초록

Described herein are processes for fabricating microfluidic fuel cell systems with embedded components in which micron-scale features are formed by bonding layers of DuPont Kapton™ polyimide laminate. A microfluidic fuel cell system fabricated using this process is also described.

대표청구항 ▼

1. An apparatus comprising:a plurality of polyimide layers wherein, at least one layer contains at least one resistive heater, at least one layer contains at least one microfluidic channel, at least one layer contains at least one anode manifold having a flowing means for a fuel to flow to an anode,

1. An apparatus comprising:a plurality of polyimide layers wherein, at least one layer contains at least one resistive heater, at least one layer contains at least one microfluidic channel, at least one layer contains at least one anode manifold having a flowing means for a fuel to flow to an anode, wherein said flowing means comprise: (a) a fuel inlet, (b) a porous membrane, and (c) a fuel outlet, wherein said fuel inlet and said fuel outlet are configured such that said fuel flows horizontally through said fuel inlet, then vertically through said porous membrane to said anode, wherein whatever portion of fuel that does not flow vertically continues to flow horizontally through said fuel outlet, and wherein said porous membrane comprises a plastic material having pores with diameters less than 1 μm and a thickness ranging from 10-100 μm, at least one layer contains a cathode manifold having removing means for removing reaction by-products from a cathode; an MEA layer, wherein said MEA comprises an electrolyte sandwiched between said anode and said cathode; an electrical feedthrough extending through all layers; and a fuel feedthrough extending through at least four of the layers to form a bonded polyimide microfluidic fuel cell system. 2. The apparatus recited in claim 1, wherein (1) said layer containing at least one microfluidic channel, (2) said layer containing at least one anode manifold, (3) said layer containing at least one cathode manifold and (4) said MEA layer communicate by a fuel feedthrough.3. The apparatus recited in claim 1, further comprising additional layers comprising sheets of polyimide material.4. The apparatus recited in claim 1, wherein said MEA operates at a temperature less than 200° C.5. The apparatus recited in claim 3, wherein at least one of said sheets of polyimide material are positioned between said porous membrane and said anode forms a seal between said porous membrane and said anode.6. A apparatus recited in claim 1, wherein said removing means comprise:at least one of microchannel communicating with said cathode, wherein an additional sheet of polyimide material forms a seal between said microchannel and said cathode. 7. The apparatus recited in claim 1, wherein said MEA comprises three perfluorosulfonic acid layers, said first perfluorosulfonic acid layer containing said anode comprising an anode catalyst material, said third perfluorosulfonic acid layer containing said cathode comprising a cathode catalyst material.8. The apparatus recited in claim 1, wherein said anode and said cathode comprise carbon cloth.9. The apparatus recited in claim 7, wherein said catalyst material comprises Platinim-Ruthenium in a ratio range of about 50-100% Platinum to 0-50% Ruthinium.10. The apparatus recited in claim 1, wherein said fuel is a methanol-water mixture.11. The apparatus recited in claim 1, wherein said fuel is a methanol-water mixture comprising hydrogen, carbon dioxide and less than 1% carbon monoxide.12. The apparatus recited in claim 1, wherein said porous membrane comprises a layer of polyimide having an array of greater than 104 channels per square centimeter, wherein the width of the channels is less than 10 μm.13. The apparatus recited in claim 1, further comprising two polyimide layer having at least one microfluidic connection device embedded between the two layers, wherein said microfluidic connection device communicates with said fuel feedthrough.14. The apparatus recited in claim 13, wherein said microfluidic connection device is capillary tubing.15. The apparatus recited in claim 1, further comprising at least two polyimide layers having at least one pump embedded between the two layers, wherein said pump communicates with said fuel feedthrough.16. The apparatus recited in claim 1, further comprising at least two polyimide layers having at least one valve embedded between the two layers, wherein said valve communicates with said fuel feedthrough.17. The apparatus recited in claim 1, wherein the thickness of each polyimide layer ranges from 25-200 μm.18. The apparatus recited in claim 1, wherein said apparatus has a power output ranging from 0.1 to 20 Watts.19. The apparatus recited in claim 1, wherein said fuel feedthrough of said bonded polyimide microfluidic fuel cell system communicates with a fuel feedthrough of another bonded polyimide microfluidic fuel cell system, said bonded polyimide microfluidic fuel cell systems being connected in series.20. The apparatus recited in claim 19, wherein said apparatus has a power output ranging from 100 milliWatts to 20 Watts.21. The apparatus recited in claim 1, wherein said fuel feedthrough of said bonded polyimide microfluidic fuel cell communicates with a fuel feedthrough of another bonded polyimide microfluidic fuel cell system, said bonded polyimide microfluidic fuel cell systems being connected in parallel.22. The apparatus recited in claim 21, wherein said apparatus has a power output ranging from 100 milliWatts to 20 Watts.