Abstract: A fuel cell includes an anode layer, a polymeric ion conductive membrane disposed over the anode layer, a cathode layer disposed over the polymeric ion conductive membrane, and an effective amount of a reactive material that corrodes at a higher rate than support carbon in the cathode layer, anode layer, or both. The reactive material is either proximate to or distributed within the cathode catalyst layer. In a variation, reactive material is also included proximate to the anode layer.

Abstract: A method of operating a fuel cell stack including disconnecting the primary electrical device and purging gas in the cathode reactant gas flow field by flowing air into the cathode reactant gas flow field. Thereafter, the gas in the cathode reactant flow field is purged again by flowing hydrogen into the cathode reactant gas flow field. Gas in the anode reactant gas flow field is purged by flowing air into the anode reactant gas flow field. Thereafter, the anode reactant gas flow field is filled with hydrogen and both the anode and the cathode are stored with hydrogen.

Abstract: A rapid start reactor is provided that can be used, for example, in a water gas shift reactor of a fuel processor. A reactor has a catalyst support structure with one or more surfaces overlaid with an active coating that includes a catalyst. The active coating heats upon exposure to a non-thermal energy source. The reactor also includes a generator of non-thermal energy for applying non-thermal energy to the active coating. Methods for operating such a reactor during transient and/or start-up conditions are also provided.

Abstract: A product includes a fuel cell stack, and an enclosure apparatus sealingly enclosing the fuel cell stack to define a hydrogen chamber between the fuel cell stack and the enclosure apparatus.

Abstract: Processes to shut down a fuel cell system are described. In one implementation (300), a load (215) is cyclically engaged and disengaged across a fuel cell stack (205) so as to deplete the fuel available to the system's fuel cells (205). Voltage and/or current thresholds may be used to determine when to engage and disengage the load (215) and when to terminate the shutdown operation. In another implementation (500), a variable load (405) is engaged and adjusted so as to deplete the fuel available to the system's fuel cells (205). As before, voltage and/or current thresholds may be used to determine when to adjust the load (405) and when to terminate the shutdown process. In still another implementation, a load (215 or 405) may be periodically engaged and disengaged during some portion of the shutdown process and engaged but adjusted during other portions of the shutdown process.

Abstract: One embodiment of the invention includes a method including providing a cathode catalyst ink comprising a first catalyst, an oxygen evolution reaction catalyst, and a solvent; and depositing the cathode catalyst ink on one of a polymer electrolyte membrane, a gas diffusion medium layer, or a decal backing.

Abstract: One embodiment of the invention includes a product comprising: a membrane electrolyte having a first face and a second face; and an anode over the first face and a cathode over the second face, and wherein the anode has a catalyst loading that is less than 50% of the catalyst loading of the cathode.

Abstract: A method of operating a fuel cell stack including disconnecting the primary electrical device and purging gas in the cathode reactant gas flow field by flowing air into the cathode reactant gas flow field. Thereafter, the gas in the cathode reactant flow field is purged again by flowing hydrogen into the cathode reactant gas flow field. Gas in the anode reactant gas flow field is purged by flowing air into the anode reactant gas flow field. Thereafter, the anode reactant gas flow field is filled with hydrogen and both the anode and the cathode are stored with hydrogen.

Abstract: A method of operating the fuel cell stack having an anode side and a cathode side by flowing hydrogen into the anode side and flowing air into the cathode side. The fuel cell produces electricity that is used to operate a primary electrical device. To shut down the stack in one embodiment, the primary electrical device is disconnected from the stack. The flow of air into the cathode side is stopped and positive hydrogen pressure is maintained on the anode side. The fuel cell stack is shorted and oxygen in the cathode side is allowed to be consumed by hydrogen. The inlet and outlet valves of the anode and the cathode sides are closed. Thereafter, the flow of hydrogen into the anode side is stopped and the flow of exhaust from the cathode side is stopped.

Abstract: A system for the slow purge of a fuel cell stack. A pump can be used to keep the coolant circulating, so that the stack, an associated radiator, and coolant plumbing therebetween are maintained at the same temperature. The heat from the stack, liquid coolant, and radiator can be used to provide the heat of vaporization of the liquid in the stack, and the liquid water can be removed from the stack as water vapor. Because the air flow rate is relatively low, there is sufficient time for the water to vaporize and for the air to come to the same temperature as the stack, which is also facilitated by high surface area for heat transfer. Purge air can be drawn into the stack through the radiator, via a purge air blower, which preheats the air to help avoid frigid air contacting the stack.

Abstract: A fuel cell system that employs a process for minimizing corrosion in the cathode side of a fuel cell stack in the system by combining cathode re-circulation and stack short-circuiting at system shut-down and start-up.

Abstract: A fuel cell includes an anode layer, a polymeric ion conductive membrane disposed over the anode layer, a cathode layer disposed over the polymeric ion conductive membrane, and an effective amount of a reactive material that corrodes at a higher rate than support carbon in the cathode layer, anode layer, or both. The reactive material is either proximate to or distributed within the cathode catalyst layer. In a variation, reactive material is also included proximate to the anode layer.

Abstract: A fuel cell system that employs a procedure for delaying an air purge of a fuel cell stack at system shut-down until the temperature of the stack is reduced below a predetermined temperature. The fuel cell stack includes an anode side, a cathode side, an anode input, a cathode input and an anode exhaust. The system includes a temperature sensor for monitoring the temperature of a cooling fluid flowing through the stack. The anode side of the fuel cell stack is purged at the stack shut-down by directing air from the cathode input line to the anode input line after the temperature of the cooling fluid is reduced to a predetermined temperature.

Abstract: A heat exchanger (60) for a fuel processing system (10) that produces a hydrogen reformate gas. The heat exchanger (60) includes a catalyst for converting carbon monoxide to carbon dioxide. The heat exchanger (60) can be any suitable heat exchanger, such as a tube and fin type heat exchanger, that is able to cool the reformate gas and includes a suitable surface on which the catalyst can be mounted. In one embodiment, the heat exchanger (60) is part of a WGS reactor assembly (48). The WGS reactor assembly (48) includes a first stage WGS adiabatic reactor (52) followed by the catalyzed heat exchanger (60) and a second stage WGS adiabatic reactor (68). Also, in one embodiment, both the first stage and the second stage WGS reactors (52, 68) are medium temperature reactors. By catalyzing the heat exchanger (60) in the WGS reactor assembly (48), the assembly (48) can be smaller than what is currently known in the art.

Abstract: A heat exchanger (60) for a fuel processing system (10) that produces a hydrogen reformate gas. The heat exchanger (60) includes a catalyst for converting carbon monoxide to carbon dioxide. The heat exchanger (60) can be any suitable heat exchanger, such as a tube and fin type heat exchanger, that is able to cool the reformate gas and includes a suitable surface on which the catalyst can be coated. In one embodiment, the heat exchanger (60) is part of a WGS reactor assembly (48). The WGS reactor assembly (48) includes a first stage WGS adiabatic reactor (52) followed by the catalyzed heat exchanger (60) and a second stage WGS adiabatic reactor (68). Also, in one embodiment, both the first stage and the second stage WGS reactors (52, 68) are medium temperature reactors. By catalyzing the heat exchanger (60) in the WGS reactor assembly (48), the assembly (48) can be smaller than what is currently known in the art.

Abstract: Reducing the size of a water-gas-shift reactor by injecting oxygen into the tail section thereof to react the oxygen with CO in the tail section without consuming untoward amounts of hydrogen.

Abstract: A fuel cell system having a methanol decomposition reactor that is used to solve cold startup and transient operating condition problems. Methanol is charged into a methanol decomposition reactor and heat is supplied to decompose methanol (an endothermic reaction) and to produce hydrogen molecules and carbon monoxide. Hot exhaust gas (effluent) from the methanol decomposition reactor is charged to a steam reformer to preheat the reformer. The hydrogen produced by methanol decomposition is used by a fuel cell stack.

Abstract: Reducing the size of a water-gas-shift reactor by injecting oxygen into the tail section thereof to react the oxygen with CO in the tail section without consuming untoward amounts of hydrogen.