Improved catalyst layers for use in fuel cell membrane electrode assemblies, and methods for making such catalyst layers, are provided. Catalyst layers can comprise structured units of catalyst, catalyst support, and ionomer. The structured units can provide for more efficient electrical energy production and/or increased lifespan of fuel cells utilizing such membrane electrode assemblies. Catalyst layers can be directly deposited on exchange membranes, such as proton exchange membranes.

A non-woven gas diffusion substrate including: (i) a non-woven carbon fiber web; (ii) a carbon particulate material; and 10 (iii) a hydrophobic binder characterized in that the non-woven gas diffusion substrate further includes a conductive material having a x:y aspect ratio from 0.01 to 100, a x:z aspect ratio of at least 500 and a y:z aspect ratio of at least 500.

A solid oxide fuel cell (SOFC) (100) for use in generating electricity while tolerating sulfur content in a fuel input stream. The solid oxide fuel cell (100) includes an electrolyte (106), a cathode (102), and a sulfur tolerant anode (104). The cathode (102) is disposed on a first side of the electrolyte (106). The sulfur tolerant anode (104) is disposed on a second side of the electrolyte (106) opposite the cathode (102). The sulfur tolerant anode (104) includes a composition of nickel, copper, and ceria to exhibit a substantially stable operating voltage at a constant current density in the presence of the sulfur content within the fuel input stream. The solid oxide fuel cell (100) is useful within a SOFC stack to generate electricity from reformate which includes synthesis gas (syngas) and sulfur content. The solid oxide fuel cell (100) is also useful within a SOFC stack to generate electricity from unreformed hydrocarbon fuel.

The invention relates to a cathode for a metal/air battery comprising at least one active layer produced in an active material and having an air side and a metal side, a current collector and a hydrophobic membrane produced in a hydrophobic material and deposited on the air side of the active layer. Said hydrophobic material has a porous structure and has penetrated into the air side of the active layer so as to form, between the hydrophobic membrane and the active layer, an interpenetration zone of hydrophobic material in the active material, in which there is a concentration gradient of hydrophobic material which decreases in the ingoing direction of air into the cathode.

A unit cell of a fuel cell may include: a membrane-electrode assembly including a proton exchange membrane, an anode electrode fastened to a first face of the proton exchange membrane, a first flow guide plate positioned facing the anode electrode and including at least one flow channel having a fuel inlet zone, a median flow zone and a fuel outlet zone. The anode electrode may have, at the fuel outlet zone, a tolerance to carbon monoxide pollution greater than its average tolerance to carbon monoxide pollution at the median flow zone and at the fuel inlet zone.

A solid oxide fuel cell (SOFC) for use in generating electricity while tolerating sulfur content in a fuel input stream. The solid oxide fuel cell includes an electrolyte, a cathode, and a sulfur tolerant anode. The cathode is disposed on a first side of the electrolyte. The sulfur tolerant anode is disposed on a second side of the electrolyte opposite the cathode. The sulfur tolerant anode includes a composition of nickel, copper, and ceria to exhibit a substantially stable operating voltage at a constant current density in the presence of the sulfur content within the fuel input stream. The solid oxide fuel cell is useful within a SOFC stack to generate electricity from reformate which includes synthesis gas (syngas) and sulfur content. The solid oxide fuel cell is also useful within a SOFC stack to generate electricity from unreformed hydrocarbon fuel.

In an example, a process includes applying a platinum catalyst ink solution to a polymeric substrate to form a platinum-coated polymeric material having a first catalytic surface area. The process further includes utilizing a laser to process a portion of the platinum-coated polymeric material to form a patterned platinum-coated proton exchange membrane (PEM) material. The patterned platinum-coated PEM material has a second catalytic surface area that is greater than the first catalytic surface area.

A fuel cell comprises an anode, a cathode, and a solid electrolyte layer. The cathode contains a perovskite composite oxide as a main component and contains a compound that includes at least one of S and Cr as a secondary component. The cathode has a surface on the opposite side to the solid electrolyte layer. The surface of the cathode includes a first region and a second region that is positioned downstream of the first region in relation to the direction of oxidant gas flow in which the oxidant gas flows over the surface. The first region and the second region respectively contain a main phase configured by a perovskite composite oxide and a secondary phase that is configured by the compound. The occupied surface area ratio of the secondary phase in the first region is greater than the occupied surface area ratio of the secondary phase in the second region.

According to at least one aspect of the present invention, a fuel cell electrode assembly is provided. In one embodiment, the fuel cell electrode assembly includes a substrate and a plurality of catalyst regions supported on the substrate to provide a passage way formed between the catalyst regions for passing fuel cell reactants, at least a portion of the plurality of catalyst regions including a number of atomic layers of catalyst metals. In certain instances, the number of atomic layers of catalyst metals is greater than zero and less than 300. In certain other instances, the number of atomic layers of catalyst metals is between 1 and 100. In yet certain other instances, the number of atomic layers of catalyst metals is between 1 and 20.

A solid oxide fuel cell having a plurality of planar layered fuel cell units, an electrically conductive flow separator plate disposed between each of the fuel cell units, and a cathode contact material element disposed between each cathode electrode of the fuel cell units and each electrically conductive flow separator plate. The cathodes of the individual fuel cell units are modified such that the operating temperatures of the cathodes are matched with the temperatures they experience based upon their locations in the fuel cell stack. The modification involves adding to the cathode contact material and/or cathode at least one alloying agent which modifies the temperature of the cathode electrodes based upon the location of the cathode electrodes within the fuel cell stack. These alloying agents react with a component of the cathode electrode to form alloys.