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 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 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: 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 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 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 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 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: A power adaptor for use with a portable fuel cell system may have an adapter housing having at least one external surface and a battery receiving region, the battery receiving region configured to at least partially receive a battery, a first set of electrical contacts provided on the at least one external surface of the adapter housing, a power source interface provided within the battery receiving region of the adapter housing, the power source interface in electrical communication with the first set of electrical contacts, and at least one mechanical connector provided in or on the adapter housing to facilitate detachable attachment of the adapter housing to a fuel cell system housing.

Abstract: Described herein is a portable fuel cell system with water recovery capabilities. The system generates one or more exhaust streams from which water can be recovered. A water removal system contained in the portable fuel cell system package draws water from an exhaust stream; the exhaust may include a burner exhaust, a reformer exhaust, and/or a fuel cell exhaust. The water can then be provided to the incoming fuel.

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 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.