Abstract: A channeled metal clad fiber comprises one or more surface channels that extend along directions substantially parallel to the longitudinal axis of such fiber. Metal clad fibers may include multiple protective layers, and one or more protective layers may contain multiple conductors therein. A microfibrous fuel cell structure includes a hollow microfibrous membrane separator having an electrolyte medium therein and defining a bore side and a shell side. An inner current collector formed of a channeled metal clad or unclad metal fiber, and an inner electrocatalyst layer are positioned at the bore side of such fuel cell, and an outer current collector and an outer electrocatalyst layer are positioned at the shell side thereof. Surface channels on the inner current collector provide inner fluid passages for passing a fuel-containing or an oxidant-containing fluid through the microfibrous fuel cell.

Abstract: The present invention relates to fuel cell modules. The fuel cell module includes a housing that contains a plurality of fuel cell elements called unicells. Each unicell comprises a plurality of microcells. The housing is divided into a plurality of housing sections. A compressible bulkhead disposed between two adjacent housing sections and has a plurality of holes formed therein to allow respective unicells to pass through the bulkhead. A clamp element compresses the bulkhead to form a gas-tight seal between said bulkhead and the unicells.

Abstract: The present invention relates to microfibrous fuel cell sub-bundle structures, fuel cell bundles and fuel cell assemblies formed by such fuel cell sub-bundles and bundles. Specifically, a fuel cell sub-bundle is provided, which comprises multiple microfibrous fuel cells. Each microfibrous fuel cell comprises: (a) a hollow microfibrous membrane separator comprising an electrolyte medium, (b) an inner electrocatalyst layer in contact with an inner surface of such membrane separator, (c) an outer electrocatalyst layer in contact with an outer surface of such membrane separator, and (d) an individual current collector in electrical contact with the inner surface of such membrane separator. Each of such multiple microfibrous fuel cells is in electrical contact with a common current collector at the outer surface of its membrane separator.

Abstract: A microfibrous fuel cell structure of elongated form with a longitudinal axis. Such microfibrous fuel cell includes electrocatalyst layers supported by a fiber network formed of unidirectional or substantially unidirectional conductive fibers. The conductive fibers of such fiber network are oriented parallelly or substantially parallelly to the longitudinal axis of the fuel cell, therefore allowing such fiber network to conform to the curvature of the microfibrous fuel cell along the radial direction but without causing overbending of the individual fibers.

Abstract: The present invention relates to a substrate-supported process for continuous and automated manufacturing of microfibrous fuel cells and other electrochemical cells. Specifically, a removable substrate layer is formed around an inner current collector, followed by sequentially coating multiple structure layers, such as the inner catalyst layer, the membrane separator, and the outer catalyst layer, over such removable substrate layer, and subsequent removing such removable substrate layer, so as to form a lumen around the inner current collector, to allow passage of fluid therethrough. The removable substrate layer preferably comprises a water-soluble polymer, such as polyvinyl pyrrolidone (PVP), polyvinyl alcohol (PVA), or polyethylene glycol (PEG).

Abstract: The present invention relates to fuel cell modules. The fuel cell module includes a housing that contains a plurality of fuel cell elements called unicells. Each unicell comprises a plurality of microcells. The housing is divided into a plurality of housing sections. A compressible bulkhead disposed between two adjacent housing sections and has a plurality of holes formed therein to allow respective unicells to pass through the bulkhead. A clamp element compresses the bulkhead to form a gas-tight seal between said bulkhead and the unicells.

Abstract: The present invention relates to fuel cell assembly having a plurality of microcells, and to methods of assembling fuel cell assemblies from microcells. A plurality of microcells is circumferentially spaced around a central member. Each microcell comprises an inner current collector having one or more microchannels formed therein, a proton exchange membrane surrounding said inner current collector, and an outer current collector disposed on the outside of said proton exchange membrane. A first electrical connector disposed at a first end of the fuel cell assembly electrically connects to the inner current collectors of said microcells. A second electrical connector disposed at a second end of the fuel cell assembly electrically connects to the outer current collectors of the microcells. In one embodiment, inner and outer seals are disposed in spaced relation to one another adjacent the first end of said fuel cell assembly.

Abstract: The present invention relates to a gas storage and dispensing system, which comprising a carrier material for a target gas and multiple microtubular elements in contact with such carrier material. Each microtubular element comprises a tubular wall that defines a bore side and a shell side that are sealed from each other, preferably by one or more potting members. The carrier material is either at the bore sides or at the shell sides of the microtubular elements, and it can be either a solid sorbent material for the target gas, or a liquid carrier therefor. Such gas storage and dispensing system is particular useful for hydrogen storage, when the carrier material can be a hydrogen-sorbent that contains hydrogen gas, or liquefied hydrogen, or an organic hydrogen solution, or a metal hydride solution capable of generating hydrogen gas. Such microtubular elements can further be designed as microfibrous fuel cells, while each microfibrous fuel cell comprises a carrier material at its bore side.

Abstract: The present invention relates to a channeled metal clad fiber comprising one or more surface channels that extend along directions that are substantially parallel to the longitudinal axis of such fiber. The present invention also provides a microfibrous fuel cell structure that comprises a hollow microfibrous membrane separator having an electrolyte medium therein and defining a bore side and a shell side. An inner current collector, which is formed of a channeled metal clad fiber or a channeled metal fiber that is unclad, and an inner electrocatalyst layer are positioned at the bore side of such microfibrous fuel cell, and an outer current collector and an outer electrocatalyst layer are positioned at the shell side of such microfibrous fuel cell. The surface channels on such inner current collector provide inner fluid passages for passing a fuel-containing or an oxidant-containing fluid through the microfibrous fuel cell.

Abstract: Fuel cells having microfibrous hollow membrane separators with fiber-reinforced ion exchange polymeric membrane walls. The reinforcing fibers are continuous and extend along directions which are substantially parallel to the longitudinal axis of the microfibrous fuel cell.

Abstract: The present invention relates to a substrate-supported process for continuous and automated manufacturing of microfibrous fuel cells and other electrochemical cells. Specifically, a removable substrate layer is formed around an inner current collector, followed by sequentially coating multiple structure layers, such as the inner catalyst layer, the membrane separator, and the outer catalyst layer, over such removable substrate layer, and subsequent removing such removable substrate layer, so as to form a lumen around the inner current collector, to allow passage of fluid therethrough. The removable substrate layer preferably comprises a water-soluble polymer, such as polyvinyl pyrrolidone (PVP), polyvinyl alcohol (PVA), or polyethylene glycol (PEG).

Abstract: The present invention relates to microfibrous fuel cell sub-bundle structures, fuel cell bundles and fuel cell assemblies formed by such fuel cell sub-bundles and bundles. Specifically, a fuel cell sub-bundle is provided, which comprises multiple microfibrous fuel cells. Each microfibrous fuel cell comprises: (a) a hollow microfibrous membrane separator comprising an electrolyte medium, (b) an inner electrocatalyst layer in contact with an inner surface of such membrane separator, (c) an outer electrocatalyst layer in contact with an outer surface of such membrane separator, and (d) an individual current collector in electrical contact with the inner surface of such membrane separator. Each of such multiple microfibrous fuel cells is in electrical contact with a common current collector at the outer surface of its membrane separator.

Abstract: The present invention relates to microfibrous fuel cell sub-bundle structures, fuel cell bundles and fuel cell assemblies formed by such fuel cell sub-bundles and bundles. Specifically, a fuel cell sub-bundle is provided, which comprises multiple microfibrous fuel cells. Each microfibrous fuel cell comprises: (a) a hollow microfibrous membrane separator comprising an electrolyte medium, (b) an inner electrocatalyst layer in contact with an inner surface of such membrane separator, (c) an outer electrocatalyst layer in contact with an outer surface of such membrane separator, and (d) an individual current collector in electrical contact with the inner surface of such membrane separator. Each of such multiple microfibrous fuel cells is in electrical contact with a common current collector at the outer surface of its membrane separator.

Abstract: A fibrous microcell structure comprising: (1) an inner electrode, (2) a hollow fibrous membrane separator in contact with the inner electrode, (3) an electrolyte embedded in the hollow fibrous membrane separator, and (4) an outer electrode, wherein at least one of the inner and outer electrodes comprises a metal clad composite having two or more metal layers bonded together by solid-phase bonding. Preferably, such fibrous microcell structure is a fuel cell that comprises inner current collector, an inner catalyst layer, a hollow fibrous membrane separator in contact with the inner catalyst layer and the inner current collector, an electrolyte embedded in the hollow fibrous membrane separator, an outer catalyst layer, and an outer current collector.

Abstract: Corrosion management componentry for use in fibrous electrochemical systems for generation/conversion of energy. Fibrous structures are provided for enhanced resistance to oxidative degradation of microcell-based high voltage, high power density fuel cell and battery systems.

Abstract: Microcell structures and assemblies utilized for electrochemical generation/conversion of energy, in which high voltage, high power density outputs are produced for applications such as fuel cell and battery systems, with high efficiency extraction of heat produced in electrochemical reaction. The superior efficacy of thermal management achieved by the invention permits highly compact, small footprint electrochemical cells to be usefully employed in a variety of vehicular, consumer and industrial applications.

Abstract: A microcell assembly wherein water is generated by electrochemical reaction and sorptive channeling elements are provided in the assembly to remove excess water from the locus of electrochemical reaction. The water management techniques of the invention enhance electrochemical generation/conversion of energy, and facilitate high voltage, high power density outputs for applications such as fuel cell and battery systems.

Abstract: Fabrication process for manufacture of microcell structures and assemblies, in which a microcell precursor is contacted with one or more of electrolytes, electrocatalysts, electrocatalyst reducing agents, and hydrophicity-imparting materials. The process may derive the precursor from a high rate extrusion process in which the electrocatalyst is impregnated, coated or extruded on a fibrous substrate to form an electrode. The process of the invention permits the high volume production of fibrous microcell elements for correlative high volume production of highly compact, small footprint electrochemical cells useful for a variety of vehicular, consumer and industrial applications.

Abstract: Series-connected microcell structures and assemblies are efficiently utilized for electrochemical generation/conversion of energy. The microcell structures of the invention are readily constructed from discrete fibrous microcell elements that are fabricated in sheet form and assembled into layered, sub-bundled and bundled conformations that produce high voltage, high power density outputs in applications such as fuel cell and battery systems.

Abstract: A fibrous microcell structure comprising at least one electrically conductive fibrous element circumscribed by a porous membrane separator having coated, impregnated or extruded at an inner surface thereof a first electrocatalyst layer having an electrically conductive hydrogen- or oxygen-permselective membrane thereon, with an electrolyte disposed in porosity of the porous membrane separator. The structure includes a central lumen, at least one electrically conductive fibrous element and interstitial volume accommodating flow of feed through the lumen, at least one electrically conductive fibrous element in contact with the second electrocatalyst layer, and the porous membrane separator at its outer surface being in contact with an electrocatalyst and at least one electrically conductive fiber.