Proton exchange membrane fuel cell power system

A proton exchange membrane fuel cell power system for producing electrical power comprising:

• a plurality of discrete fuel cell modules each having at least two membrane electrode diffusion assemblies, each of the membrane electrode diffusion assemblies having opposite anode and cathode sides;
• a pair of current collectors each disposed in juxtaposed ohmic electrical contact with the opposite anode and cathode sides of each of the membrane electrode diffusion assemblies;
• and
• individual force application assemblies for applying force to each pair of the current collectors and the individual membrane electrode diffusion assemblies.

A proton exchange membrane fuel cell power system comprising:

• a plurality of discrete proton exchange membrane fuel cell modules each having a hydrogen distribution frame defining discrete, substantially opposed cavities;
• a membrane electrode diffusion assembly which has opposite anode and cathode sides and which is sealably mounted in each of the cavities;
• a pair of current collectors positioned in each of the cavities and individually oriented in juxtaposed ohmic electrical contact with the opposite anode and cathode sides of each of the membrane electrode diffusion assemblies;
• a pressure transfer assembly positioned in each of the cavities and disposed in force transmitting relation relative to the membrane electrode diffusion assembly and the pair of current collectors;
• and
• a cathode cover oriented in partially occluding relation relative to each of the cavities and matingly cooperating with the hydrogen distribution frame.

A proton exchange membrane fuel cell power system comprising:

• a plurality of discrete fuel cell modules each having a hydrogen distribution frame defining discrete, substantially opposed cavities, the hydrogen distribution frame defining a first passageway which permits the simultaneous delivery of hydrogen gas to each of the cavities, and a second passageway which facilitates the removal of impurities, water and unreacted hydrogen from each of the cavities;
• a membrane electrode diffusion assembly which has opposite anode and cathode sides and which is sealably mounted in each of the cavities, the membrane electrode diffusion assembly having a solid proton conducting electrolyte membrane which has opposite anode and cathode sides;
• individual catalytic anode and cathode electrodes disposed in ionic contact with the respective anode and cathode sides of the electrolyte membrane;
• and a diffusion layer borne on each of the anode and cathode electrodes and which is electrically conductive and has a minimum pore size;
• a pair of current collectors positioned in each of the cavities and individually oriented in juxtaposed ohmic electrical contact with the opposite anode and cathode sides of each of the membrane electrode diffusion assemblies, and wherein the current collectors have a surface coating which is inert and galvanically cathodic;
• a pressure transfer assembly positioned in each of the cavities and disposed in force transmitting relation relative to the membrane electrode diffusion assembly and the pair of current collectors, and wherein the pressure transfer assembly has a main body with a plurality of resilient members extending therefrom;
• a cathode cover oriented in partially occluding relation relative to each of the cavities and matingly cooperating with the hydrogen distribution frame, and wherein the cathode covers and the respective pressure transfer assembly define a third passageway which permits delivery of air to each of the cavities and to the cathode side of the membrane electrode diffusion assembly;
• and
• a biasing assembly oriented between the respective cathode covers and the pressure transfer assembly, and wherein a force of at least about 175 pounds per square inch is realized between the membrane electrode diffusion assembly and the associated pair of current collectors.

A power system housing comprising:

• an enclosure defining a cavity;
• a subrack mounted in the cavity and supporting a plurality of discrete proton exchange membrane full cell modules in the cavity, and wherein the subrack has forward and rearward edges, and top and bottom portions, and wherein the power system housing further comprises an air distribution assembly which is received in the enclosure and coupled in fluid flowing relation relative to the top and bottom portions of the subrack, and wherein the subrack further includes a plenum made integral with each of the subracks, the plenum having an intake end which receives air from each of the discrete proton exchange membrane fuel cell modules supported on the subrack at the top and bottom portions thereof, and air which comes from outside of the respective proton exchange membrane fuel cell modules;
• and an exhaust end which delivers both air which has passed through each of the proton exchange membrane fuel cell modules, and air which comes from outside of the respective proton exchange membrane fuel cell modules;
• an air movement assembly operably coupled to the plenum for moving the air from the intake end to the exhaust end of the plenum;
• and
• an air mixing valve operably coupled with the plenum and controlling the amount of air which has passed through the respective fuel cells and which is recirculated back to each of the fuel cell modules.

A power system housing comprising:

• an enclosure defining a cavity,
• a subrack mounted in the cavity and supporting a plurality of discrete proton exchange membrane fuel cell modules;
• and
• a digital programmable controller electrically coupled with each of the discrete proton exchange membrane fuel cell modules.

A power system housing comprising:

• an enclosure defining a cavity;
• a subrack mounted in the cavity and supporting a plurality of discrete proton exchange membrane fuel cell modules, and wherein the subrack has forward and rearward edges;
• and
• a direct current bus mounted adjacent the rearward edge of the subrack, and the discrete proton exchange membrane fuel cell modules are releasably electrically coupled with the direct current bus.

A power system housing, comprising:

• an enclosure defining a cavity;
• a subrack mounted in the cavity, the subrack having forward and rearward edges, and top and bottom portions, the subrack supporting a plurality of discrete proton exchange membrane fuel cell modules in the cavity, and wherein the proton exchange fuel cell modules each produce thermal energy;
• a hydrogen distribution assembly received in the cavity of the enclosure and mounted in fluid flowing relation relative to each of the discrete proton exchange membrane fuel cell modules;
• and
• an air distribution assembly received in the enclosure and operably coupled with the subrack, the air distribution assembly delivering air to each of the proton exchange membrane fuel cell modules, and wherein the preponderance of the thermal energy is removed from the proton exchange membrane fuel cell modules by the air delivered bv the air distribution assembly.

A power system housing comprising:

• an enclosure defining a cavity;
• a subrack mounted in the cavity and supporting a plurality of discrete proton exchange membrane fuel cell modules;
• a hydrogen distribution assembly received in the cavity of the enclosure and mounted in fluid flowing relation relative to each of the discrete proton exchange membrane fuel cell modules;
• an air distribution assembly received in the enclosure and operably coupled with the subrack, the air distribution assembly delivering air to each of the proton exchange membrane fuel cell modules;
• and
• a digital programmable controller electrically coupled with each of the discrete proton exchange membrane fuel cell modules.

A power system housing comprising:

• an enclosure defining a cavity;
• a subrack having a rearward edge, and which is mounted in the cavity, and which supports a plurality of discrete proton exchange membrane fuel cell modules;
• a hydrogen distribution assembly mounted in fluid flowing relation relative to each of the discrete proton exchange membrane fuel cell modules;
• an air distribution assembly coupled to the subrack and delivering air to each of the proton exchange membrane fuel cell modules;
• and
• a direct current bus mounted adjacent the rearward edge of the subrack, and wherein the discrete proton exchange membrane fuel cell modules are releasably electrically coupled with the direct current bus.

A power system housing comprising:

• an enclosure defining a cavity;
• a subrack mounted in the cavity, the subrack having forward and rearward edges, and top and bottom portions, the subrack supporting a plurality of discrete proton exchange membrane fuel cell modules in the cavity;
• a hydrogen distribution assembly received in the cavity of the enclosure and mounted in fluid flowing relation relative to each of the discrete proton exchange membrane fuel cell modules;
• an air distribution assembly comprising a plenum made integral with each of the subracks, the plenum having an exhaust end which delivers air to each of the proton exchange membrane fuel cell modules supported on the subrack at a location intermediate the top and bottom portions thereof, and an intake end which receives both air which has passed through each of the proton exchange membrane fuel cell modules and air which comes from outside of the respective proton exchange membrane fuel cell modules;
• an air movement assembly operably coupled to the plenum for moving the air from the intake end to the exhaust end of the plenum;
• and
• an air mixing valve operably coupled with the plenum and controlling the amount of air which has passed through the respective proton exchange membrane fuel cell modules and which is recirculated back to each of the proton exchange membrane fuel cell modules.

A power system housing comprising:

• an enclosure defining a cavity;
• a subrack mounted in the cavity, the subrack having forward and rearward edges, and top and bottom portions, the subrack supporting a plurality of discrete proton exchange membrane fuel cell modules in the cavity, each of the proton exchange membrane fuel cell modules producing direct current voltage, and wherein the top and bottom portions of the subrack are connected in fluid flowing relation relative to each of the discrete proton exchange membrane fuel cell modules;
• a hydrogen distribution assembly received in the cavity of the enclosure and mounted in fluid flowing relation relative to each of the discrete proton exchange membrane fuel cell modules, the hydrogen distribution assembly operably coupled to each of the discrete proton exchange membrane fuel cell modules at a location adjacent the rearward edge of the subrack;
• an air distribution assembly received in the enclosure and coupled in fluid flowing relation relative to the top and bottom portions of the subrack, the air distribution assembly delivering air to each of the proton exchange membrane fuel cell modules, and wherein the air distribution assembly includes a plenum having an exhaust end which is positioned intermediate the top and bottom portions of the subrack and which delivers air to each of the discrete proton exchange membrane fuel cell modules, and an intake end connected at the top and bottom portions of the subrack and which receives both air which has passed through each proton exchange membrane fuel cell modules and air which comes from outside the respective proton exchange membrane fuel cell modules;
• an air movement assembly operably coupled to the plenum for moving the air along the plenum to the individual proton exchange membrane fuel cell modules;
• and an air mixing valve operably coupled with the plenum and controlling the amount of air which has passed through the respective proton exchange membrane fuel cell modules and which is delivered back to each of the proton exchange membrane fuel cell modules;
• and
• an inverter electrically coupled with each of the proton exchange membrane fuel cell modules and converting the direct current voltage to alternating voltage.

A proton exchange membrane fuel cell module, comprising:

• a hydrogen distribution frame defining a pair of discrete, substantially opposed cavities;
• a membrane electrode diffusion assembly sealably mounted in each of the cavities which are defined by the hydrogen distribution frame, the membrane electrode diffusion assemblies each having opposite anode and cathode sides;
• and
• a pair of current collectors each disposed in juxtaposed ohmic electrical contact with the opposite anode and cathode sides of each of the membrane electrode diffusion assemblies, and wherein the proton exchange membrane fuel cell module is self humidifying and produces heat energy, and wherein the proton exchange membrane fuel cell module has a cathode air flow, and a preponderance of the heat energy is removed from the proton exchange membrane fuel cell module by the cathode air flow.

A proton exchange membrane fuel cell module comprising:

• a hydrogen distribution frame defining a pair of cavities;
• a membrane electrode diffusion assembly having opposite anode and cathode sides and which is sealably mounted on the hydrogen distribution frame and oriented in each of the cavities defined by the hydrogen distribution frame, the hydrogen distribution frame positioning the respective membrane electrode diffusion assemblies in substantially parallel spaced relation one to the other, and wherein the membrane electrode diffusion assembly comprises a solid proton conducting electrolyte membrane which has opposite anode and cathode sides;
• individual catalytic anode and cathode electrodes disposed in ionic contact with the respective anode and cathode sides of the electrolyte membrane;
• and a diffusion layer borne on each of the anode and cathode electrodes and which is electrically conductive and has a pore size;
• a pair of current collectors each disposed in juxtaposed ohmic electrical contact with the opposite anode and cathode sides of each of the membrane electrode diffusion assemblies;
• a pressure transfer assembly disposed in force transmitting relation relative to each membrane electrode diffusion assembly and associated pair of current collectors which are received in each of the cavities defined by the hydrogen distribution frame;
• a cathode cover partially occluding each of the respective cavities of the hydrogen distribution frame, the cathode covers matingly cooperating with the hydrogen distribution frame and with the pressure transfer assembly;
• and
• a biasing member disposed intermediate the cathode cover and the adjacent pressure transfer assembly.

A proton exchange membrane fuel cell module comprising:

• a hydrogen distribution frame defining multiple pairs of discretely opposed cavities, the hydrogen distribution frame further defining first and second passageways, the first passageway facilitating the delivery of a source of hydrogen gas to each cavity, and the second passageway facilitating the removal of unreacted hydrogen gas, water and impurities from each of the cavities;
• a membrane electrode diffusion assembly having opposite anode and cathode sides and which is sealably mounted on the hydrogen distribution frame and positioned in each of the cavities, the membrane electrode diffusion assembly having a solid proton conducting electrolyte membrane with opposite anode and cathode sides, and which has at least about a 20% molar concentration of sulfonic acid;
• individual anode and cathode electrodes disposed in ionic contact with the respective anode and cathode sides of the electrolyte membrane;
• and a diffusion layer borne on each of the anode and cathode electrodes;
• a pair of current collectors individually disposed in juxtaposed ohmic electrical contact with the diffusion layer borne on each of the anode and cathode electrodes, the current collectors each having a base substrate which is electrically conductive;
• and a contact layer over the base substrate, and wherein the individual current collectors have a given surface area of which at least about 70% is open area;
• a pressure transfer assembly juxtaposed relative to the current collector which is oriented in ohmic electrical contact with the cathode side of the membrane electrode diffusion assembly, and wherein the pressure transfer assembly has an elongated main body having top and bottom surfaces, and a plurality of resilient members depend downwardly from the bottom surface thereof and forcibly engage the current collector which is disposed in ohmic electrical contact with the cathode side of the membrane electrode diffusion assembly, and wherein the pressure transfer assembly defines in part a third passageway which facilitates the delivery of a source of air to the cathode side of the membrane electrode diffusion assembly;
• a cathode cover disposed in partially occluding relation relative to each of the cavities, and matingly cooperating with the pressure transfer assembly, the cathode cover, in part defining the third passageway, the individual cathode covers matingly engaging each other, and the hydrogen distribution frame;
• and
• a biasing assembly positioned between the respective cathode covers, and the pressure transfer assembly, the biasing assembly transferring by means of the force transfer assembly substantially uniform force such that at least about 175 pounds per square inch is generated between each membrane electrode diffusion assembly and associated pair of current collectors.

A proton exchange membrane fuel cell power system comprising:

• a proton exchange membrane fuel cell module;
• a subrack supporting the proton exchange membrane fuel cell module;
• a fuel distribution assembly coupled in fluid flowing relation relative to the subrack;
• an air distribution assembly coupled in fluid flowing relation relative to the subrack;
• and
• a D.C. bus releasably electrically coupled to the proton exchange membrane fuel cell module.

A proton exchange membrane fuel cell module, comprising:

• a hydrogen distribution frame defining a cavity;
• a proton exchange membrane mounted in the cavity, the proton exchange membrane having opposite anode and cathode sides;
• and
• individual current collectors disposed in ohmic electrical contact with the anode and cathode sides, and wherein the proton exchange membrane fuel cell module has a cathode air flow, and produces heat energy, and wherein the preponderance of the heat energy is removed from the proton exchange membrane fuel cell module by the cathode air flow.

A proton exchange membrane fuel cell comprising:

• a module which receives a proton conducting electrolyte membrane which produces heat energy, and which has a cathode air flow, and wherein the preponderance of the heat energy is removed by the cathode air flow, and wherein the proton conducting electrolyte membrane further comprises:
• about 35% to about 50%, by molar concentration, of a methacrylate moiety;
• about 30% to about 50%, by molar concentration, of an acrylate moiety;
• about 25% to about 45%, by molar concentration, of a sulfonic acid moiety;
• and
• about 5% to about 20% by molar concentration of a compatible crosslinking agent.