Abstract: To mitigate bubble blockage in water passageways (78, 85), in or near reactant gas flow field plates (74, 81) of fuel cells (38), passageways are configured with (a) intersecting polygons, obtuse angles including triangles, trapezoids, or (b) hydrophobic surfaces (111), or (c) differing adjacent channels (127, 128), or (d) water permeable layers (93, 115, 116, 119) adjacent to water channels or hydrophobic/hydrophilic layers (114, 120).

Abstract: A method of controlling an amount of liquid in a fuel cell includes increasing the oxygen utilization within the fuel cell to increase heat. The heat reduces the amount of liquid in the fuel cell. A disclosed example method includes decreasing a supply of air to the fuel cell to lower a fuel cell voltage by increasing the oxygen utilization. The example method includes maintaining an essentially electrical current density while decreasing the supply of air.

Abstract: To mitigate bubble blockage in water passageways (78, 85), in or near reactant gas flow field plates (74, 81) of fuel cells (38), passageways are configured with (a) cross sections having intersecting polygons or other shapes, obtuse angles including triangles and trapezoids, or (b) hydrophobic surfaces (111), or (c) differing adjacent channels (127, 128), or (d) water permeable layers (93, 115, 116, 119) adjacent to water channels or hydrophobic/hydrophilic layers (114, 120), or (e) diverging channels (152).

Abstract: A fuel cell stack (31) includes a plurality of fuel cells (9) each having an electrolyte such as a PEM (10), anode and cathode catalyst layers (13, 14), anode and cathode gas diffusion layers (16, 17), and water transport plates (21, 28) adjacent the gas diffusion layers. The cathode diffusion layer of cells near the cathode end (36) of the stack have a high water permeability, such as greater than 3×10?4 g/(Pa s m) at about 80° C. and about 1 atmosphere, whereas the cathode gas diffusion layer in cells near the anode end (35) have water vapor permeance greater than 3×10?4 g/(Pa s m) at about 80° C. and about 1 atmosphere. In one embodiment, the anode gas diffusion layer of cells near the anode end (35) of the stack have a higher liquid water permeability than the anode gas diffusion layer in cells near the cathode end; a second embodiment reverses that relationship.

Abstract: To mitigate bubble blockage in water passageways (78, 85), in or near reactant gas flow field plates (74, 81) of fuel cells (38), passageways are configured with (a) intersecting polygons, obtuse angles including triangles, trapezoids, or (b) hydrophobic surfaces (111), or (c) differing adjacent channels (127, 128), or (d) water permeable layers (93, 115, 116, 119) adjacent to water channels or hydrophobic/hydrophilic layers (114, 120).

Abstract: A fuel cell system includes a fuel cell having a cathode and an anode. A water flow field is in communication with the cathode for producing moist air. A cooling system for an evaporatively cooled fuel cell includes a condenser arranged to receive the moist air and produce condensed water. A separator may be arranged to receive the condensed water. A return line fluidly connects the separator and the water flow field. A reservoir has additional water that is in fluid communication with the return line for selectively providing the additional water to the water flow field in an out-of-balance hot fuel cell condition. The reservoir is connected in and to the cooling system in a manner that does not block water flow if the reservoir freezes.

Abstract: A fuel cell stack (32) includes a plurality of fuel cells in which each fuel cell is formed between a pair of conductive, porous, substantially hydrophilic plates (17) having oxidant reactant gas flow field channels (12-15) on a first surface and fuel reactant gas flow field channels (19, 19a) on a second surface opposite to the first surface, each ˜f the plates being separated from a plate adjacent thereto by a unitized electrode assembly (20) including a cathode electrode (22), having a gas diffusion layer (GDL) an anode electrode (23) having a GDL with catalyst between each GDL and a membrane (21) disposed therebetween. Above the stack is a condenser (33} having tubes (34) that receive coolant air (39, 40} to condense water vapor out of oxidant exhaust in a chamber (43). Inter-cell wicking strips (26) receive condensate and conduct it along the length of the stack to all cells.

Abstract: The invention is a hydrogen passivation shut down system for a fuel cell power plant (10). An anode flow path (24) is in fluid communication with an anode catalyst (14) for directing hydrogen fuel to flow adjacent to the anode catalyst (14), and a cathode flow path (38) is in fluid communication with a cathode catalyst (16) for directing an oxidant to flow adjacent to the cathode catalyst (16) of a fuel cell (12). Hydrogen fuel is permitted to transfer between the anode flow path (24) and the cathode flow path (38). A hydrogen reservoir (66) is secured in fluid communication with the anode flow path (24) for receiving and storing hydrogen during fuel cell (12) operation, and for releasing the hydrogen into the fuel cell (12) whenever the fuel cell (12) is shut down.

Abstract: The invention is a hydrogen passivation shut down system for a fuel cell power plant (10). An anode flow path (24) is in fluid communication with an anode catalyst (14) for directing hydrogen fuel to flow adjacent to the anode catalyst (14), and a cathode flow path (38) is in fluid communication with a cathode catalyst (16) for directing an oxidant to flow adjacent to the cathode catalyst (16) of a fuel cell (12). Hydrogen fuel is permitted to transfer between the anode flow path (24) and the cathode flow path (38). A hydrogen reservoir (66) is secured in fluid communication with the anode flow path (24) for receiving and storing hydrogen during fuel cell (12) operation, and for releasing the hydrogen into the fuel cell (12) whenever the fuel cell (12) is shut down.

Abstract: A fuel cell power plant (9, 60) includes a plurality of fuel cells in a stack (10, 61) each having coolant channels (13, 64) with coolant outlets (27, 80) directed to a water gas separator (40, 77), a gas outlet (45, 82) being connected to an orifice (47, 84) through a pressure detector (46, 83). Detection of excessive pressure, indicative of excessive ingestion of gas into the coolant, causes a controller (39, 102) to control operating parameters of the fuel cell stack, such pressure or shutdown of coolant or reactant gas, to avoid fuel cell damage due to the gas ingestion.

Abstract: A method of controlling an amount of liquid in a fuel cell includes increasing the oxygen utilization within the fuel cell to increase heat. The heat reduces the amount of liquid in the fuel cell. A disclosed example method includes decreasing a supply of air to the fuel cell to lower a fuel cell voltage by increasing the oxygen utilization. The example method includes maintaining an essentially electrical current density while decreasing the supply of air.

Abstract: A fuel cell includes a water transport plate providing a water flow field. The water flow field includes water having gas. A vent is in fluid communication with the water flow field. The vent includes a membrane that obstructs flow of water past the membrane while permitting the flow of gas past the membrane. The membrane can include a pore size between approximately 0.1? to 10.0?, which enables gases to pass through the pores while blocking water. The membrane can be hydrophobic, for example, Teflon, to prevent the passage of water through the membrane. A hydrophobic fluid can also be arranged on the membrane to act as a check valve.

Abstract: A fuel cell power plant (19, 19a) has a plurality of fuel cells (70, 70a, 70c) arranged in a stack (20, 20c), each fuel cell having porous, at least partially hydrophilic water transport plates (75, 81) with fuel (74) and oxidant (82) reactant gas channels, there being water channels (78, 85, 78a, 85a, 78c, 85c) exchanging water with the water transport plates. On shut down, water is retained in the water channels and water transport plates by means of either a micro vacuum pump (46), one or two valves (89, 90, 118, 120), a check valve (95, 99), capillary force in the water channels to prevent water from entering the reactant channels which, if frozen, could block flow of reactant gas upon startup.

Abstract: A PEM fuel cell power plant includes fuel cells, each of which has a cathode reactant flow field plate which is substantially impermeable to fluids, a water coolant source, and a fluid permeable anode reactant flow field plate adjacent to said water coolant source. The anode reactant flow field plates pass water from the coolant sources into the cells where the water is evaporated to cool the cells. The cathode flow field plates prevent reactant crossover between adjacent cells. By providing a single water permeable plate for each cell in the power plant the amount of water present in the power plant at shut down is limited to a degree which does not require adjunct water purging components to remove water from the plates when the power plant is shut down during freezing ambient conditions. Thus the amount of residual ice in the power plant that forms in the plates during shut down in such freezing conditions will be limited.

Abstract: Fuel cells (38) have water passageways (67; 78, 85; 78a, 85a) that provide water through reactant gas flow field plates (74, 81) to cool the fuel cell. The water passageways may be vented to atmosphere (99), by a porous plug (69), or pumped (89, 146) with or without removing any water from the passageways. A condenser (59, 124) receives reactant air exhaust, may have a contiguous reservoir (64, 128), may be vertical, (a vehicle radiator, FIG. 2), may be horizontal, contiguous with the top of the fuel cell stack (37, FIG. 5), or below (124) the fuel cell stack (120). The passageways may be grooves (76, 77; 83, 84) or may comprise a plane of porous hydrophilic material (78a, 85a) contiguous with substantially the entire surface of one or both of the reactant gas flow field plates. Air flow in the condenser may be controlled by shutters (155). The condenser may be a heat exchanger (59a) having freeze-proof liquid flowing through a coil (161) thereof, the amount being controlled by a valve (166).

Abstract: A fuel cell stack (32) includes a plurality of fuel cells in which each fuel cell is formed between a pair of conductive, porous, substantially hydrophilic plates (17) having oxidant reactant gas flow field channels (12-15) on a first surface and fuel reactant gas flow field channels (19, 19a) on a second surface opposite to the first surface, each ˜f the plates being separated from a plate adjacent thereto by a unitized electrode assembly (20) including a cathode electrode (22), having a gas diffusion layer (GDL) an anode electrode (23) having a GDL with catalyst between each GDL and a membrane (21) disposed therebetween. Above the stack is a condenser (33} having tubes (34) that receive coolant air (39, 40) to condense water vapor out of oxidant exhaust in a chamber (43). Inter-cell wicking strips (26) receive condensate and conduct it along the length of the stack to all cells. In-cell wicking strips (1G.

Abstract: A cascaded fuel cell stack (9a) includes a plurality of groups (10-12) of fuel cells (13) connected electrically in series by means of conductive separator plates (58, 59) and current collecting pressure plates (56, 57). Each group has an inlet fuel distributing fuel inlet manifold (17a, 19c, 20c), a fuel exit manifold (19a, 20a) of each group except the last feeding the inlet manifold of each subsequent group. A microcontroller responds to signals from a plurality of voltage sensing devices (48a-48c) to cause corresponding switches (50a-50c) (a) to connect each group, and all preceding groups in the sequence, to a voltage limiting device (VLD) (45), or (b) to connect each group to its own (VLD (45a-45c), in response to sensing a predetermined average cell voltage across the corresponding group. When normal operation occurs, the microcontroller connects the main load and disconnects the voltage limiting device (53) (25).

Abstract: A fuel cell power plant (19, 19a) has a plurality of fuel cells (70, 70a, 70c) arranged in a stack (20, 20c), each fuel cell having porous, at least partially hydrophilic water transport plates (75, 81) with fuel (74) and oxidant (82) reactant gas channels, there being water channels (78, 85, 78a, 85a, 78c, 85c) exchanging water with the water transport plates. On shut down, water is retained in the water channels and water transport plates by means of either a micro vacuum pump (46), one or two valves (89, 90, 118, 120), a check valve (95, 99), capillary force in the water channels to prevent water from entering the reactant channels which, if frozen, could block flow of reactant gas upon startup.

Abstract: A fuel cell power plant (19) has a stack of fuel cells (20) cooled by a mixture of water with a non-volatile, miscible fluid that sufficiently depresses the freezing point, such as polyethylene glycol (PEG). The water and fluid are mixed in a reservoir (21), a small pump (22, 60) flows the mixture through coolant channels (28) in or adjacent water transport plates (29); heat of the catalytic reaction warms the water transport plates causing water to evaporate therefrom thereby cooling the stack. The PEG is non-volatile at stack operating temperature and does not evaporate; concentrated PEG is returned (33) to the reservoir (21). Water in the process air flow channels (41), including evaporated process water, is recovered in a condensation-rate-controlled (53, 54)) condenser (46) in communication (48) with the reservoir (21) for remixture with the concentrated PEG solution. Hydrophobic gas diffusion layers (72) shield the proton exchange membrane (70) from the PEG.

Abstract: The invention is a system (10) and method for determining a gas composition within a fuel cell (12) of a shut down fuel cell power plant. The system (10) includes at least one fuel cell (12), a sensor circuit (86) secured in electrical connection with the fuel cell (12), wherein the circuit (86) includes a power source (88), a voltage-measuring device (90), and a sensor circuit switch (92). The circuit (86) is secured so that the power source (88) may selectively deliver a pre-determined sensing current to the fuel cell (12) for a pre-determined sensing duration. The system (10) selectively admits the reducing fluid into an anode flow field (28) of the cell (12) whenever the sensor circuit (86) senses that a shut down monitoring voltage of the fuel cell (12) is the same as or exceeds a calibrated sensor voltage limit of the fuel cell (12).