High power density fuel cell stack using micro structured components
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
H01M-008/02
H01M-008/24
출원번호
UP-0998436
(2007-11-29)
등록번호
US-RE41577
(2010-09-13)
발명자
/ 주소
McLean, Gerard Francis
출원인 / 주소
Angstrom Power Incorporated
대리인 / 주소
Schwegman, Lundberg & Woessner, P.A.
인용정보
피인용 횟수 :
4인용 특허 :
30
초록▼
The invention is a multiple fuel cell layer structure with numerous fuel cell layers, each fuel cell has an anode, a cathode, a positive end and a negative end, wherein a first fuel cell layer is stacked on top of a second fuel cell layer such that the anode side of the first fuel cell and the anode
The invention is a multiple fuel cell layer structure with numerous fuel cell layers, each fuel cell has an anode, a cathode, a positive end and a negative end, wherein a first fuel cell layer is stacked on top of a second fuel cell layer such that the anode side of the first fuel cell and the anode side of the second fuel cell adjoin, additional fuel cell layers can then be added in a like manner, at least one seal disposed between the adjacent fuel cell layers forming at least one plenum, and a positive and a negative connector is connected to the stack to an outside load such that when fuel is presented to the anode sides of the fuel cell layers and oxidant is presented to the cathode sides of the fuel cell layers current is produced to drive the outside load.
대표청구항▼
What is claimed is: 1. A multiple fuel cell layer structure comprising: a. a plurality of layers of fuel cells, each layer of fuel cells comprising an anode side and a cathode side, a positive end and a negative end, and wherein a first layer of fuel cells is stacked on top of a second layer of fu
What is claimed is: 1. A multiple fuel cell layer structure comprising: a. a plurality of layers of fuel cells, each layer of fuel cells comprising an anode side and a cathode side, a positive end and a negative end, and wherein a first layer of fuel cells is stacked on top of a second layer of fuel cells such that the anode side of the first layer of fuel cells and the anode side of the second layer of fuel cells adjoin, a third layer of fuel cells is stacked on the second layer of fuel cells such that the third layer of fuel cells cathode side adjoins the second layer of fuel cells cathode side forming a stack with adjacent layers of fuel cells, additional layers of fuel cells can then be disposed on said first, second, and third layers of fuel cells in a like manner; b. at least one seal disposed between said adjacent layers of fuel cells forming at least one plenum; c. a positive connector for said stack to an outside load; and d. a negative connector for connecting said stack to said outside load; such that when fuel is presented to the anode sides of the plurality of said layers, and oxidant is presented to the cathode sides of the plurality of said layers current is produced to drive said outside load. 2. The multiple fuel cell layer structure of claim 1, wherein said at least one plenum is a member of the group: fuel plenum, an oxidant plenum and combinations thereof. 3. The multiple fuel cell layer structure of claim 1, wherein said at least one plenum is a permeable material. 4. The multiple fuel cell layer structure of claim 1, wherein said at least one plenum is a solid material with a flow field. 5. The multiple fuel cell layer structure of claim 1, wherein said at least one plenum is open to an ambient environment. 6. The multiple fuel cell layer structure of claim 1, wherein said positive and negative ends are connected in series between the positive and negative connectors. 7. The multiple fuel cell layer structure of claim 1, wherein said positive ends and negative ends are connected in parallel to the positive and negative connectors. 8. The multiple fuel cell layer structure of claim 1, wherein said positive ends and said negative ends are connected in a combination of in series and in parallel between the positive and negative connectors. 9. A multiple fuel cell layer structure comprising: a. a plurality of layers of fuel cells, each layer of fuel cells comprising an anode side and a cathode side, a positive end and a negative end, and wherein a first layer of fuel cells is stacked on top of a second layer of fuel cells such that the anode side of the first layer of fuel cells and the anode side of the second layer of fuel cells adjoin, a third layer of fuel cells is stacked on the second layer of fuel cells such that the third layer of fuel cells cathode side adjoins the second layer of fuel cells cathode side forming a stack with adjacent layers of fuel cells, additional layers of fuel cells can then be disposed on said first, second and third layers of fuel cells in a like manner; b. at least one seal disposed between said adjacent layers of fuel cells forming at least one plenum; c. at least one flowfield is formed in at least one of said layer of said stack; d. a positive connector for connecting said stack to an outside load; and e. a negative connector for connecting said stack to said outside load; such that when fuel is presented to the anode sides of the plurality of layers of fuel cells, and oxidant is presented to the cathode sides of the plurality of layers of fuel cells current is produced to drive said outside load. 10. The multiple fuel cell layer structure of claim 9, wherein said at least one plenum is a member of the group consisting of fuel plenum, an oxidant plenum and combinations thereof. 11. The multiple fuel cell layer structure of claim 9, wherein said at least one plenum is a permeable material. 12. The multiple fuel cell layer structure of claim 9, wherein said at least one plenum is a solid material with a flow field. 13. The multiple fuel cell layer structure of claim 9, wherein said at least one plenum is open to an ambient environment. 14. The multiple fuel cell layer structure of claim 9, wherein said positive and negative ends are connected in series between the positive and negative connectors. 15. The multiple fuel cell layer structure of claim 9, wherein said positive ends and negative ends are connected in parallel to the positive and negative connectors. 16. The multiple fuel cell layer structure of claim 9, wherein said positive ends and said negative ends are connected in a combination of in series and in parallel between the positive and negative connectors. 17. The multiple fuel cell layer structure of claim 9, wherein said flowfield is formed by a method selected from the group consisting of cutting, ablating, molding, embossing, etching, laminating, embedding, melting and combinations thereof. 18. A bi-level fuel cell layer structure comprising: a. a first fuel cell layer and a second fuel cell layers layer, each fuel cell layer operating with diffusion of reactant from an anode side to a cathode side, and further comprising, a positive end and a negative end, and wherein said first fuel cell layer is stacked on top of said second fuel cell layer such that the anode side of the first fuel cell layer and the anode side of the second fuel cell layer adjoin forming a bi-level stack; b. a seal disposed between said first and second fuel cell layers forming a fuel plenum; c. a positive connector for connecting said bi-level stack to an outside load; and d. a negative connector for connecting said bi-level stack to said outside load; such that when fuel is introduced to the fuel plenum and the cathode sides are exposed to an oxidant, current is produced to drive said outside load. 19. The bi-level fuel cell layer structure of claim 18, wherein said fuel plenum is a permeable material. 20. The bi-level fuel cell layer structure of claim 18, wherein said fuel plenum is a solid material with a flow field. 21. The bi-level fuel cell layer structure of claim 18, wherein said fuel plenum is open to an ambient environment. 22. The bi-level fuel cell layer structure of claim 18, wherein said positive and negative ends are connected in series between the positive and negative connectors. 23. The bi-level fuel cell layer structure of claim 18, wherein said positive ends and negative ends are connected in parallel to the positive and negative connectors. 24. The bi-level fuel cell layer structure of claim 18, wherein said fuel plenum comprises a volume comprising a hydrogen storage material. 25. The bi-level fuel cell layer structure of claim 18, further comprising at least one flowfield formed in at least one fuel cell layer. 26. The bi-level fuel cell layer structure of claim 25, wherein said flowfield is formed by a method selected from the group consisting of cutting, ablating, molding, embossing, etching, laminating, embedding, melting and combinations thereof. 27. A bi-level fuel cell layer structure comprising: a cell first layer of fuel cells and a second layer of fuel cells, each fuel cell comprising an anode side and a cathode side, a positive end and a negative end, and wherein said first fuel cell layer is stacked on top of said second fuel cell layer such that the cathode side of the first fuel cell layer and the cathode side of the second fuel cell layer adjoin forming a bi-level stack; a seal disposed between said first and second fuel cell layer forming a oxidant plenum; a positive connector for connecting said bi-level stack to an outside load; and a negative connector for connecting said bi-level stack to said outside load; such that when oxidant is introduced to the oxidant plenum and the anode sides are exposed to a fuel, current is produced to drive said outside load. 28. The bi-level fuel cell layer structure of claim 27, wherein said oxidant plenum is a permeable material. 29. The bi-level fuel cell layer structure of claim 27, wherein said oxidant plenum is a solid material with a flow field. 30. The bi-level fuel cell layer structure of claim 27, wherein said oxidant plenum is open to an ambient environment. 31. The bi-level fuel cell layer structure of claim 27, wherein said positive and negative ends are connected in series between the positive and negative connectors. 32. The bi-level fuel cell layer structure of claim 27, wherein said positive ends and negative ends are connected in parallel to the positive and negative connectors. 33. The bi-level fuel cell layer structure of claim 27, further comprising at least one flowfield formed in at least one fuel cell layer. 34. The bi-level fuel cell layer structure of claim 33, wherein said flowfield is formed by a method selected from the group consisting of cutting, ablating, molding, embossing, etching, laminating, embedding, melting and combinations thereof. 35. A bi-level fuel cell layer structure, comprising: a first fuel cell layer and a second fuel cell layer, each fuel cell layer comprising: a plurality of fuel cell units comprising: an electrolyte disposed in a channel formed in a substrate; one or more conductive sealant barriers, positioned to provide gas impermeable separation between adjacent fuel cell units; a first coating, in contact with the electrolyte and the one or more conductive sealant barriers; a second coating, in contact with the electrolyte and the one or more conductive sealant barriers; a positive end and a negative end; a seal in contact with the first fuel cell layer and second fuel cell layer and positioned to form a reactant plenum; a positive connector and negative connector, each in contact with an outside load; wherein the first fuel cell layer and second fuel cell layer are in contact such that the reactant plenum is utilized by like coatings of each fuel cell layer and wherein the negative ends of each fuel cell layer are in electrical contact sufficient to form a bi-level structure. 36. The bi-level fuel cell layer structure of claim 35, wherein the first and second coatings comprise thin metallic layers. 37. The bi-level fuel cell layer structure of claim 35, wherein the first and second coatings comprise platinum. 38. The bi-level fuel cell layer structure of claim 35, further comprising a conductive substrate positioned between adjacent fuel cell units to facilitate a current flow between the fuel cell units. 39. The bi-level fuel cell layer structure of claim 35, further comprising a fuel within the reactant plenum. 40. The bi-level fuel cell layer structure of claim 39, wherein the fuel comprises hydrogen. 41. The bi-level fuel cell layer structure of claim 35, further comprising an oxidant within the reactant plenum. 42. A bi-level fuel cell layer structure, comprising: a first fuel cell layer and a second fuel cell layer, each fuel cell layer comprising: a plurality of fuel cell units, each said fuel cell unit comprising: a substrate having a channel formed therein, the channel defined by first and second walls; an electrolyte disposed in the channel; a first catalyst layer disposed on the first wall; a second catalyst layer disposed on the second wall; one or more conductive sealant barriers positioned to provide gas impermeable separation between adjacent fuel cell units; a positive end and a negative end; a seal in contact with the first fuel cell layer and second fuel cell layer and positioned to form a reactant plenum; a positive connector and negative connector, each in contact with an outside load; wherein the first fuel cell layer and second fuel cell layer are in contact such that the reactant plenum is utilized by like catalyst layers of each fuel cell layer and wherein the negative ends of each fuel cell layer are in electrical contact sufficient to form a bi-level structure. 43. The bi-level fuel cell layer structure of claim 42, wherein the first and second catalyst layers comprise thin metallic layers. 44. The bi-level fuel cell layer structure of claim 42, wherein the first and second catalyst layers comprise platinum. 45. The bi-level fuel cell layer structure of claim 42, further comprising a fuel within the reactant plenum. 46. The bi-level fuel cell layer structure of claim 42, wherein the fuel comprises hydrogen. 47. The bi-level fuel cell layer structure of claim 42, further comprising an oxidant within the reactant plenum. 48. The bi-level fuel cell layer structure of claim 42, further comprising a solid material with a flowfield within the reactant plenum. 49. The bi-level fuel cell layer structure of claim 42, wherein the reactant plenum is open to an ambient environment. 50. The bi-level fuel cell layer structure of claim 42, wherein the positive and negative ends of the fuel cell layers are connected in series between the positive and negative connectors. 51. The bi-level fuel cell layer structure of claim 42, wherein the positive ends and negative ends of the fuel cell layers are connected in parallel to the positive and negative connectors. 52. The bi-level fuel cell layer structure of claim 42, further comprising a hydrogen storage material within the reactant plenum. 53. The bi-level fuel cell layer structure of claim 42, further comprising at least one flowfield formed in at least one fuel cell layer. 54. The bi-level fuel cell layer structure of claim 53, wherein the flowfield is formed by a method selected from the group consisting of cutting, ablating, molding, embossing, etching, laminating, embedding, melting and combinations thereof. 55. A multiple layer fuel cell structure, comprising: a first fuel cell layer and a second fuel cell layer, said first and second fuel cell layers arranged vertically with respect to one another, each fuel cell layer comprising: a plurality of fuel cell units arranged laterally with respect to one another, each fuel cell unit comprising: at least one substrate defining first and second walls in spaced relation to one another, the first and second walls defining a channel; a first catalyst layer disposed on the first wall; a second catalyst layer disposed on the second wall; an electrolyte disposed in the channel between the first and second walls, whereby said first wall forms an anode and said second wall forms a cathode of said fuel cell unit; at least one sealant barrier, at least one such sealant barrier placed between laterally adjacent fuel cell units, and configured to provide gas impermeable separation between such adjacent fuel cell units; and a positive connector and negative connector, each configured for contacting an outside load; a first enclosure configured to form a first reactant plenum, said first enclosure in fluid communication with each of said first and second vertically arranged fuel cell layers and further in fluid communication with each fuel cell unit in each said layer; a first electrical connection formed connecting said positive connectors of said first and second fuel cell layers; and a second electrical connection formed connecting said negative connectors of said first and second fuel cell layers. 56. The multiple layer fuel cell structure of claim 55, wherein said first enclosure is placed vertically between said first and second fuel cell layers. 57. The multiple layer fuel cell structure of claim 55, further comprising a second enclosure configured to form a second reactant plenum, said second enclosure in fluid communication with each of said first and second vertically arranged fuel cell layers and with each fuel cell unit in each said layer. 58. The multiple layer fuel cell structure of claim 55, wherein a plurality of fuel cell units within each fuel cell layer are electrically coupled in series within said layer. 59. A method of making a multiple level fuel cell structure, comprising the acts of: forming a first fuel cell layer, comprising, forming a plurality of fuel cell units, each fuel cell unit comprising a volume of electrolyte, and further comprising an anode and a cathode coupled to opposing sides of said volume of electrolyte; forming a sealant barrier between each fuel cell unit and a laterally adjacent fuel cell unit; and forming an electrical connection between each fuel cell unit and at least one adjacent fuel cell unit in said first fuel cell layer, comprising forming a connection between the anode of one such fuel cell unit and the cathode of the adjacent fuel cell unit; forming a positive contact for said first fuel cell layer; and forming a negative contact for said first fuel cell layer; forming a second fuel cell layer, said second fuel cell layer vertically disposed relative to said first fuel cell layer, comprising, forming a plurality of fuel cell units, each fuel cell unit comprising a volume of electrolyte, and further comprising an anode and a cathode coupled to opposing sides of said volume of electrolyte; forming a sealant barrier between each fuel cell unit and a laterally adjacent fuel cell unit in said second fuel cell layer; and forming an electrical connection between each fuel cell unit and at least one adjacent fuel cell unit in said second fuel cell layer, comprising forming a connection between the anode of one such fuel cell unit and the cathode of the adjacent fuel cell unit; forming a positive contact for said second fuel cell layer; and forming a negative contact for said second fuel cell layer; forming a first reactant plenum, said reactant plenum in fluid communication with each fuel cell in said first and second fuel cell layers; forming a first electrical connection between said positive contacts of said first and second fuel cell layers; and forming a second electrical connection between said negative contacts of said first and second fuel cell layers. 60. The method of making a multiple level fuel cell structure of claim 59, wherein said first reactant plenum is placed vertically between said first and second fuel cell layers. 61. The method of making a multiple level fuel cell structure of claim 59, further comprising the act of forming a second reactant plenum, said reactant plenum in fluid communication with each fuel cell in said first and second fuel cell layers. 62. The method of claim 61, further comprising the acts of: introducing a fuel into one of said first and second reactant plenums; and introducing an oxidant into the other of said first and second reactant plenums. 63. A method of making a bi-level fuel cell layer structure, comprising the acts of: forming first and second fuel cell layers, each fuel cell layer formed through acts comprising, forming a substrate having a first side and second side; coating at least a portion of the first side with a first coating; coating at least a portion of the second side with a second coating; forming a channel in the substrate, including a first channel wall and second channel wall; forming an anode by depositing a first catalyst layer on the first channel wall; forming a cathode by depositing a second catalyst layer on the second channel wall; disposing electrolyte in at least a portion of the channel in contact with the anode and cathode; contacting a positive electrical connection on one end to the first side of the substrate; contacting a negative electrical connection on one end to the second side of the substrate, sufficient to form a fuel cell unit; disposing a sealant barrier around at least a portion of the fuel cell unit; forming a first reactant plenum; and placing said first reactant plenum in contact with a first side of the first fuel cell layer and a first side of the second fuel cell layer, to form a bi-level structure wherein the first reactant plenum is utilized by like electrodes of the first fuel cell layer and second fuel cell layer.
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