The fuel cell (100) includes an oxidant flow plate (212), an adjacent cathode substrate layer (216) having a cathode catalyst (222), a matrix (224) for retaining a liquid electrolyte (230), wherein the matrix (224) is secured adjacent and between the cathode catalyst (222) and an anode catalyst (232). A first anode substrate (102) is secured adjacent the anode catalyst (232), and at least a second duplicate anode substrate layer (108) is secured adjacent the first anode substrate layer (102) for providing greater pore volume for storage of the liquid electrolyte (230) and to limit obstruction of the pore volume of the anode substrates (102, 108). The duplicate anode substrate layer (108) may be partially filled with the liquid electrolyte (230) at the beginning of life of the fuel cell (100).

An illustrative example method of making a fuel cell component includes mixing a catalyst material with a hydrophobic binder in a solvent to establish a liquid mixture having at least some coagulation of the catalyst material and the hydrophobic binder. The liquid mixture is applied to at least one side of a porous gas diffusion layer. At least some of the solvent of the applied liquid mixture is removed from the porous gas diffusion layer. The catalyst material remaining on the porous gas diffusion layer is dried under pressure.

Provided is a fuel cell catalyst composition comprising a C12A7:X.sup.− inorganic material having a structure in which oxygen anions of C12A7 are replaced by halogen (X) anions, or comprising a C12A7:X.sup.−-based inorganic material which is a C12A7:X.sup.− partially converted to electride. A fuel cell comprising the fuel cell catalyst composition in a catalyst layer is also provided. Also provided is a method of producing a fuel cell catalyst composition, comprising a step of heat-treating C12A7:X.sup.− at temperature of 1000-1300° C. for at least 20 hours under a nitrogen atmosphere.

Provided is a fuel cell catalyst composition comprising a C12A7:X.sup.− inorganic material having a structure in which oxygen anions of C12A7 are replaced by halogen (X) anions, or comprising a C12A7:X.sup.−-based inorganic material which is a C12A7:X.sup.− partially converted to electride. A fuel cell comprising the fuel cell catalyst composition in a catalyst layer is also provided. Also provided is a method of producing a fuel cell catalyst composition, comprising a step of heat-treating C12A7:X.sup.− at temperature of 1000-1300° C. for at least 20 hours under a nitrogen atmosphere.

A reformer assembly includes a vortex tube receiving heated fuel mixed with steam. A catalyst coats the inner wall of the main tube of the vortex tube and a hydrogen-permeable tube is positioned in the middle of the main tube coaxially with the main tube. With this structure the vortex tube outputs primarily Hydrogen from one end and Carbon-based constituents from the other end. In some embodiments a second vortex tube receives the Carbon output of the first vortex tube to establish a water gas shift reactor, producing Hydrogen from the Carbon output of the first vortex tube.

A reformer assembly includes a vortex tube receiving heated fuel mixed with steam. A catalyst coats the inner wall of the main tube of the vortex tube and a hydrogen-permeable tube is positioned in the middle of the main tube coaxially with the main tube. With this structure the vortex tube outputs primarily Hydrogen from one end and Carbon-based constituents from the other end. In some embodiments a second vortex tube receives the Carbon output of the first vortex tube to establish a water gas shift reactor, producing Hydrogen from the Carbon output of the first vortex tube.

A reformer is disclosed in one embodiment of the invention as including a channel to convey a preheated plurality of reactants containing both a feedstock fuel and an oxidant. A plasma generator is provided to apply an electrical potential to the reactants sufficient to ionize one or more of the reactants. These ionized reactants are then conveyed to a reaction zone where they are chemically transformed into synthesis gas containing a mixture of hydrogen and carbon monoxide. A heat transfer mechanism is used to transfer heat from an external heat source to the reformer to provide the heat of reformation.

A reformer is disclosed in one embodiment of the invention as including a channel to convey a preheated plurality of reactants containing both a feedstock fuel and an oxidant. A plasma generator is provided to apply an electrical potential to the reactants sufficient to ionize one or more of the reactants. These ionized reactants are then conveyed to a reaction zone where they are chemically transformed into synthesis gas containing a mixture of hydrogen and carbon monoxide. A heat transfer mechanism is used to transfer heat from an external heat source to the reformer to provide the heat of reformation.

A stack (10) of fuel cells (11) is provided with barriers (32) to prevent migration of a liquid electrolyte (such as phosphoric acid) out of the cells (11). The barrier (32) is secured within a step (34) defined within a land region (28) of a separator plate assembly (18) and extends from an edge (30) of the separator plate assembly (18) all or a portion of a distance between the edge (30) and a flow channel (24) defined within the separator plate assembly (18). The barrier (32) also extends away from the edge (30) a distance of between 0.051 and 2.0 millimeters (2 and 80 mils). The barrier (32) includes a hydrophobic, polymeric film (36), a pressure sensitive adhesive (38), as an assembly aid, and a fluoroelastomer bonding agent (40).

A stack (10) of fuel cells (11) is provided with barriers (32) to prevent migration of a liquid electrolyte (such as phosphoric acid) out of the cells (11). The barrier (32) is secured within a step (34) defined within a land region (28) of a separator plate assembly (18) and extends from an edge (30) of the separator plate assembly (18) all or a portion of a distance between the edge (30) and a flow channel (24) defined within the separator plate assembly (18). The barrier (32) also extends away from the edge (30) a distance of between 0.051 and 2.0 millimeters (2 and 80 mils). The barrier (32) includes a hydrophobic, polymeric film (36), a pressure sensitive adhesive (38), as an assembly aid, and a fluoroelastomer bonding agent (40).