FUEL CELL

• US 20100151346A1
• Filed: 02/12/2010
• Published: 06/17/2010
• Est. Priority Date: 12/15/2008
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Eickhoff, Steven J.
• Granted Patent: US 8,932,780 B2
• Time in Patent Office: Days
• US Class Current: 429/466
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 38/0012 Mechanical treatment, e.g. roughening, deforming, stretching
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 4/8626 characterised by the form
• CPC Class Codes: H01M 8/004 Cylindrical, tubular or wound
• CPC Class Codes: H01M 8/0232 Metals or alloys
• CPC Class Codes: H01M 8/0239 Organic resins; Organic polymers
• CPC Class Codes: H01M 8/0245 in the form of layered or coated products
• CPC Class Codes: H01M 8/0252 tubular
• CPC Class Codes: H01M 8/0273 with sealing or supporting means in the form of a frame
• CPC Class Codes: H01M 8/065 by dissolution of metals or alloys; by dehydriding metallic substances
• CPC Class Codes: H01M 8/1006 Corrugated, curved or wave-shaped MEA
• CPC Class Codes: H01M 8/242 comprising framed electrodes or intermediary frame-like gaskets H01M8/2425, H01M8/244 take precedence
• CPC Class Codes: H01M 8/2465 Details of groupings of fuel cells
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly

Abstract

An example fuel cell assembly may include a proton exchange membrane (or membrane electrode assembly) that has a first major surface and a second major surface. An anode electrode, which may include a patterned metal layer with a plurality of apertures extending through the patterned metal layer, may also be provided. An anode gas diffusion layer secured to an anode adhesive frame may be situated between the anode electrode and the first major surface of the proton exchange membrane. A cathode electrode may, in some instances, include a patterned metal layer with a plurality of apertures extending through the patterned metal layer. A cathode gas diffusion layer secured to a cathode adhesive frame may be situated between the cathode electrode and the second major surface of the proton exchange membrane. In some instances a fuel cell assembly may be flexible so that the fuel cell assembly can be rolled into a rolled configuration that defines an inner cavity with open ends. A fuel pellet may be inserted into the inner cavity, and one or more end caps may be provided to cover and seal the open ends.

Claims

1. A fuel cell assembly, comprising:

a proton exchange membrane having a first major surface and a second major surface;

an anode electrode, the anode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer;

an anode gas diffusion layer with an anode adhesive frame, wherein the anode gas diffusion layer with the anode adhesive frame is situated between the anode electrode and the first major surface of the proton exchange membrane, wherein the anode gas diffusion layer and the anode adhesive frame lie substantially in a common plane;

a cathode electrode, the cathode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer; and

a cathode gas diffusion layer with a cathode adhesive frame, wherein the cathode gas diffusion layer with the cathode adhesive frame is situated between the cathode electrode and the second major surface of the proton exchange membrane, wherein the cathode gas diffusion layer and the cathode adhesive frame lie substantially in a common plane.

2. The fuel cell assembly of claim 1, wherein:

the fuel cell assembly is arranged in a rolled configuration to define an inner cavity; and

a fuel pellet disposed in the cavity.

3. The fuel cell assembly of claim 2, wherein the fuel cell assembly includes opposing edges, wherein when the fuel cell assembly is arranged in the rolled configuration, the two opposing edges of the fuel cell assembly are secured together to define the inner cavity.

4. The fuel cell assembly of claim 3, further comprising end caps for covering each of the two open ends of the fuel cell assembly when the fuel cell assembly is arranged in the rolled configuration.

5. The fuel cell assembly of claim 1, wherein the anode electrode includes a substrate, a dielectric layer on the substrate, and a patterned metal layer on the dielectric layer, wherein the plurality of apertures of the anode electrode extend through the patterned metal layer, the dielectric layer and the substrate.

6. The fuel cell assembly of claim 5, wherein the substrate is a metal foil.

7. The fuel cell assembly of claim 5, wherein the substrate extends beyond the pattern metal layer in at least one region of the anode electrode.

8. The fuel cell assembly of claim 5, wherein the cathode electrode includes a substrate, a dielectric layer on the substrate, and a patterned metal layer on the dielectric layer, wherein the plurality of apertures of the cathode electrode extend through the patterned metal layer, the dielectric layer and the substrate.

9. A method for forming a fuel cell stack, the method comprising:

providing an anode electrode, the anode electrode including a plurality of apertures;

disposing an anode gas diffusion layer adjacent the anode electrode,

disposing a membrane electrode assembly adjacent the anode gas diffusion layer;

disposing a cathode gas diffusion layer adjacent the membrane electrode assembly;

providing a cathode electrode adjacent the cathode gas diffusion layer; and

securing the anode electrode, anode gas diffusion layer, membrane electrode assembly, cathode gas diffusion layer and cathode electrode together to form a relatively planar fuel cell assembly having opposing edges; and

rolling the fuel cell assembly into a rolled configuration to define an inner cavity.

10. The method of claim 9, wherein when the fuel cell assembly is arranged in the rolled configuration, the two opposing edges of the fuel cell assembly are secured together to define the inner cavity.

11. The method of claim 10, wherein the two opposing edges of the fuel cell assembly are secured together by a weld bond.

12. The method of claim 10, wherein the two opposing edges of the fuel cell assembly are secured together by an adhesive bond.

13. The method of claim 10, further comprising:

installing end caps for covering each of two open ends of the fuel cell assembly when the fuel cell assembly is arranged in the rolled configuration.

14. The method of claim 9 further comprising:

inserting a fuel pellet into the cavity.

15. The method of claim 9, wherein rolling the fuel cell assembly includes rolling the fuel cell assembly into a substantially cylindrical configuration.

16. A fuel cell assembly, comprising:

a proton exchange membrane having a first major surface and a second major surface;

an anode electrode, the anode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer;

an anode gas diffusion layer secured to an anode adhesive frame, wherein the anode gas diffusion layer and the anode adhesive frame are situated between the anode electrode and the first major surface of the proton exchange membrane;

a cathode electrode, the cathode electrode including a patterned metal layer with a plurality of apertures extending through the patterned metal layer;

a cathode gas diffusion layer secured to a cathode adhesive frame, wherein the cathode gas diffusion layer and the cathode adhesive frame are situated between the cathode electrode and the second major surface of the proton exchange membrane;

wherein, the fuel cell assembly is arranged in a rolled configuration to define an inner cavity with open ends; and

one or more end caps for covering the open ends.

17. The fuel cell assembly of claim 16 further comprising a fuel pellet disposed in the inner cavity.

18. The fuel cell assembly of claim 16, wherein when the fuel cell assembly is arranged in the rolled configuration, two opposing edges of the fuel cell assembly are secured together to define the inner cavity.

19. The fuel cell assembly of claim 18, wherein the two opposing edges of the fuel cell assembly are secured together by a weld bond.

20. The fuel cell assembly of claim 18, wherein the two opposing edges of the fuel cell assembly are secured together by an adhesive bond.