Doosan Fuel Cell America, Inc.

Manish Khandelwal

Nicholas Edward Osepowicz

Sridhar V Kanuri

Shampa Kandoi

Drew Bradley Stolar

Susan G Yan

Steven M Nelson

A cloud tower () receives microscopic particles () impelled by an inert gas () for deposition on a porous substrate () having vacuum () disposed on opposite side. To alter the size and/or shape of the deposition field without changing the entire tower structure, a pair of flaps () are hinged () on one side or on a pair of opposed sides of the cloud primary tower. Another embodiment places selectable tower inserts () within the primary tower structure, fitting therein and sealing thereto.

Deposition cloud tower with an insert for adjusting the deposition area

According to an example embodiment, a method of making a fuel cell component includes permeating at least a portion of a component layer with a polymer. The portion of the component layer is adjacent an edge of the component layer. Some of the polymer is allowed to extend beyond the edge to thereby establish a flap beyond the edge of the component layer. A fuel cell component includes a component layer having a portion adjacent an edge of the layer that is impregnated with a polymer material and a flap of the polymer material extending beyond the edge.

Fuel cell component having a flap extending from a polymer impregnated region

According to an example embodiment, a method of making a phosphoric acid fuel cell component includes situating at least one polymer film layer against a permeable component layer. The polymer film layer comprises a polymer that is chemically resistant to phosphoric acid. The polymer film layer is melted. The permeable component layer is impregnated with the melted polymer to thereby establish a region on the component layer that is impermeable to phosphoric acid. The impregnated region also provides a seal against reactant leakage from the component.

Phosphoric acid fuel cell component having a polymer impregnated region

The fuel cell () includes an oxidant flow plate (), an adjacent cathode substrate layer () having a cathode catalyst (), a matrix () for retaining a liquid electrolyte (), wherein the matrix () is secured adjacent and between the cathode catalyst () and an anode catalyst (). A first anode substrate () is secured adjacent the anode catalyst (), and at least a second duplicate anode substrate layer () is secured adjacent the first anode substrate layer () for providing greater pore volume for storage of the liquid electrolyte () and to limit obstruction of the pore volume of the anode substrates (). The duplicate anode substrate layer () may be partially filled with the liquid electrolyte () at the beginning of life of the fuel cell ().

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South Windsor, CT, United States of America

Manish Khandelwal