Micro fuel cell

• US 7,879,472 B2
• Filed: 05/21/2004
• Issued: 02/01/2011
• Est. Priority Date: 12/29/2003
• Status: Expired due to Fees

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Rezachek, Tom, Wood, Roland A.
• Primary Examiner(s): Hodge; Robert
• Application Number:
  US10/850,673
• Publication Number:
  US 20050260461A1
• Time in Patent Office: 2,447 Days
• Field of Search: None
• US Class Current: 429/453
• CPC Class Codes: H01M 2250/30 Fuel cells in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 8/0247 characterised by the form characterised by a channel configuration H01M8/0258
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• 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 8/1023 having only carbon, e.g. polyarylenes, polystyrenes or polybutadiene-styrenes
• CPC Class Codes: H01M 8/1039 halogenated, e.g. sulfonated polyvinylidene fluorides
• CPC Class Codes: H01M 8/241 with solid or matrix-supported electrolytes
• CPC Class Codes: Y02B 90/10 Applications of fuel cells in buildings
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 156/1056 Perforating lamina
• CPC Class Codes: Y10T 156/1062 Prior to assembly

Abstract

A fuel cell, fuel cell array and methods of forming the same are disclosed. The fuel cell can be made by forming a first aperture defined by a first aperture surface through a first electrode layer and forming a second aperture defined by a second aperture surface through a second electrode layer. A proton exchange membrane is laminated between the first electrode layer and the second electrode layer. At least a portion of the first aperture is at least partially aligned with the second aperture.

Claims

1. A fuel cell comprising:

a first substantially planar substrate defining a first aperture therethrough;

a second substantially planar substrate defining a second aperture therethrough;

a proton exchange membrane having a first major surface and an opposing second major surface, with an edge extending between the first major surface and the second major surface, the proton exchange membrane disposed between the first substantially planar substrate and the second substantially planar substrate so that the first major surface is supported by the first substantially planar substrate and the second major surface is supported by the second substantially planar substrate, the proton exchange membrane also spanning across the first aperture and the second aperture;

wherein, the first aperture is at least partially aligned with the second aperture and the proton exchange layer is unsupported across at least a major portion of the first aperture and the second aperture;

the first substantially planar substrate having a portion that extends laterally beyond the edge of the proton exchange membrane;

the second substantially planar substrate having a portion that extends laterally beyond the edge of the proton exchange membrane;

a first electrode extending along the first substantially planar substrate from the first aperture to the portion of the first substantially planar substrate that extends laterally beyond the edge of the proton exchange membrane; and

a second electrode extending along the second substantially planar substrate from the second aperture to the portion of the second substantially planar substrate that extends laterally beyond the edge of the proton exchange membrane, wherein the first and second electrodes are positioned to be electrically connected at a location that is beyond the edge of the proton exchange membrane.

2. The fuel cell according to claim 1, wherein the proton exchange membrane has a thickness of 1 mil or less.

3. The fuel cell according to claim 2, wherein at least one of the first aperture and the second aperture has a cross-sectional area of 1 mm² or less.

4. The fuel cell according to claim 2, wherein the aligned portion of the first aperture and the second aperture has a cross-sectional area of 1 mm² or less.

5. The fuel cell according to claim 1, wherein the first substrate has a thickness of 2 mil or less.

6. The fuel cell according to claim 5, wherein the second substrate has a thickness of 2 mil or less.

7. The fuel cell according to claim 1 wherein the first electrode is positioned on an inner surface of the first substantially planar substrate facing the proton exchange membrane.

8. The fuel cell according to claim 7 wherein the second electrode is positioned on an inner surface of the second substantially planar substrate facing the proton exchange membrane.

9. The fuel cell according to claim 8 wherein the second electrode extends adjacent to the second aperture.

10. A fuel cell according to claim 9 wherein the inner surface of the first substantially planar substrate extends beyond the edge of the proton exchange membrane to a first interconnect region, and the inner surface of the second substantially planar substrate extends beyond the edge of the proton exchange membrane to a second interconnect region, wherein the first electrode extends into the first interconnect region and the second electrode extends into the second interconnect region.