Abstract: The present invention relates to fuel cells and components used within a fuel cell. Heat transfer appendages are described that improve fuel cell thermal management. Each heat transfer appendage is arranged on an external portion of a bi-polar plate and permits conductive heat transfer between inner portions of the bi-polar plate and outer portions of the bi-polar plate proximate to the appendage. The heat transfer appendage may be used for heating or cooling inner portions of a fuel cell stack. Improved thermal management provided by cooling the heat transfer appendages also permits new channel field designs that distribute the reactant gases to a membrane electrode assembly. Flow buffers are described that improve delivery of reactant gases and removal of reaction products. Single plate bi-polar plates may also include staggered channel designs that reduce the thickness of the single plate.

Abstract: The invention relates to a fuel processor that produces hydrogen from a fuel and includes a low pressure drop burner. The low pressure drop burner permits the use of a low pressure air supply such as a fan to move products and reactants through the burner.

Abstract: In one embodiment, a fuel processor for use in a fuel cell system, may have a bottom plate, having a regenerator having a first inlet to receive an air flow, a burner flow chamber within the regenerator, the burner flow chamber having a second inlet to receive the air flow from the regenerator, and a reformer flow chamber positioned between the regenerator and the burner flow chamber, the reformer flow chamber having a third inlet to receive the air flow from the burner chamber, wherein the burner flow chamber and the reformer flow chamber is formed of a monolithic structure having an elongated, rounded baffle in the center of the monolithic structure. The fuel processor may also have a top plate coupled to the bottom plate to enclose the fuel processor, the top plate having a top surface and a bottom surface.

Abstract: The present invention relates to fuel cells and components used within a fuel cell. Heat transfer appendages are described that improve fuel cell thermal management. Each heat transfer appendage is arranged on an external portion of a bi-polar plate and permits conductive heat transfer between inner portions of the bi-polar plate and outer portions of the bi-polar plate proximate to the appendage. The heat transfer appendage may be used for heating or cooling inner portions of a fuel cell stack. Improved thermal management provided by cooling the heat transfer appendages also permits new channel field designs that distribute the reactant gases to a membrane electrode assembly. Flow buffers are described that improve delivery of reactant gases and removal of reaction products. Single plate bi-polar plates may also include staggered channel designs that reduce the thickness of the single plate.

Abstract: Fuel cell systems and methods are described. A method for generating electrical energy in a fuel cell receives hydrogen from a fuel processor configured to process a fuel source to produce the hydrogen, includes transporting a heating medium from the fuel processor to the fuel cell when electrical energy output by the fuel cell includes less than an electrical threshold or when temperature of a component in the fuel cell is less than a temperature threshold, heating a portion of the fuel cell, transporting hydrogen from the fuel processor to the fuel cell, detecting temperature of the component or electrical output of the fuel cell, and generating electrical energy in the fuel cell when the temperature of the component is about equal to or greater than the threshold temperature or when electrical energy output by the fuel cell is about equal to or greater than an electrical threshold.

Abstract: Described herein is a fuel processor that produces hydrogen from a fuel source. The fuel processor comprises a reformer, boiler and burner. The reformer includes a catalyst to facilitate the production of hydrogen from the fuel source. A boiler heats the fuel source before receipt by the reformer. The burner provides heat to the reformer and to the boiler. The fuel processor may also comprise a dock that maintains position of the reformer and boiler within the fuel processor. Dewars are also described that improve thermal management of a fuel processor by reducing heat loss and increasing burner efficiency.

Abstract: Described herein is a fuel processor that produces hydrogen from a fuel source. The fuel processor comprises a reformer, boiler and burner. The reformer includes a catalyst to facilitate the production of hydrogen from the fuel source. A boiler heats the fuel source before receipt by the reformer. The burner provides heat to the reformer and to the boiler. The fuel processor may also comprise a dock that maintains position of the reformer and boiler within the fuel processor. Dewars are also described that improve thermal management of a fuel processor by reducing heat loss and increasing burner efficiency.

Abstract: A method for manufacturing a fuel processor may comprise coupling a plurality of micro-tubes in parallel to form a flow field tube array, each of the plurality of micro-tubes designed to receive a fluid flow, depositing a catalyst layer inside each of the plurality of micro-tubes, and attaching at least one burner to a first end of the flow field tube array.

Abstract: In one embodiment, an engine block may comprise an interconnect having: a first manifold section, a second manifold section perpendicular to the first manifold section, the first manifold section and the second manifold section having a plurality of conduits to receive a gas flow, wherein the first manifold section and the second manifold section are formed from a single manifold device; a fuel cell stack housing coupled to the second manifold section to receive a fuel cell stack; and a fuel processor coupled to the first manifold section, wherein the fuel cell processor and the fuel cell stack operate at substantially the same temperature.

Abstract: Described herein is a portable storage device that stores a hydrogen fuel source. The storage device includes a bladder that contains the hydrogen fuel source and conforms to the volume of the hydrogen fuel source. A housing provides mechanical protection for the bladder. The storage device also includes a connector that interfaces with a mating connector to permit transfer of the fuel source between the bladder and a device that includes the mating connector. The device may be a portable electronics device such as a laptop computer. Refillable hydrogen fuel source storage devices and systems are also described. Hot swappable fuel storage systems described herein allow a portable hydrogen fuel source storage device to be removed from a fuel processor or electronics device it provides the hydrogen fuel source to, without shutting down the receiving device or without compromising hydrogen fuel source provision.

Abstract: Described herein is a portable storage device that stores a hydrogen fuel source. The storage device includes a bladder that contains the hydrogen fuel source and conforms to the volume of the hydrogen fuel source. A housing provides mechanical protection for the bladder. The storage device also includes a connector that interfaces with a mating connector to permit transfer of the fuel source between the bladder and a device that includes the mating connector.

Abstract: The invention relates to hybrid fuel cell systems that protect a fuel cell with a second electrical energy source. The second electrical energy source powers a load to prevent the fuel cell from witnessing stoichiometric levels that may lead to reductions in fuel cell performance or health. The hybrid fuel cell system includes an electrical circuit that electrically initiates the electrical energy source to provide power to the load in response to detecting a potential stoichiometric disturbance for the fuel cell.

Abstract: In one embodiment, a fuel cell stack for use in a fuel cell comprises a plurality of cathode flow field plates having a first plurality of through-cuts to form a first plurality of shared flow fields to receive a first reactant gas flow, a plurality of anode flow field plates having a second plurality of through-cuts to form a second plurality of shared flow fields to receive a second reactant gas flow, and a plurality of MEA layers, each MEA layer disposed between one of the plurality of cathode flow field plates and one of the plurality of anode flow field plates, each of the MEA layers including an anode electrode a cathode electrode, wherein adjacent cathode electrodes of adjacent MEA layers share the first plurality of shared flow fields, and wherein adjacent anode electrodes of adjacent MEA layers share the second plurality of shared flow fields.

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.

Abstract: In one embodiment, a fuel processor for use in a fuel cell system, may have a bottom plate, having a regenerator having a first inlet to receive an air flow, a burner flow chamber within the regenerator, the burner flow chamber having a second inlet to receive the air flow from the regenerator, and a reformer flow chamber positioned between the regenerator and the burner flow chamber, the reformer flow chamber having a third inlet to receive the air flow from the burner chamber, wherein the burner flow chamber and the reformer flow chamber is formed of a monolithic structure having an elongated, rounded baffle in the center of the monolithic structure. The fuel processor may also have a top plate coupled to the bottom plate to enclose the fuel processor, the top plate having a top surface and a bottom surface.

Abstract: Described herein are systems and methods that test authentication information on a fuel cartridge. A controller on a device that interfaces with the cartridge tests and validates the authentication information before permitting fuel provision from the cartridge. The authentication information can be used to prevent unauthorized cartridges from providing fuel. This permits the device to ensure that the cartridge, its manufacturer, and/or its contents are acceptable. Authentication information stored in a cartridge memory may also be encrypted.

Abstract: Described herein are portable fuel cell systems for producing electrical energy. The portable fuel cell systems include a fuel processor including a reformer and a burner. The reformer receives fuel and outputs hydrogen using the fuel. The burner processes fuel to generate heat. The system also includes a fuel cell configured to produce electrical energy using hydrogen output by the reformer. The system also includes a heat exchanger configured to transfer heat generated in the fuel cell or generated in the fuel processor to a reactant fluid.