Hydrodynamic transport and flow channel passageways associated with fuel cell electrode structures and fuel cell electrode stack assemblies

• US 6,924,058 B2
• Filed: 05/15/2001
• Issued: 08/02/2005
• Est. Priority Date: 11/17/1999
• Status: Expired due to Term

• Current Assignee: XNRGI, Inc.
• Original Assignee: Neah Power Systems, Inc.
• Inventors: Ohlsen, Leroy J., Chan, Chung M., Mallari, Jonathan C., Cooke, Aaron M.
• Primary Examiner(s): Crepeau, Jonathan
• Application Number:
  US09/858,327
• Publication Number:
  US 20020028372A1
• Time in Patent Office: 1,540 Days
• Field of Search: 429/40, 429/41, 429/43, 429/44, 429/30, 429/38
• US Class Current: 429/498
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 4/8647 consisting of more than one material, e.g. consisting of composites
• CPC Class Codes: H01M 4/921 Alloys or mixtures with metallic elements
• CPC Class Codes: H01M 8/023 Porous and characterised by the material
• CPC Class Codes: H01M 8/0245 in the form of layered or coated products
• CPC Class Codes: H01M 8/0258 characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1011 Direct alcohol fuel cells [DAFC], e.g. direct methanol fuel cells [DMFC]
• CPC Class Codes: H01M 8/2483 characterised by internal manifolds
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

Hydrodynamic transport and flow channel passage structures associated with fuel cell electrode structures and fuel cell electrode stack assemblies, as well as to methods relating thereto, are disclosed. More specifically, the present invention is directed to a novel fluid delivery and removal channel passage structures integrally associated with electrode structures adapted for use within a fuel cell system. In one embodiment, the fluid delivery and removal channel passage structure comprises: a fluid delivery channel disposed across a first face of a silicon-based electrode structure; a fluid removal channel disposed across a second face of the silicon-based electrode structure (wherein the second face opposes the first face); and a porous bulk matrix fluid transport layer interposed between the fluid delivery channel and the fluid removal channel, wherein the porous bulk matrix fluid transport layer is adapted to hydrodynamically flow a gas or liquid therethrough, and wherein the porous bulk matrix fluid transport layer is in fluid communication with the fluid delivery and the fluid removal channels.

Claims

1. A fluid delivery and removal channel passage structure integrally associated with an electrode structure of a fuel cell system, comprising:

a fluid delivery channel disposed across a first face of the electrode structure;

a fluid removal channel disposed across a second face of the electrode structure, wherein the second face opposes the first face; and

a porous bulk matrix fluid transport layer interposed between the fluid delivery channel and the fluid removal channel, wherein the porous bulk matrix fluid transport layer is adapted to hydrodynamically flow a gas or liquid therethrough, wherein the porous bulk matrix fluid transport layer is in fluid communication with the fluid delivery and the fluid removal channels, and wherein the porous bulk matrix fluid transport layer comprises a sol-gel.

2. A fluid delivery and removal channel passage structure associated with an electrode structure of a fuel cell system, characterized in that the fluid delivery and removal passage structure comprises an inlet passage and an outlet passage separated by a porous bulk matrix fluid transport layer, wherein the porous bulk matrix fluid transport layer is adapted to hydrodynamically flow a gas or liquid therethrough, wherein the porous bulk matrix fluid transport layer is in fluid communication with the inlet passage and the outlet passage, and wherein porous bulk matrix fluid transport layer comprises a sol-gel.

3. A fuel cell system comprising:

an anode derived from a first planar silicon substrate;

a cathode derived from a second planar silicon substrate;

and a liquid electrolyte that ionically connects the anode to the cathode;

wherein the anode and the cathode are spaced apart and substantially parallel to each other so as to define a spaced apart region, wherein the liquid electrolyte is interposed between the anode and the cathode and within the spaced apart region, wherein the anode has a plurality of anodic porous regions, wherein the plurality of anodic porous regions each comprise a plurality of interconnected mesoporous anodic pores, and wherein the plurality of interconnected mesoporous anodic pores are acicular and substantially parallel to one another.

4. A fuel cell system comprising:

an anode derived from a first planar silicon substrate;

a cathode derived from a second planar silicon substrate;

and a liquid electrolyte that ionically connects the anode to the cathode;

wherein the anode and the cathode are spaced apart and substantially parallel to each other so as to define a spaced apart region, wherein the liquid electrolyte is interposed between the anode and the cathode and within the spaced apart region, wherein the cathode has a plurality of cathodic porous regions, wherein the plurality of cathodic porous regions each comprise a plurality of interconnected mesoporous cathodic pores, and wherein the plurality of interconnected cathodic mesoporous pores are acicular and substantially parallel to one another.