Abstract: A flow-field plate for a flow stack in a flow cell battery system is described. The flow-field plate includes first electrolyte channels formed in a molded plate to direct a first electrolyte to a first flow-field on a first side of the molded plate and second electrolyte channels formed in the molded plate to direct a second electrolyte to a second flow-field on the second side of the molded plate.

Abstract: A flow-field plate for a flow stack in a flow cell battery system is described. The flow-field plate includes first electrolyte channels formed in a molded plate to direct a first electrolyte to a first flow-field on a first side of the molded plate and second electrolyte channels formed in the molded plate to direct a second electrolyte to a second flow-field on the second side of the molded plate.

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 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: 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 invention relates to a fuel processor that produces hydrogen from a fuel. The fuel processor comprises a reformer and a heater. The reformer includes a catalyst that facilitates the production of hydrogen from the fuel; the heater provides heat to the reformer. Multipass reformer and heater chambers are described that reduce fuel processor size. Single layer fuel processors include reformer and heater chambers in a compact form factor that is well suited for portable applications. Some fuel processors described herein place an electrically resistive material in contact with a thermally conductive material to heat fuel entering the fuel processor. This is particularly useful during start-up of the fuel processor. Fuel processors described may also include features that facilitate assembly.

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 a portable electrical energy generator, its components, and manufacture of the components and generator. The generator includes a bi-polar plate stack, which is well suited for use in a fuel cell. The stack may include at least one spacer that limits compression of a membrane electrode assembly in the fuel cell. The stack may also include a polymer binder that holds the stack together and/or maintains a compression force on the membrane electrode assembly. An open cathode manifold may also provided to ease oxygen movement. High throughput and low cost manufacture of bi-polar plates is also described herein.

Abstract: The invention relates to a fuel processor that produces hydrogen from a fuel. The fuel processor comprises a reformer and a heater. The reformer includes a catalyst that facilitates the production of hydrogen from the fuel; the heater provides heat to the reformer. Multipass reformer and heater chambers are described that reduce fuel processor size. Single layer fuel processors include reformer and heater chambers in a compact form factor that is well suited for portable applications. Some fuel processors described herein place an electrically resistive material in contact with a thermally conductive material to heat fuel entering the fuel processor. This is particularly useful during start-up of the fuel processor. Fuel processors described may also include features that facilitate assembly.

Abstract: The invention relates to a compact and portable fuel cell package. The package includes a fuel cell that generates electrical energy. Some packages also include a fuel processor that produces hydrogen from a fuel source. Fuel cell packages described herein provide power densities (power per unit volume or mass) at levels not yet seen. One package employs an interconnect disposed at least partially between a fuel cell and a fuel processor. The interconnect forms a structural and plumbing intermediary between the two. Given the portable size of fuel cell packages described herein, the invention is well suited to power portable electronics devices. One portable fuel cell package includes a tether, which allows electrical and detachable coupling to an electronics device.

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 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.