Abstract: A phosphoric acid fuel cell according to one embodiment includes an array of microchannels defined by a porous electrolyte support structure extending between bottom and upper support layers, the microchannels including fuel and oxidant microchannels; fuel electrodes formed along some of the microchannels; and air electrodes formed along other of the microchannels. A method of making a phosphoric acid fuel cell according to one embodiment includes etching an array of microchannels in a substrate, thereby forming walls between the microchannels; processing the walls to make the walls porous, thereby forming a porous electrolyte support structure; forming anode electrodes along some of the walls; forming cathode electrodes along other of the walls; and filling the porous electrolyte support structure with a phosphoric acid electrolyte. Additional embodiments are also disclosed.

Abstract: A microreactor comprising a silicon wafer, a multiplicity of microchannels in the silicon wafer, and a catalyst coating the microchannels. In one embodiment the catalyst coating the microchannels comprises a nanostructured material. In another embodiment the catalyst coating the microchannels comprises an aerogel. In another embodiment the catalyst coating the microchannels comprises a solgel. In another embodiment the catalyst coating the microchannels comprises carbon nanotubes.

Abstract: A phosphoric acid fuel cell according to one embodiment includes an array of microchannels defined by a porous electrolyte support structure extending between bottom and upper support layers, the microchannels including fuel and oxidant microchannels; fuel electrodes formed along some of the microchannels; and air electrodes formed along other of the microchannels. A method of making a phosphoric acid fuel cell according to one embodiment includes etching an array of microchannels in a substrate, thereby forming walls between the microchannels; processing the walls to make the walls porous, thereby forming a porous electrolyte support structure; forming anode electrodes along some of the walls; forming cathode electrodes along other of the walls; and filling the porous electrolyte support structure with a phosphoric acid electrolyte. Additional embodiments are also disclosed.

Abstract: A phosphoric acid fuel cell system comprising a porous electrolyte support, a phosphoric acid electrolyte in the porous electrolyte support, a cathode electrode contacting the phosphoric acid electrolyte, and an anode electrode contacting the phosphoric acid electrolyte.

Abstract: A phosphoric acid fuel cell system comprising a porous electrolyte support, a phosphoric acid electrolyte in the porous electrolyte support, a cathode electrode contacting the phosphoric acid electrolyte, and an anode electrode contacting the phosphoric acid electrolyte.

Abstract: A microreactor comprising a silicon wafer, a multiplicity of microchannels in the silicon wafer, and a catalyst coating the microchannels. In one embodiment the catalyst coating the microchannels comprises a nanostructured material. In another embodiment the catalyst coating the microchannels comprises an aerogel. In another embodiment the catalyst coating the microchannels comprises a solgel. In another embodiment the catalyst coating the microchannels comprises carbon nanotubes.

Abstract: A phosphoric acid fuel cell system comprising a porous electrolyte support, a phosphoric acid electrolyte in the porous electrolyte support, a cathode electrode contacting the phosphoric acid electrolyte, and an anode electrode contacting the phosphoric acid electrolyte.

Abstract: A microreactor comprising a silicon wafer, a multiplicity of microchannels in the silicon wafer, and a catalyst coating the microchannels. In one embodiment the catalyst coating the microchannels comprises a nanostructured material. In another embodiment the catalyst coating the microchannels comprises an aerogel. In another embodiment the catalyst coating the microchannels comprises a solgel. In another embodiment the catalyst coating the microchannels comprises carbon nanotubes.

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: 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: 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: A microreactor comprising a silicon wafer, a multiplicity of microchannels in the silicon wafer, and a catalyst coating the microchannels. In one embodiment the catalyst coating the microchannels comprises a nanostructured material. In another embodiment the catalyst coating the microchannels comprises an aerogel. In another embodiment the catalyst coating the microchannels comprises a solgel. In another embodiment the catalyst coating the microchannels comprises carbon nanotubes.

Abstract: A phosphoric acid fuel cell system comprising a porous electrolyte support, a phosphoric acid electrolyte in the porous electrolyte support, a cathode electrode contacting the phosphoric acid electrolyte, and an anode electrode contacting the phosphoric acid electrolyte.

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: A chemical microreactor with a high aspect ratio. In one embodiment the chemical microreactor has a chemical microreactor section with channels having a height and with spacings having a width. There is a high aspect ratio of the height to the width. The high aspect ratio in one embodiment is more than substantially 5:1. The high aspect ratio in another embodiment is more than substantially 10:1. The high aspect ratio another embodiment is more than substantially 15:1. The high aspect ratio in one embodiment is substantially 20:1.