioned against the catalyst layer along the first major face of the diffusion media and against a flow field of the fuel cell along the second major face of the diffusion media. The porous diffusion media comprises hydrophobic material disposed along the second major face of the diffusion media.

Abstract: A fuel cell system having a dry cathode stream provides moisture control of fuel cell membranes without the need for externally humidified air, thereby reducing the complexity of the system. The stoichiometry of air to the system, and in particular, the membranes of the fuel cells, is adjusted according to current density requirements. The air stoichiometry is increased or decreased according to load requirements. Proper membrane moisture levels are maintained, which results in acceptable proton conductivity levels.

Abstract: A low humidification and durable fuel cell membrane is provided with water adsorbing material embedded therein in order to adsorb water under wet conditions and provide a reservoir of water to keep the membrane irrigated under dry conditions. A hydrogen oxidation catalyst is provided on the water adsorbing material which will catalyze the reaction of hydrogen and oxygen that are crossing through the membrane and will serve to irrigate the membrane and keep the water adsorbing material full of water. Accordingly, the humidification requirements to a fuel cell stack in an operating system are reduced.

Abstract: There is provided a process for converting methanol and/or dimethyl ether to a product containing C2 to C4 olefins which comprises the step of contacting a feed which contains methanol and/or dimethyl ether with a catalyst comprising a porous crystalline material. The contacting is conducted in the presence of a cofed aromatic compound under conversion conditions including a temperature of about 350° C. to about 550° C. and a methanol and/or dimethyl ether partial pressure less than or equal to 50 psia (345 kPa). The porous crystalline material used in the catalyst has a pore size greater than the critical diameter of the aromatic compound and a Diffusion Parameter for 2,2-dimethylbutane of about 0.1 to about 26 sec−1 when measured at a temperature of 120° C. and a 2,2- dimethylbutane pressure of 60 torr (8 kPa), and the aromatic compound is capable of alkylation by the methanol and/or dimethyl ether under said conversion conditions.

Abstract: A method of making a membrane electrode assembly is provided. The method includes using a porous support to control the drying of the electrode, and the use of wettable and non-wettable solvents to control the seepage of ionomer into the porous support.

Abstract: There is provided a process for converting methanol and/or dimethyl ether to a product containing olefin, e.g., C2 to C4 olefins, C9+ aromatics and non-C9+ aromatics which comprises: 1) contacting a feed which contains methanol and/or dimethyl ether with a catalyst comprising a porous crystalline material, said contacting step being conducted in the presence of aromatics comprising C9 or C9+ aromatic compound produced in said process under conversion conditions including a temperature of 350° C. to 480° C. and a methanol partial pressure in excess of 10 psia (70 kPa), said porous crystalline material having a Diffusion Parameter for 2,2-dimethylbutane of about 0.1 sec−1 to about 20 sec−1 when measured at a temperature of 120° C.

Abstract: There is provided a process for the selective production of para-xylene which comprises reacting toluene with methanol in the presence of a catalyst comprising a porous crystalline material having a Diffusion Parameter for 2,2 dimethylbutane of about 0.1-15 sec−1 when measured at a temperature of 120° C. and a 2,2 dimethylbutane pressure of 60 torr (8 kPa). The porous crystalline material is preferably a medium-pore zeolite, particularly ZSM-5, which has been severely steamed at a temperature of at least 950° C. The porous crystalline material is preferably combined with at least one oxide modifier, preferably including phosphorus, to control reduction of the micropore volume of the material during the steaming step.