Abstract: The invention relates to fuel cell systems with improved thermal efficiency. The systems include a fuel cell that generates electrical energy using hydrogen and a fuel processor that produces hydrogen from a fuel. Some heat efficient systems described herein include a thermal catalyst that generates heat when the catalyst interacts with a heating medium. The heat is used to heat the fuel cell. The thermal catalyst may be disposed in, proximity to the fuel cell, or remote from the fuel cell and a heat transfer pipe conducts heat from the catalyst to the fuel cell. Another thermally efficient embodiment uses a recuperator to transfer heat generated in the fuel cell system to incoming fuel. A fuel cell package may also include a multi-layer insulation arrangement to decrease heat loss from the fuel cell and fuel processor, which both typically operate at elevated temperatures.

Abstract: The invention relates to systems and methods that improve distribution of fuel cartridges. The cartridges include compatibility information. A controller on the device validates the compatibility information before permitting fuel provision from the cartridge to the device. Invalid compatibility information, or absence of the compatibility information, then denies fuel flow to the device. This permits the device to validate that the cartridge and its contents are acceptable. This improves distribution by allowing the device or fuel cell manufacturer to implement cartridge selectivity by permitting cartridges from select manufacturers to provide fuel and denying cartridge of other manufacturers from providing fuel. Compatibility information stored in the cartridge memory may also be encrypted to prevent open access to the compatibility information. The compatibility information also improves fuel refilling distribution.

Abstract: The present invention relates to compact and high power density fuel cells. The fuel cells generate electrical energy and include a three-dimensional (3-D) architecture. The 3-D architectures include active surfaces whose dimensions may be varied during fuel cell design in three dimensions. Fabrication of the 3-D architectures may use wafer-processing technologies such as etching and deposition on etched surfaces. Fuel cells described herein provide power densities (power per unit volume or mass) at levels not yet seen in the fuel cell industry; some fuel cells are small enough to fit in a cell phone and power the cell phone.

Abstract: Described herein are fuel cell systems and methods of using fuel cell systems. The systems include a fuel cell that generates electrical energy using hydrogen and a fuel processor that produces hydrogen from a fuel source. The fuel processor includes a reformer and a burner that heats the reformer. One heat efficient fuel cell system described herein heats internal portions of a fuel cell using a heating medium from a fuel processor. The heating medium may comprise gases exhausted at high temperatures from the fuel processor, which are then transported to the fuel cell. The heating medium may also include a gas that reacts catalytically in the fuel cell to produce heat. Systems and methods for expediting fuel cell system start up are provided. Methods for shutting down a fuel cell system are also described that reduce the amount of moisture and gases in the reformer and in one or more fuel cell components. One hydrogen efficient fuel cell system described herein transports hydrogen to an inlet of a burner.

Abstract: Described herein is a fuel processor that produces hydrogen from a fuel source. The fuel processor comprises a reformer and burner. The reformer includes a catalyst that facilitates the production of hydrogen from the fuel source. Voluminous reformer chamber designs are provided that increase the amount of catalyst that can be used in a reformer and increase hydrogen output for a given fuel processor size. The burner provides heat to the reformer. One or more burners may be configured to surround a reformer on multiple sides to increase thermal transfer to the reformer. Dewars are also described that increase thermal management of a fuel processor and increase burner efficiency. A dewar includes one or more dewar chambers that receive inlet air before a burner receives the air. The dewar is arranged such that air passing through the dewar chamber intercepts heat generated in the burner before the heat escapes the fuel processor.