Gm Global Technolgoy Operations, Inc.

John P Healy

Bradley M Houghtaling

Scott C Moose

Gerald W Fly

Timothy J Fuller

Steven G Goebel

Craig S Gittleman

Pinkhas A Rapaport

Hubert Gasteiger

Susan Yan

Bhaskar Sompalli

Scott Lawrence Peters

Wenbin Gu

Ronald L James

Brian A Litteer

Ruichun Jiang

Anastasios P Angelopoulos

Matthew Dioguardi

Clark G Hochgraf

Seth D Valentine

Balsu Lakshmanan

Disclosed are fuel cell systems, reinforced membrane electrode assemblies, and methods for fabricating a reinforced membrane electrode assembly. In an example, a disclosed method includes depositing an electrode ink onto a first substrate to form a first electrode layer, and applying a first porous reinforcement layer onto a surface of the first electrode layer to form a first catalyst coated substrate. The method also includes depositing a first ionomer solution onto the first catalyst coated substrate to form a first ionomer layer. A membrane porous reinforcement layer is applied onto a surface of the first ionomer layer to form a reinforced membrane layer.

Reinforced electrode assembly

A fuel cell, a reinforced membrane electrode assembly and a method of fabricating a reinforced membrane electrode assembly. The method comprises depositing an electrode ink onto a first substrate to form a first electrode layer, applying a first porous reinforcement layer on a surface of the first electrode layer to form a first catalyst coated substrate, depositing a first ionomer solution onto the first catalyst coated substrate to form a first ionomer layer, and applying a membrane porous reinforcement layer on a surface of the first ionomer layer to form a reinforced membrane layer.

Methods of making a substantially crack-free electrode layer are described. The methods include depositing an electrode ink on a substrate; placing a layer of porous reinforcement layer on a surface of the wet electrode ink; and drying the electrode ink to form the substantially crack-free electrode layer on the substrate. Substantially crack-free electrode layers and fuel cells incorporating substantially crack-free electrode layers are also described.

Wet lamination process for reducing mud cracking in fuel cell components

A bipolar plate assembly for a fuel cell is provided. The bipolar plate assembly includes a first electroformed unipolar plate disposed adjacent a second electroformed unipolar plate. The first and second unipolar plates are bonded by a plurality of localized electrically and thermally conductive plugs by electroplated material deposited within apertures formed in the substrates onto which the unipolar plates are electroformed. A method for forming the bipolar plate assembly is also described.

Electroformed bipolar plates for fuel cells

Disclosed are methods for fabricating a reinforced membrane electrode assembly having one or more freestanding external reinforcement layers. The method comprises providing a freestanding external reinforcement layer, and depositing a catalyst solution and membrane solution onto at least a portion of the freestanding external reinforcement layer.

Direct coated membrane electrode assembly on external reinforcement for fuel cells

A fuel cell including an anode-side catalyst coated membrane and a cathode-side catalyst coated membrane. At least a portion of a reduced-permeability layer is disposed between the ionically conductive membrane and the anode-side and cathode-side gas diffusion media, wherein the reduced-permeability layer is formed of a material that has a permeability that is less than a permeability of the ionically conductive member. The reduced-permeability layer may also be formed of a material that is softer than the ionically conductive membrane.

Edge-protected catalyst-coated membrane electrode assemblies

A process for fabricating a unitized electrode assembly for a polyelectrolyte membrane is disclosed. The process includes providing a gas diffusion medium and a membrane electrode assembly, printing an adhesive on the gas diffusion medium, locating the gas diffusion medium relative to the membrane electrode assembly and pressing the gas diffusion medium and the adhesive against the membrane electrode assembly.

Manufacture of unitized electrode assembly for PEM fuel cells

A method of addressing one MEA failure mode by controlling MEA catalyst layer overlap, and the apparatus formed thereby is disclosed. The present invention addresses a feature of membrane electrode assembly (MEA) architecture that is associated with field failures due to the loss of ionomer from the edges of the electrolyte. To address ionomer degradation, the present invention provides a MEA design in which the cathode catalyst edges are closer than the anode catalyst edges to the edges of the electrolyte.

Addressing one MEA failure mode by controlling MEA catalyst layer overlap

Fuel cell stack having a plurality of liquid-cooled, bipolar plates separating one cell from the next. Coolant inlet and outlet manifolds are defined, in part, by surfaces of the bipolar plates, and respectively supply coolant to, and remove coolant from, the bipolar plates. The surfaces of the bipolar plates that define the coolant manifolds and confront the coolant in the manifolds are coated with a non-conductive coating to reduce shunt current flow through the coolant.

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Pittsford, NY, United States of America

John P Healy