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: An electrode for a fuel cell includes a catalyst layer adjacent to a gas diffusion layer and a proton exchange membrane, and ionomer-free active metal-loaded carbon nanostructures and active metal-free ionomer-coated carbon nanostructures arranged to define pores therebetween to facilitate transport of reactant gases and product water in 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: An electrode for a fuel cell includes a catalyst layer adjacent to a gas diffusion layer and a proton exchange membrane, and ionomer-free active metal-loaded carbon nanostructures and active metal-free ionomer-coated carbon nanostructures arranged to define pores therebetween to facilitate transport of reactant gases and product water in the fuel cell.

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: 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: A catalyst assembly having a substrate including an intermetallic compound of W and Ir. The weight ratio of W to Ir is in a range between a first ratio and a second ratio. A catalyst includes at least one noble metal is supported on and contacts the substrate. The first ratio may be in the range of 48:52 and the second ratio may be in the range of 51:49.

Abstract: In one or more embodiments, an electrochemical device includes a substrate having a substrate surface; an amorphous metal oxide layer supported on the substrate surface; and a noble metal catalyst supported on the amorphous metal oxide layer to form a catalyst layer. The amorphous metal oxide layer may contact only 25 to 75 percent of the substrate surface. The amorphous metal oxide layer may include less than 10 weight percent of crystalline metal oxide. In certain instances, the amorphous metal oxide layer is substantially free of crystalline metal oxide.

Abstract: A method including the steps of combining a catalyst metal and a leachable metal to obtain a metallic alloy; and electrochemically removing at least a portion of the leachable metal from the metallic alloy to form a catalyst structure having nanometric pores.

Abstract: According to at least one aspect of the present invention, a layered catalyst having an active area is provided. In at least one embodiment, the layered electrode includes a first catalyst layer having a first noble metal concentration and a first ionomer concentration, and a second catalyst layer disposed next to the first catalyst layer, the second catalyst layer having a second noble metal concentration different from the first noble metal concentration and a second ionomer concentration different from the first ionomer concentration. In at least another embodiment, the metallic alloy includes a metallic alloy of platinum, nickel, and cobalt.

Abstract: A catalyst assembly having a substrate including an intermetallic compound of W and Ir. The weight ratio of W to Ir is in a range between a first ratio and a second ratio. A catalyst includes at least one noble metal is supported on and contacts the substrate. The first ratio may be in the range of 48:52 and the second ratio may be in the range of 51:49.

Abstract: In one or more embodiments, an electrochemical device includes a catalyst promoter including an amorphous metal oxide, the amorphous metal oxide being of an amount greater than 50 percent by weight of the total weight of the substrate, and a substrate including graphene and supporting the substrate.

Abstract: A purging system for removing oxygen from a fuel cell system during a shutdown period for the fuel cell system. The purging system includes a separator having an inlet and an outlet; a first exhaust line for communicating a first exhaust gas stream from an outlet of the fuel cell system to the separator inlet during the shutdown period of the fuel cell system; and a second exhaust line for communicating a second exhaust gas stream to an inlet of the fuel cell system for delivering the second exhaust gas stream to the fuel cell system during the shutdown period. The separator removes oxygen from the first exhaust gas stream such that the first stream nitrogen molar volume is lower than the second steam nitrogen molar volume and the first stream oxygen molar volume is higher than the second stream oxygen molar volume.

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: According to at least one aspect of the present invention, there is provided a fuel cell catalyst formed from a metallic alloy of one or more catalyst metals and one or more leachable metals through potential cycling to remove at least a portion of the leachable metals such that an effective catalytic surface area of the fuel cell catalyst per a given amount of the catalyst metals is enhanced after removal of the at least a portion of the one or more leachable metals.

Abstract: According to at least one aspect of the present invention, a layered catalyst having an active area is provided. In at least one embodiment, the layered electrode includes a first catalyst layer having a first noble metal concentration and a first ionomer concentration, and a second catalyst layer disposed next to the first catalyst layer, the second catalyst layer having a second noble metal concentration different from the first noble metal concentration and a second ionomer concentration different from the first ionomer concentration. In at least another embodiment, the metallic alloy includes a metallic alloy of platinum, nickel, and cobalt.

Abstract: A purging system for removing oxygen from a fuel cell system during a shutdown period for the fuel cell system. The purging system includes a separator having an inlet and an outlet; a first exhaust line for communicating a first exhaust gas stream from an outlet of the fuel cell system to the separator inlet during the shutdown period of the fuel cell system; and a second exhaust line for communicating a second exhaust gas stream to an inlet of the fuel cell system for delivering the second exhaust gas stream to the fuel cell system during the shutdown period. The separator removes oxygen from the first exhaust gas stream such that the first stream nitrogen molar volume is lower than the second steam nitrogen molar volume and the first stream oxygen molar volume is higher than the second stream oxygen molar volume.

Abstract: The present invention provides a method for initiating a fuel cell power system by directly introducing a gas containing oxygen into the fuel cell stack 10. A gas storage source 28 provides oxidizer to the fuel cell 10 such that there is enough initial power to generate a load. The air compressor 24 is started electrically by a portion of the load, and begins to supply compressed air to the cathode 14. The fuel cell stack 10 thereby obtains a further quantity of oxidizer from the compressed air. The air system valve 32 then operates to transfer the fuel cell stack 10 from the gas storage source 28 to the air compressor 24.