Fuel cell and membrane

• US 20020122972A1
• Filed: 10/30/2001
• Published: 09/05/2002
• Est. Priority Date: 05/06/1999
• Status: Active Grant

• Current Assignee: National Technology & Engineering Solutions Of Sandia LLC (Honeywell International Inc.)
• Original Assignee: Alan P. Sylwester, Andrew Hecht, Gail N. Ryba, Stanley H. Kravitz, Thomas E. Zipperian, Tom Klitsner
• Inventors: Hecht, Andrew, Kravitz, Stanley H., Sylwester, Alan P., Zipperian, Thomas E., Klitsner, Tom, Ryba, Gail N.
• Granted Patent: US 6,841,290 B2
• Time in Patent Office: Days
• US Class Current: 429/42
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 2300/0074 Ion conductive at high temperature
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 2300/0094 in the form of layered products, e.g. coatings
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 4/8807 Gas diffusion layers
• CPC Class Codes: H01M 4/92 Metals of platinum group H01M4/94 , H01M4/9058 take precedence
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1007 with both reactants being gaseous or vaporised H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1016 characterised by the electrolyte material H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1097 Fuel cells applied on a support, e.g. miniature fuel cells deposited on silica supports
• CPC Class Codes: H01M 8/1213 characterised by the electrode/electrolyte combination or the supporting material
• CPC Class Codes: H01M 8/1231 with both reactants being gaseous or vaporised
• CPC Class Codes: H01M 8/1253 the electrolyte containing zirconium oxide
• CPC Class Codes: H01M 8/2418 Grouping by arranging unit cells in a plane H01M8/2425, H01M8/244 take precedence
• CPC Class Codes: H01M 8/2457 with both reactants being gaseous or vaporised
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Fuel cells and a novel membrane for use in fuel cells and manufacturing processes.

Claims

1. A fuel cell comprising at least one etch-processed, conductive, porous film comprising at least one electrode, wherein said film comprises at least one dielectric layer and at least one conductive layer, and wherein said at least one conductive layer comprises at least one material selected from the group consisting of gold, aluminum, platinum, and a conductive organic material.

2. The fuel cell of claim 1 wherein said dielectric layer comprises silicon.

3. The fuel cell of claim 2 wherein said dielectric layer comprises silicon nitride.

4. The fuel cell of claim 3 wherein said dielectric layer comprises pores formed by reactive ion etching.

5. The fuel cell of claim 1 further comprising at least one catalyst disposed on the conductive layer.

6. The fuel cell of claim 5 wherein said at least one catalyst comprises platinum.

7. The fuel cell of claim 5 wherein said at least one catalyst is deposited by an ink deposition process.

8. The fuel cell of claim 1 further comprising at least one support substrate supporting said film.

9. The fuel cell of claim 8 wherein said support substrate comprises at least one fuel flow path for providing fuel to said electrode.

10. The fuel cell of claim 1 wherein said porous film comprises a plurality of pores perforating said film, wherein diameters of said pores are 0.18-1 microns.

11. The fuel cell of claim 10 wherein said support substrate is etched.

12. The fuel cell of claim 1 wherein said electrode comprises an etch and anodization processed, silicon-based, porous electrode.

13. The fuel cell of claim 1 wherein said fuel cell is operable to produce electricity from hydrogen and oxygen.

14. The fuel cell of claim 1 wherein said fuel cell is operable to produce hydrogen and oxygen from water.

15. The fuel cell of claim 1 wherein said film is 1-20 microns in thickness.

16. The fuel cell of claim 1 comprising a plurality of said electrodes arranged as a planar array.

17. The fuel cell of claim 16 wherein said planar array of electrodes comprises an interdigitated array of cathodes and anodes.

18. The fuel cell of claim 17 wherein a surface area of each cathode is approximately four times larger than a surface area of each anode.

19. A method of combinatorial experimentation comprising the steps of:

providing materials for making fuel cells wherein the materials comprise a silicon substrate;

making a plurality of fuel cells on the silicon substrate; and

testing the fuel cells.