METHOD OF FORMING A FUEL CELL STACK

• US 20090117442A1
• Filed: 11/01/2007
• Published: 05/07/2009
• Est. Priority Date: 11/01/2007
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Eickhoff, Steven J.
• Granted Patent: US 9,029,038 B2
• Time in Patent Office: Days
• US Class Current: 429/515
• CPC Class Codes: F17C 11/005 for hydrogen
• CPC Class Codes: H01M 8/004 Cylindrical, tubular or wound
• CPC Class Codes: H01M 8/0289 Means for holding the electrolyte solid polymer electrolytes H01M8/1018
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/04201 Reactant storage and supply, e.g. means for feeding, pipes
• CPC Class Codes: H01M 8/04216 characterised by the choice for a specific material, e.g. carbon, hydride, absorbent
• CPC Class Codes: H01M 8/065 by dissolution of metals or alloys; by dehydriding metallic substances
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/2475 Enclosures, casings or containers of fuel cell stacks
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A method of forming a fuel cell stack, wherein the stack includes an anode electrode layer, an adhesive and anode gas diffusion layer coupled to the anode electrode layer, an ion exchange membrane coupled on a first side to the gas diffusion layer opposite the anode electrode layer, an adhesive and cathode gas diffusion layer coupled to a second side of the ion exchange membrane, and a cathode electrode layer coupled to the adhesive and cathode gas diffusion layer opposite the ion exchange membrane. The fuel cell stack may be flexible.

Claims

1. A method of making a fuel cell stack comprising:

forming an anode electrode layer;

forming an adhesive and anode gas diffusion layer coupled to the anode electrode layer;

forming an ion exchange membrane coupled on a first side to the gas diffusion layer opposite the anode electrode layer;

forming an adhesive and cathode gas diffusion layer coupled to a second side of the ion exchange membrane;

forming a cathode electrode layer coupled to the adhesive and cathode gas diffusion layer opposite the ion exchange membrane; and

pressing the formed layers together to form a flexible fuel cell stack.

2. The method of claim 1 wherein the a thickness of the stack is approximately 1 mm or less.

3. The method of claim 1 and further comprising conforming the fuel cell stack to a cylindrical shape.

4. The method of claim 1 wherein the layers are formed such that the fuel cell stack is comprised of two series connected fuel cells.

5. The method of claim 1 wherein the anode electrode layer and the cathode electrode layer are formed with multiple through holes.

6. The method of claim 1 wherein each of the layers are adhered together, forming a gas tight stack.

7. The method of claim 1 wherein the anode layer and the cathode layer are formed by depositing a titanium or aluminum layer and depositing gold on such layer.

8. The method of claim 7 wherein the anode layer has two fuel cell anodes, each with a tab for facilitating an electrical series connection between two fuel cells in the fuel cell stack.

9. The method of claim 1 wherein the gas diffusion layers are formed with carbon paper.

10. The method of claim 1 wherein the ion exchange membrane is formed with Nafion.

11. A method of forming a power generator, the method comprising:

forming a container having a desired shape;

placing a hydrogen producing fuel within the container;

adding a sliding valve arrangement within the container and positioned around the hydrogen producing fuel;

coupling a pressure responsive diaphragm to the sliding valve arrangement;

wrapping a fuel cell stack around an anode support and sliding valve arrangement within the container, the fuel cell stack having a cathode electrode for exposure to oxygen and an anode electrode for exposure to hydrogen;

electrically coupling the container to the cathode electrode of the fuel cell stack such that a desired portion of the container forms a cathode; and

forming an anode electrically coupled to the anode electrode of the fuel cell stack and supported by the container such that at least a portion of it is exposed on the outside of the container spaced apart from the exposed cathode.

12. The method of claim 11 wherein the fuel cell stack is formed by the method comprising:

forming an anode electrode layer;

forming an adhesive and anode gas diffusion layer coupled to the anode electrode layer;

forming an ion exchange membrane coupled on a first side to the gas diffusion layer opposite the anode electrode layer;

forming an adhesive and cathode gas diffusion layer coupled to a second side of the ion exchange membrane;

forming a cathode electrode layer coupled to the adhesive and cathode gas diffusion layer opposite the ion exchange membrane; and

pressing the formed layers together to form a flexible fuel cell stack.

13. The method of claim 13 wherein the thickness of the stack is approximately 1 mm or less and wherein the container is cylindrical and the stack is conformed to a cylindrical shape.

14. The method of claim 13 wherein the stack is comprised of two series connected fuel cells.

15. The method of claim 13 wherein the anode electrode layer and the cathode electrode layer have multiple through holes.

16. The method of claim 13 wherein each of the layers are adhered together.

17. The method of claim 13 wherein the anode layer and the cathode layer are formed by depositing a titanium or aluminum adhesion layer on a polymer substrate and depositing gold on such layer and by forming multiple holes through both the anode and the cathode layers.

18. The method of claim 17 wherein the anode layer is formed with fuel cell anodes, each with a tab for facilitating an electrical series connection between two fuel cells in the fuel cell stack.

19. A method of forming a power generator, the method comprising:

forming a container having a desired shape;

placing a hydrogen producing fuel within the container;

adding a sliding valve arrangement within the container and positioned around the hydrogen producing fuel;

coupling a pressure responsive diaphragm to the sliding valve arrangement;

wrapping a fuel cell stack around the sliding valve arrangement within the container, the fuel cell stack formed by a method comprising;

forming an anode electrode layer;

forming an adhesive and anode gas diffusion layer coupled to the anode electrode layer;

forming an ion exchange membrane coupled on a first side to the gas diffusion layer opposite the anode electrode layer;

forming an adhesive and cathode gas diffusion layer coupled to a second side of the ion exchange membrane;

forming a cathode electrode layer coupled to the adhesive and cathode gas diffusion layer opposite the ion exchange membrane; and

pressing the formed layers together to form a flexible fuel cell stack;

electrically coupling the container to the cathode electrode of the fuel cell stack such that a desired portion of the container forms a cathode; and

forming an anode electrically coupled to the anode electrode of the fuel cell stack and supported by the container such that at least a portion of it is exposed on the outside of the container spaced apart from the exposed cathode.

20. The method of claim 19 wherein the hydrogen producing fuel is formed by stacking multiple fissurized pellets into the container wherein the stack of pellets is encapsulated in a water vapor and hydrogen permeable, liquid water impermeable membrane.