Method of Compressing Fuel Cell Electrodes, Resultant Fuel Cell, and a Housing for the Fuel Cell Which Utilizes Electrolyte Reservoirs

• US 20150027884A1
• Filed: 07/28/2014
• Published: 01/29/2015
• Est. Priority Date: 07/26/2013
• Status: Active Grant

• Current Assignee: Alcotek, Inc.
• Original Assignee: Alcotek, Inc.
• Inventors: Wolf, Karl R. Jr., Fodor, Joe
• Granted Patent: US 9,453,834 B2
• Time in Patent Office: Days
• US Class Current: 204/403.01
• CPC Class Codes: G01N 27/4045 for gases other than oxygen
• CPC Class Codes: G01N 33/4972 Determining alcohol content for vehicle safety devices B60K28/06
• CPC Class Codes: H01M 16/003 of fuel cells with other electrochemical devices, e.g. capacitors, electrolysers
• CPC Class Codes: H01M 2250/30 Fuel cells in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 4/92 Metals of platinum group H01M4/94 , H01M4/9058 take precedence
• CPC Class Codes: H01M 8/0239 Organic resins; Organic polymers
• CPC Class Codes: H01M 8/0247 characterised by the form characterised by a channel configuration H01M8/0258
• CPC Class Codes: H01M 8/04276 Arrangements for managing the electrolyte stream, e.g. heat exchange
• CPC Class Codes: Y02B 90/10 Applications of fuel cells in buildings
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

An electrode element and fuel cell and a new method of manufacturing a fuel cell, particularly for use in a breath alcohol detector. This new element includes a reservoir for extra electrolyte that can allow near perfect capillary action to keep the electrode substrate full of electrolyte for long periods of time, increasing its useful life, especially under harsh conditions. Further, the capillary action need not work through a layer of electrode and can be integrally formed with the electrode element to eliminate or reduce loss due to connective surfaces. Wire connections and arrangements are generally of no concern in this design as the reservoirs for electrolyte connect directly to the substrate and electrolyte does not need to pass through an electrode.

Claims

1. A fuel cell comprising:

at least two electrodes; and

a porous substrate, said substrate comprising a compressed portion and an uncompressed portion which portions are integrally formed and in fluid communication with each other;

wherein a first of said at least two electrodes is arranged on a first side of said compressed portion of said porous substrate; and

wherein a second of said at least two electrodes is arranged on a second side of said compressed portion of said porous substrate.

2. The fuel cell of claim 1 further comprising an encapsulating housing.

3. The fuel cell of claim 2 wherein said housing includes at least one liquid reservoir in fluid communication with said uncompressed portion of said porous substrate.

4. The fuel cell of claim 3 wherein said at least one liquid reservoir comprises at least three liquid reservoirs, said at least three liquid reservoirs being positioned so that liquid in at least one of said at least three reservoirs contacts said uncompressed portion of said porous substrate regardless of orientation of said fuel cell.

5. The fuel cell of claim 1 wherein said electrodes comprise platinum.

6. The fuel cell of claim 1 wherein said fuel cell is used in a breath alcohol sensor.

7. The fuel cell of claim 1 wherein said porous substrate comprises porous polypropylene.

8. The fuel cell of claim 1 wherein said porous substrate comprises porous polyvinylchloride (PVC).

9. The fuel cell of claim 1 wherein pores in said porous substrate include a liquid electrolyte.

10. The fuel cell of claim 1 wherein said at least two electrodes are smaller than said substrate.

11. The fuel cell of claim 1 wherein said electrodes are circular.

12. The fuel cell of claim 11 wherein said substrate is polygonal.

13. The fuel cell of claim 1 wherein said compressed substrate includes a megapore.

14. The fuel cell of claim 1 wherein said uncompressed substrate includes a megapore.

16. The method of claim 13 wherein said moving comprises moving both said first electrode and said second electrode.

17. The method of claim 13 wherein said moving comprises moving only one of said first electrode and said second electrode.

15. A method of forming a fuel cell, the method comprising:

placing a first electrode on a first side of a substrate, said first electrode covering only a portion of said first side;

placing a second electrode on a second opposing side of a substrate, said second electrode covering only a portion of said second side;

moving said first electrode and said second electrode toward each other so as to compress said substrate located between said first electrode and said second electrode while not compressing said substrate not located between said first electrode and said second electrode.