Abstract: A method and apparatus for making fuel cell components via a roll to roll process are described. Spaced apart apertures are cut in first and second gasket webs that each include adhesives. The first and second gasket webs are transported to a bonding station on conveyers. A membrane web that includes at least an electrolyte membrane is also transported to the bonding station. At the bonding station, a gasketed membrane web is formed by attaching the first and second gasket webs to the membrane web. The first gasket web is attached to a first surface of the membrane web via the adhesive layer of the first gasket web. The second gasket web is attached to a second surface of the membrane web via the adhesive layer of the second gasket web.

Abstract: This invention provides a binder for a fuel cell which has high adhesion, low methanol solubility, high methanol permeability and high proton conductivity, a composition for electrode formation, an electrode for a fuel cell, and a fuel cell using them. The binder is particularly suitable for a binder for a direct methanol type fuel cell which requires high proton conductivity. The binder for a fuel cell comprises a block copolymer which comprises a block having a repeating structural unit of a divalent aromatic group that contains a protonic acid group and a block having a repeating structural unit of a divalent aromatic group that does not contain a protonic acid group, and which has a glass transition temperature (Tg) of 180° C. or less. In particular, it is preferable that the block copolymer has an ion exchange group equivalent of from 200 to 1,000 g/mole and a weight retention ratio of 90% or more as measured by immersion in a 64 weight % aqueous methanol solution at 25° C. for 24 hours.

Abstract: A first metal separator and an electrolyte electrode assembly are stacked in a fuel cell. The first metal separator comprises a convex portion that abuts against the electrolyte electrode assembly, and a concave portion forming an oxygen-containing gas flow channel between the electrolyte electrode assembly and the concave portion. A gold coating layer is formed on the convex portion. The gold coating layer includes a main gold coating portion and a reticulate gold coating portion that extends around the main gold coating portion.

Abstract: The invention relates to a method for manufacturing an assembly (1) for a fuel cell comprising at least two adjacent cell components, applied by means of the successive steps consisting of: a) solidifying by laser sintering a powder layer (Ci) deposited beforehand so that it forms a section of the assembly; and b) depositing a successive powder layer on the powder layer (Ci) deposited beforehand and solidified by laser sintering; the steps a) and b) being alternately repeated until the obtained stacked sections form together the assembly comprising at least two components. According to the invention, the method is applied so that at least one of the obtained sections (S1-Sp) has at least two areas with different porosities.

Abstract: A method to produce an aluminium air battery, comprising: forming a selectively reactive coating on a surface of an anode core to form a composite anode, the selectively reactive coating comprising a zinc alloy and the anode core comprising aluminium; and storing an electrolyte in contact with the composite anode, wherein the selectively reactive coating is capable of chemically reacting with the electrolyte during discharging of the aluminium air battery the reactive coating may also include an anode corrosion inhibitor material consisting of one or more of indium, gallium, lead, thallium or mercury

Abstract: A fuel cell catalyst layer includes first spaced apart strands extending longitudinally in a first direction, second spaced apart strands extending longitudinally in a second direction, the first and second spaced apart strands collectively defining openings bounded by an adjacent pair of the first spaced apart strands and an adjacent pair of the second spaced apart strands, a number of wires extending longitudinally in a third direction from one of the first and second spaced apart strands, the wires including an organic material, and a catalyst contacting at least a portion of the plurality of wires.

Abstract: A self-humidifying fuel cell is made by preparing a porous substrate, coating the substrate with a zeolitic material and filling the pores with a proton-conducting material. The coating of the substrate includes selecting a zeolitic material, and applying coating on the pore walls and surface of the porous substrate, to form zeolitic material-coated pores. The resulting composite material is used as a self-humidifying proton-conducting membrane in a fuel cell.

Abstract: The present invention relates to methods and compositions for reducing damaging oxidation of metals. In particular, the present invention relates to nanoparticle surface treatments and use of nanoparticle surface treatments to reduce the damaging oxidation and corrosion of stainless steel and other alloy components in oxidating and corrosive conditions.

Abstract: There is provided a method for manufacturing a fuel cell, such as a hydrogen separation membrane fuel cell, having in its anode a hydrogen separation membrane (12f) selectively permeable by hydrogen. An electrolyte membrane (10) is formed on the hydrogen separation membrane, and the curvature of the electrolyte membrane is changed to generate a compressive stress in the electrolyte membrane.

Abstract: The present invention provides an electrode for a polymer electrolyte membrane fuel cell. In one embodiment, a planar nanoporous or microporous metal foam or metal aerogel structure is provided, from which an electrode with a catalyst layer integrally formed by fixing a catalyst in the metal foam or metal aerogel is formed.

Abstract: Methods of heat treating at least one component of a solid oxide fuel cell (SOFC) system. The method includes heating the at least one component with a rapid thermal process, wherein the rapid thermal process heats at least a portion of the component at a rate of approximately 50° C./sec or more.

Abstract: The substrate-supported anode for a high-temperature fuel cell comprises an at least three-layer anode laminate on a metallic substrate. Each of the layers of the anode laminate comprises yttria-stabilized zirconia and nickel, wherein the mean particle size of the nickel decreases from one layer to the next as the distance from the substrate increases. The last layer of the anode laminate, which is provided for contact with the electrolyte, has a root mean square roughness of less than 4 ?m. The overall mean pore size of this layer is typically between 0.3 and 1.5 ?m. Starting powders having a bimodal particle size distribution of yttria-stabilized zirconia and nickel-containing powder are used at least for the first and second layers of the anode laminate. The mean particle size of the nickel-containing powder is reduced from one layer to the next, whereby it is advantageously no more than 0.5 ?m in the last layer of the anode laminate.

Abstract: A fuel cell component includes a first fluid distribution layer, a second fluid distribution layer, a cap layer, a third fluid distribution layer, and a pair of fluid diffusion medium layers. The individual layers are polymeric, mechanically integrated, and formed from a radiation-sensitive material. The first fluid distribution layer, the second fluid distribution layer, the cap layer, the third fluid distribution layer, and the pair of fluid diffusion medium layers are coated with an electrically conductive material. A pair of the fuel cell components may be arranged in a stack with a membrane electrode assembly therebetween to form a fuel cell.

Abstract: This invention provides novel fuel cell electrodes and catalysts comprising a series of catalytically active thin-film metal alloys with low platinum concentration supported on nanostructured materials (nanoparticles). Processing of the electrodes and catalysts can include electrodeposition methods, and high-pressure coating techniques. In certain embodiments, an integrated gas-diffusion/electrode/catalyst layer can be prepared by processing catalyst thin films and nanoparticles into gas-diffusion media such as Toray or SGL carbon fiber papers. The catalysts can be placed in contact with an electrolyte membrane for PEM fuel cell applications.

Abstract: A hydrogen-permeable structure is disclosed, which includes a hydrogen-permeable base in which a fluctuation range of a d value by X-ray analysis measurement is at most 0.05% in a region within 2 ?m deep from a surface, and an oxide proton conductive film formed on a surface thereof. The disclosure also relates to a method of manufacturing the hydrogen-permeable structure and a fuel cell using the hydrogen-permeable structure.

Abstract: A fuel cell component is provided, including a substrate disposed adjacent at least one radiation-cured flow field layer. The flow field layer is one of disposed between the substrate and a diffusion medium layer, and disposed on the diffusion medium layer opposite the substrate. The flow field layer has at least one of a plurality of reactant flow channels and a plurality of coolant channels for the fuel cell. The fuel cell component may be assembled as part of a repeating unit for a fuel cell stack. A method for fabricating the fuel cell component and the associated repeating unit for the fuel cell is also provided.

Abstract: A metallic bipolar plate for a fuel cell, in which a carbon coating layer containing fluorine is formed on the surface of a stainless steel base material, thus having excellent electrical conductivity and corrosion resistance and further excellent water draining performance and heat radiating performance. In the metallic bipolar plate for a fuel cell of the present invention, the internal residual stress in the surface coating layer is significantly reduced due to the addition of fluorine, and thereby it is possible to improve the adhesive strength between the stainless steel and the surface coating layer.

Abstract: Method and apparatus for depositing multiple lines on an object, specifically contact and busbar metallization lines on a solar cell. The contact lines are preferably less than 100 microns wide, and all contact lines are preferably deposited in a single pass of the deposition head. There can be multiple rows of nozzles on the deposition head. Multiple materials can be deposited, on top of one another, forming layered structures on the object. Each layer can be less than five microns thick. Alignment of such layers is preferably accomplished without having to deposit oversized alignment features. Multiple atomizers can be used to deposit the multiple materials. The busbar apparatus preferably has multiple nozzles, each of which is sufficiently wide to deposit a busbar in a single pass.

Abstract: A module of a biofuel cell includes three module elements each having a porous membrane. At least two of the porous membranes are electrically conducting and form the cathode and the anode of the biofuel cell. The third membrane, which is preferably positioned between the two electrically conducting membranes need not be conducting, but defines two emergent cavities within the module. A porous through-channel extends through a silicon support of the module so as to connect one of the emergent cavities to at least one external wall of the silicon support.

Abstract: A bipolar plate for fuel cells includes a flow plate having a first surface for the introduction of hydrogen fuel gas and water vapor and a second surface for the introduction of an oxygen containing gas, wherein at least a portion of the first and/or second surface comprises a nanostructured carbon material (NCM) coating deposited thereon, said coating having a thickness of 1 nm to 5 ?m.

Abstract: A highly dispersed, unsupported, electrocatalyst made of pyrolyzed porphyries and a method for synthesizing the same. The disclosed synthesis procedure allows for optimization of pore size and therefore transport properties. Compounds suitable for use include transition metal N4-chelates such as, but not necessarily limited to, N4-chelates containing different metal centers including Co, Fe, Mn, Ni, Ru, Cu, etc., and other N4-chelates such as porphyrin, phthalocyanies, and structures based on their pyro products.

Abstract: A solid oxide electrochemical device having a laminar composite electrode with improved electrochemical and mechanical performance, the laminar composite electrode comprising a porous support electrode layer, a thin and patterned structure layer, and a thin and dense electrolyte layer and methods for making.

Abstract: Novel proton exchange membrane fuel cells and direct methanol fuel cells with nanostructured components are configured with higher precious metal utilization rate at the electrodes, higher power density, and lower cost. To form a catalyst, platinum or platinum-ruthenium nanoparticles are deposited onto carbon-based materials, for example, single-walled, dual-walled, multi-walled and cup-stacked carbon nanotubes. The deposition process includes an ethylene glycol reduction method. Aligned arrays of these carbon nanomaterials are prepared by filtering the nanomaterials with ethanol. A membrane electrode assembly is formed by sandwiching the catalyst between a proton exchange membrane and a diffusion layer that form a first electrode. The second electrode may be formed using a conventional catalyst. The several layers of the MEA are hot pressed to form an integrated unit.

Abstract: One exemplary embodiment includes a method of selectively electroplating an electrically conductive coating on portions of a first face of a bipolar plate for use in a proton exchange membrane (PEM) fuel cell. The first face of the bipolar plate defines at least one reactant gas flow channel and a plurality of lands adjacent the at least one channel. The electrically conductive coating may be selectively electroplated on a plurality of first portions of the lands leaving second portions of the lands uncoated by the electrically conductive coating.

Abstract: A method for manufacturing a carbon nanotube/polymer composite includes the steps of: (a) providing a carbon nanotube array formed on a substrate in a container; (b) providing a prepolymer of polymethyl methacrylate (PMMA); (c) putting the prepolymer into the container for a period of over 30 minutes to fill in clearances of the carbon nanotube array; and (d) polymerizing the prepolymer film at a temperature of about 50° C. to 60° C. for a period of about 1 hour to 4 hours and then heating the prepolymer film to about 90° C. to 100° C. to form a polymer film, the carbon nanotube array thereby being embedded within the polymer film.

Abstract: The invention relates to an electrode for a molten carbonate fuel cell, having an electrode framework and an active layer comprising pores which is applied to the electrode framework. According to the invention, the active layer contains at least one structure stabilizer. The invention also relates to a method for producing said type of electrode.

Abstract: Methods of fabricating gas diffusion electrodes and gas diffusion electrodes made from such methods are disclosed herein. One method of fabricating a gas diffusion electrode for a fuel cell comprises preparing a catalyst ink of a predetermined viscosity. Preparing the catalyst ink comprises mixing a catalyst solution comprising catalyst particles, an ionomer and a solvent at a first speed for a first period of time and homogenizing the catalyst solution at a second speed in a temperature controlled environment for a second period of time, wherein the second period of time is longer than the first period of time, the second period of time and the second speed selected to preserve a structure of the catalyst particles during homogenization. An active electrode layer is formed by spraying the catalyst ink directly on a gas diffusion layer in a single application and a uniform loading.

Abstract: The present invention provides a material and a method for its creation and use wherein a reactive element, preferably a rare earth element, is included in an oxide coating material. The inclusion of this material modifies the growth and structure of the scale beneath the coating on metal substrate and improves the scale adherence to the metal substrate.

Abstract: The invention disclosed is a catalyst composition for an air cathode for use in an electrochemical cell, in particular in alkaline electrolyte metal-air e.g. zinc-air, fuel cells. The catalyst composition comprises an active material CoTMMP and silver, supported on carbon wherein the ratio of silver to CoTMPP is 1:1 to 2.4:1. Optional ingredients include a hydrophobic and a hydrophobic bonding agent, MnO2, WC/Co or both. The catalyst composition is supported on microporous support layer and nickel foam or mesh to form an air cathode.

Abstract: An electrode for use in a flow cell is presented. The electrode includes a metal plate for collecting current in the electrode that is bonded between a first and second plate.

Abstract: An interconnector is made of ferritic chromium steel, on which a cupriferous layer is disposed. This layer prevents interdiffusion between the chromium steel and additional components with which the interconnector has direct contact. According to the state of the art, such diffusion occurs particularly if these additional components contain nickel. In addition, the interconnector may comprise a chromium-containing oxide layer as a barrier against interdiffusion. For this purpose, the interconnector steel can also be preoxidized before applying the cupriferous layer. The interconnector has a significantly longer service life than interconnectors according to the state of the art, and it has improved electrical conductivity because the electrical contact surface thereof is free of oxides and has high transverse conductivity.

Abstract: A hydrogen-permeable structure is disclosed, which includes a hydrogen-permeable base in which a fluctuation range of a d value by X-ray analysis measurement is at most 0.05% in a region within 2 ?m deep from a surface, and an oxide proton conductive film formed on a surface thereof. The disclosure also relates to a method of manufacturing the hydrogen-permeable structure and a fuel cell using the hydrogen-permeable structure.

Abstract: A method for forming a hydrolytically-stable hydrophilic coating on a fuel cell flow field plate comprises contacting a flow field plate with a titanium oxide sol to form a titanium oxide layer disposed upon the flow field plate. The coated flow field plate is subsequently contacted with a silicon oxide sol to form a silicon oxide/titanium oxide bilayer disposed upon the flow field plate. A flow field plate formed by the method is also provided.

Abstract: The present invention provides a manufacturing method of an electrode catalyst layer which contains a catalyst, carbon particles and a polymer electrolyte, wherein an oxide type of non-platinum catalyst is used as the catalyst and a fuel cell employing the electrode catalyst layer achieves a high level of power generation performance. The manufacturing method of the electrode catalyst layer of the present invention includes at least: preparing a first catalyst ink, in which a catalyst, first carbon particles and a first polymer electrolyte are dispersed in a first solvent, drying the first catalyst ink to form complex particles, preparing a second catalyst ink, in which the complex particles, second carbon particles and a second polymer electrolyte are dispersed in a second solvent, and coating the second catalyst ink on a substrate to form the electrode catalyst layer.

Abstract: An apparatus and method for enhancing the surface energy and/or surface chemistry of carbon fibers involves exposing the fibers to direct or indirect contact with atmospheric pressure plasma generated using a background gas containing at least some oxygen or other reactive species. The fiber may be exposed directly to the plasma, provided that the plasma is nonfilamentary, or the fiber may be exposed indirectly through contact with gases exhausting from a plasma discharge maintained in a separate volume. In either case, the process is carried out at or near atmospheric pressure, thereby eliminating the need for vacuum equipment. The process may be further modified by moistening the fibers with selected oxygen-containing liquids before exposure to the plasma.

Abstract: The present invention provides an electrode catalyst layer and a manufacturing method thereof, wherein the electrode catalyst layer contains an oxide type of non-platinum catalyst as the catalyst and enables a fuel cell employing the electrode catalyst layer to achieve a high level of power generation performance, as well as an MEA and the fuel cell which employ the electrode catalyst layer. The manufacturing method of the electrode catalyst layer of the present invention includes preparing a “catalyst provided with electrical conductivity on the surface”. In addition, the manufacturing method may further include preparing a catalyst ink, in which the “catalyst provided with electrical conductivity on the surface”, carbon particles and a polymer electrolyte are dispersed in a solvent, and coating the catalyst ink to form the electrode catalyst layer.

Abstract: A method for forming a graphitic tin-carbon composite at low temperatures is described. The method involves using microwave radiation to produce a neutral gas plasma in a reactor cell. At least one organo tin precursor material in the reactor cell forms a tin-carbon film on a supporting substrate disposed in the cell under influence of the plasma. The three dimensional carbon matrix material with embedded tin nanoparticles can be used as an electrode in lithium-ion batteries.

Abstract: Disclosed is a novel cellulose electrode having high performance, which is capable of substituting for carbon paper used as a conventional fuel cell electrode. A method of manufacturing the cellulose electrode includes cutting cellulose fibers to a predetermined length and binding the fibers, or directly weaving the fibers, thus producing a cellulose sheet, directly growing carbon nanotubes on the cellulose sheet, and supporting a platinum nano-catalyst on the surface of the carbon nanotubes using chemical vapor deposition. An electrode including the cellulose fibers and use of cellulose fibers as fuel cell electrodes are also provided. As a novel functional material for fuel cell electrodes, porous cellulose fibers having micropores are used, thereby reducing electrode manufacturing costs and improving electrode performance.

Abstract: One exemplary embodiment includes a fuel cell component having comprising a carbon chain, and a material grafted to the coating/surface, wherein the material includes ionic or polar groups. One embodiment includes composite plates which include carbon that can be activated and treated to make their surface hydrophilic.

Abstract: A method of processing a ceramic electrolyte suitable for use in a fuel cell is provided. The method comprises situating a ceramic electrolyte layer over an anode layer; and subjecting the ceramic electrolyte layer to a stress prior to operation of the fuel cell, by: exposing the top surface of the electrolyte layer to an oxidizing atmosphere and the bottom surface of the electrolyte layer to a reducing atmosphere; and heating the electrolyte layer. The stress causes a substantial increase in the number of microcracks, or in the average size of the microcracks, or in both the number of the microcracks and their average size. A solid oxide fuel cell comprising a ceramic electrolyte layer processed by the disclosed method is also provided.

Abstract: A cathode material for a fuel cell, the cathode material for a fuel cell including a lanthanide metal oxide having a perovskite crystal structure; and a bismuth metal oxide represented by Chemical Formula 1 below, Bi2-x-yAxByO3,??Chemical Formula 1 wherein A and B are each a metal with a valence of 3, A and B are each independently at least one element selected from a rare earth element and a transition metal element, A and B are different from each other, and 0<x?0.3 and 0<y?0.3.

Abstract: The present invention provides technology for noble metal plating of titanium surfaces. A process such as the following would be carried out when manufacturing a partially gold-plated separator for a fuel cell, for example. First, a titanium component made of titanium or titanium alloy is prepared for use as the fuel cell separator (S10). This titanium component is a titanium component whose surfaces are coated with carbon-containing substance. This titanium component is then subjected to a first heat treatment at a prescribed first temperature of between 300 and 700 degrees Celsius (S20). Gold plating of the surfaces of the heat-treated titanium component is then carried out (S80). In this way it is possible to more easily carry out gold electrolytic plating of titanium surfaces.

Abstract: A porous polymer battery separator is provided that includes variable porosity along its length. Such battery separators can increase the uniformity of the current density within electrochemical battery cells that may normally experience higher current density and higher temperatures near their terminal ends than they do near their opposite ends. By disposing a variable porosity separator between the electrodes of an electrochemical cell such that its terminal end has a lower porosity than its opposite end, the transport of ions, such as lithium ions, through the separator can be more restricted in normally high current regions and less restricted in normally low current regions, thereby increasing the overall uniformity of current density within the battery cell. Variable porosity battery separators may be produced by a modified solvent exchange process.

Abstract: Methods and feedstock compositions for preparing porous electrodes as contained in lithium ion and lithium polymer batteries that comprise an electrolyte composition are described. The methods are characterized by depositing on a substrate a feedstock having a soluble pore former, precipitating at least a portion of the soluble pore former from the feedstock, and dissolving the solid pore former from the electrode using at least a portion or constituent of the electrolyte composition. The feedstock compositions are characterized by a pore former that forms a two-phase system with at least one constituent of the electrolyte composition. The feedstock does not contain materials that are not also substantially contained in the lithium ion battery.

Abstract: Provided are a process for producing a membrane/electrode assembly for a polymer electrolyte fuel cell and a process for producing a polymer electrolyte fuel cell, capable of achieving a high output voltage in a wide current density range. At least one of an anode and a cathode in a membrane/electrode assembly for a polymer electrolyte fuel cell is formed through a catalyst layer forming step of applying a first coating fluid containing a catalyst and an ion exchange resin, onto a substrate to form a catalyst layer; a gas diffusion layer forming step of applying a second coating fluid containing carbon fibers and an ion exchange resin, onto the catalyst layer to form a gas diffusion layer to serve as an outermost layer of the membrane/electrode assembly for the polymer electrolyte fuel cell; and a peeling step of peeling the substrate off from the catalyst layer.

Abstract: Disclosed herein is a method for manufacturing a metal steel separator for fuel cells that has corrosion resistance and contact resistance not only at an initial stage but also after being exposed to high temperature/high humidity conditions in the fuel cell for a long period of time. The method includes preparing a stainless steel sheet as a matrix of the metal separator, forming a discontinuous coating film on the surface of the stainless steel sheet, the coating film being composed of at least one selected from gold (Au), platinum (Pt), ruthenium (Ru), iridium (Ir), ruthenium oxide (RuO2), and iridium oxide (IrO2), and heat treating the stainless steel sheet having the discontinuous coating film to form an oxide film on a portion of the stainless steel sheet on which the coating film is not formed. A metal separator for fuel cells manufactured by the method is also disclosed.

Abstract: The invention is to provide a gas diffusion layer for fuel cells having excellent adaptability against load change by attaining a good balance between anti-dry-out properties and anti-flooding properties. The gas diffusion layer for fuel cells containing a substrate layer and an conductive fine particle layer is formed by coating a coating liquid for forming the conductive fine particle layer on at least one surface of a substrate for forming the substrate layer using a gravure roll and by a kiss coating. In coating of the coating liquid, a speed difference is generated between a line speed of transferring the substrate and a circumferential speed of the gravure roll, and apparent viscosity [?(Pa·s)] of the coating liquid as determined by type B viscosimeter satisfies the following relations: 1.0<?<200.0 (3 rpm) 0.2<?<10.

Abstract: According to the present invention, an electrolyte membrane having recesses and projections on the surface thereof is obtained. In addition, a membrane-electrode assembly comprising the electrolyte membrane, in which the effective contact area between the electrolyte membrane surface and an electrode catalyst layer is increased, is obtained. An electrolyte membrane 1 which comprises a fluorine-based electrolyte is heated and pressed with the use of plates 10a and 10b each having recesses and projections 11 on the surface thereof such that recesses and projections 2a and 2b are formed on the surface of the electrolyte membrane 1. Thereafter, the electrolyte membrane 1 is subjected to a treatment for imparting ion exchange properties to an electrolyte polymer, such as hydrolysis, such that an electrolyte membrane 3 having recesses and projections on the surface thereof is obtained.

Abstract: There are provided an electrode material for a fuel cell, a fuel cell comprising the same, and a method of manufacturing the fuel cell. The electrode material for a fuel cell comprises an electrode base material and spherical polystyrene particles forming pores on the electrode base material through heat treatment. In the case of the electrode material according to an exemplary embodiment of the present invention, the average particle size and content of the spherical polystyrene particles may be controlled to form pores having a uniform size on a sintering body formed of the electrode base material, and the control of the porosity thereof may be facilitated.

Abstract: The present invention provides a method to design, manufacture and structure a multi-component energy device having a unified structure, wherein the individual components are chosen from the list consisting of electrochemical cells, photovoltaic cells, fuel-cells, capacitors, ultracapacitors, thermoelectric, piezoelectric, microelectromechanical turbines and energy scavengers. Said components are organized into a structure to achieve an energy density, power density, voltage range, current range and lifetime range that the single components could not achieve individually, i.e. to say the individual components complement each other. The individual components form a hybrid structure, wherein the elements are in electrical, chemical and thermal conduction with each other.