Abstract: A process for improved performance in at least one fuel cell, having a loss in power output of at least 5% of an initial power output, wherein the fuel cell comprises a cathode, an anode, an anode chamber, a cathode chamber, a fuel comprising an anolyte that flows through the cell, and a catholyte gas, wherein the fuel cell is connected to an external load, and wherein the process includes the steps of taking the load off the fuel cell; and applying an external electric field from an external power source to the fuel cell to reverse electrochemical reactions until at least 5% of the lost power output is regained. Purging the fuel cell further enhances regeneration of the cell.

Abstract: A process for improved performance in a fuel cell or stack of fuel cells wherein the fuel cell has a cathode, an anode, an anode chamber, a cathode chamber, a fuel comprising an anolyte that flows through the cell, and a catholyte gas, and wherein the fuel cell is connected to an external load, and wherein the process comprises taking the load off the cell, and cycling between a minimum voltage and about 50% of the maximum voltage drawn from the fuel cell until a maximum current is reached, or a minimum load and about 50% of the maximum load until a maximum voltage is reached. Fuel cell performance is further enhanced by purging.

Abstract: Disclosed is a unitized electrochemical cell sub-assembly having a first separator plate and a second separator plate that each has a first surface. A recess is located in at least one of the first surfaces to define a chamber adjacent the periphery of the plates when the plates face each other. A membrane electrode assembly (MEA) comprising an ion exchange membrane and a pair of gas diffusion layers is disposed on and between each of the first surfaces between the two plates when the plates face each other so that the peripheral edge of the ion exchange membrane is located within the chamber. Also located in the chamber is a non-conductive sealant polymer that seals and joins the first and second plates to each other, and that seals and joins the first and second plates to the edge of the ion exchange membrane. Also disclosed is a fabrication method for making the unitized electrochemical cell sub-assembly.

Abstract: Multipurpose sealing adhesive materials for sealing different components of an electrochemical cell are provided. The sealing materials are acid, acid anhydride, acid ester or metallocene modified polyolefins that are capable of providing multiple sealing functionalities in a heat activated sealing process. These sealing polymers are capable of adhering to plain and textured metal, graphite and graphite-filled polymer composite separator plates.

Abstract: A modular unitized electrochemical fuel cell cartridge (20) is formed from a mono-polar anode plate (22), a second mono-polar cathode plate (24 ) and a solid polymer membrane electrode assembly (26) operably interposed between the anode and the cathode. An electrochemical fuel cell stack is provided having at least one removable fuel cell cartridge, a pair of current collectors which are individually disposed on opposite sides of the anode and the cathode plates and a pair of end plates which are individually disposed on opposite sides of the current collectors from the anode and cathode plates. Sealing ridges (42) and mating grooves (44) as well as alignment means (46) enable the easy assembly of a modular unitized fuel cell cartridge and stacking said cartridge.

Abstract: Disclosed is a method of making a current collector plate for use in a proton exchange membrane fuel cell. The method includes the steps of: (a) molding the current collector plate by injection, compression or any other molding process from a resin/conductive filler composition; (b) measuring the current collector plate's average thickness; (c) measuring the current collector plate's through-plane resistivity; (d) removing a portion of the current collector plate's surface layer by abrasion; and (e) repeating steps (a) to (d) until a desired plate thickness is removed. The desired plate thickness removed is no more than about 10 micrometers, and preferably about 5 micrometers.

Abstract: Disclosed is a novel fluid flow field plate for use in a solid polymer electrolyte fuel cell. The flow field plate is made of a suitable electrically conducting material and comprises a substantially planar surface, a flow field formed in said substantially planar surface, said flow field comprising a plurality of staggered lands defining a network of substantially symmetric interconnected orifices and diagonal channels in the flow field and a fluid supply manifold through which fuel and an oxidant are introduced to the flow field and a fluid exhaust manifold through which reaction by-products and excess fuel and oxidant are removed from the flow field. Streams of the fuel, oxidant and reaction by-products are continually separated and diverted into separate channels, and the separated streams are then mixed with streams from adjacent channels in the orfices.

Abstract: A method for making a shaped article or a shaped article having a volume resistivity of less than 102 ohm-cm with a desired combination of properties and processibility in an injection moldable composition. In particular the shaped articles formed include injection molded bipolar plates as current collectors in fuel cell applications.