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: 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: A fuel cell oxidation reduction reaction catalyst includes a carbon powder substrate, an amorphous conductive metal oxide intermediate layer on the substrate, and a plurality of chained electrocatalyst particle strands bound to the layer to form an interconnected network film thereon having a thickness of up to 10 atom monolayers.

Abstract: A fuel cell electrode includes a carbon nanofiber substrate and a continuous film of up to 100 atom-thick monolayers forming a network of interconnected electrocatalyst nanoparticles deposited on the carbon nanofiber substrate such that at least some of the nanoparticles are directly adhered to uppermost nanofibers of the substrate to form a layer resistant to electrocatalyst depletion.

Abstract: In at least one embodiment, a fuel cell is provided comprising a positive electrode including a first gas diffusion layer and a first catalyst layer, a negative electrode including a second gas diffusion layer and a second catalyst layer, a proton exchange membrane (PEM) disposed between the positive and negative electrodes, and a microporous layer of carbon and binder disposed between at least one of the first gas diffusion layer and the first catalyst layer and the second gas diffusion layer and the second catalyst layer. The microporous layer may have defined therein a plurality of pores with a diameter of 0.05 to 2.0 ?m and a plurality of bores having a diameter of 1 to 100 ?m. The bores may be laser perforated and comprise from 0.1 to 5 percent of a total porosity of the microporous layer.

Abstract: A fuel cell assembly includes a fuel cell arrangement having first and second plates sandwiching a membrane electrode assembly. The arrangement defines first and second header regions that each include supply and return headers. The first plate defines coolant channels that extend between the header regions and connect to the return header in the first region. The second plate defines coolant channels that extend between the header regions and connect to the supply header in the first region.

Abstract: A microporous layer forming a portion of a gas diffusion layer assembly positioned adjacent to a catalyst layer within a fuel cell electrode. The microporous includes a first carbon-based material layer comprising a plurality of hydrophobic pores with a diameter of 0.05 to 0.2 ?m and a plurality of bores with a diameter of 1 to 20 ?m. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.

Abstract: In at least one embodiment, a microporous layer configured to be disposed between a catalyst layer and a gas diffusion layer of a fuel cell electrode assembly is provided. The microporous layer may have defined therein a plurality of hydrophilic pores, a plurality of hydrophobic pores with a diameter of 0.02 to 0.5 ?m, and a plurality of bores with a diameter of 0.5 to 100 ?m. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.

Abstract: A fuel cell includes a cathode having a first gas diffusion layer and a first catalyst layer, an anode including a second gas diffusion layer and a second catalyst layer and a proton exchange membrane disposed between the cathode and anode. A microporous layer is disposed between the first gas diffusion layer and the first catalyst layer. The microporous layer defines a plurality of domains extending between opposite surfaces of the microporous layer. Under freezing conditions the microporous layer is arranged to concentrate ice formation within the domains to reduce an amount of frozen water within the catalyst layer.

Abstract: In at least one embodiment, a fuel cell is provided comprising a positive electrode including a first gas diffusion layer and a first catalyst layer, a negative electrode including a second gas diffusion layer and a second catalyst layer, a proton exchange membrane (PEM) disposed between the positive and negative electrodes, and a microporous layer of carbon and binder disposed between at least one of the first gas diffusion layer and the first catalyst layer and the second gas diffusion layer and the second catalyst layer. The microporous layer may have defined therein a plurality of pores with a diameter of 0.05 to 2.0 ?m and a plurality of bores having a diameter of 1 to 100 ?m. The bores may be laser perforated and comprise from 0.1 to 5 percent of a total porosity of the microporous layer.

Abstract: In at least one embodiment, a microporous layer configured to be disposed between a catalyst layer and a gas diffusion layer of a fuel cell electrode assembly is provided. The microporous layer may have defined therein a plurality of hydrophilic pores, a plurality of hydrophobic pores with a diameter of 0.02 to 0.5 ?m, and a plurality of bores with a diameter of 0.5 to 100 ?m. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.