Abstract: A complete fuel cell system (10) is disclosed. The fuel cell system (10) comprises at least two fuel precursors (16, 18) that react to create hydrogen. A solid fuel precursor (18) can be carried in disposable fuel cartridges (100). A passive pressure control system including a dose pump (22) and a pressure equalization system (24, 300, 504) is provided to dose a liquid fuel precursor (16) to the solid fuel precursor (18) in the fuel cartridge (100). The solid fuel precursor (18) may include larger metallic particles coated by another fine metallic particles such that multiple micro galvanic cells are formed on the surface of the larger metallic particles. The fuel cell system (10) may also include a gas buffer (40) that stores produced hydrogen that is unneeded by the fuel cell, a water trapping mechanism (604) and an electronic vent (46) that consumes unneeded hydrogen.

Abstract: The present invention relates to electrically conductive paths in planar substrates. Various embodiments provide a method of forming one or more electrically conductive paths in a planar substrate, wherein substantially none of the substrate is removed during formation of the path. In various embodiments, by avoiding the removal of substrate during formation of the electrically conductive path, problems caused by residual substrate material can be advantageously avoided. In various embodiments, the planar substrate with the electrically conductive path can be used to make a planar fuel cell array.

Abstract: A fuel cell system with planar manifold having at least one fuel cell assembly with a first side and a second side; a plurality of anodes on the first side; a plurality of cathodes on the second side; ion-conducting electrolyte between the first and second sides; a fluid manifold assembly fluidly connected to the first side. In the planar manifold a first barrier layer provides at least one inlet port in fluid communication with a hydrogen source, and at least one outlet port to remove any unreacted hydrogen and byproducts from the first side; a plurality of conduit layers, on at least one of which is disposed one or more channels fluidly connected to the at least one inlet port and one of which is fluidly connected to the at least one outlet port; and, a second barrier layer disposed above the plurality of conduit layers containing a plurality of perforations affixed to the first side to supply hydrogen gas.

Abstract: An electrochemical cell system includes a fluid manifold having a layered structure. The fluid manifold includes at least one conduit layer having a first side and a second side. The at least one conduit later has at least one conduit channel.

Abstract: Embodiments of the present invention relate to a fluid distribution system. The system may include one or more electrochemical cell layers, a bulk distribution manifold having an inlet, a cell layer feeding manifold in direct fluidic contact with the electrochemical cell layer and a separation layer that separates the bulk distribution manifold from the cell feeding manifold, providing at least two independent paths for fluid to flow from the bulk distribution manifold to the cell feeding manifold.

Abstract: Methods of manufacturing a fuel cell array that include selectively removing portions of a coating layer from a composite layer. The composite layer includes a first surface and a second surface and a first coating is disposed over at least a portion of the first surface. A laser or mechanical tool is used to selectively remove portions of the first coating to form discontinuity regions at predetermined positions in the first coating.

Abstract: Fuel cell systems and methods having reduced volumetric requirements are described. The systems include, among other things, an enclosed region formed by the bonding of a fuel cell layer with a fluid manifold. The enclosed region transforms into a fluid plenum when, for example, a fluid exiting a manifold outlet pressurizes the enclosed region causing one or more portions of the fuel cell layer and/or the fluid manifold to deform away from each other.

Abstract: The invention relates to methods and articles for coupling a fuel cell layer to a second structure. The fuel cell layer includes a superior fuel cell surface, an inferior fuel cell surface, and a perimeter fuel cell surface. An adhesive structure is adhered to the superior, inferior, and perimeter fuel cell surfaces to form a coupling or seal between the fuel cell layer and the second structure.

Abstract: Described herein are methods, articles, and systems relating to planar fuel cells having simplified structures. The planar fuel cells include current collection circuits that are disposed between a planar array of unit fuel cells and associated cover layers. The associated cover layers are porous, dielectric, and define a network of interconnected pores.

Abstract: Embodiments of the invention relate to electrochemical cells and membranes including alternating electrically conductive and dielectric regions. One embodiment describes an ion-conducting composite layer for an electrochemical cell, including two or more electrically conductive components, each electrically conductive component having one or more electrically conductive passageways and one or more dielectric components, each dielectric component having one or more ion-conducting passageways. The electrically conductive components and the dielectric components are adjacently arranged to provide a fluidically impermeable composite layer.

Abstract: Embodiments relate to a fuel cell including, an ion conducting component, two or more electrode coatings and one or more interconnects. The interconnects include a non-conductive interface region having a first surface and a second surface in which the first surface is in contact with the ion conducting component, an electron conducting component having two surfaces and a length that is parallel to the two surfaces wherein one of the surfaces is disposed adjacent to the second surface of the interface region. The electron conducting component provides an electrically conductive pathway between one of the electrode coatings and an external circuit, said pathway extending along the length of the electron conducting component.

Abstract: Fluid coupling assemblies and methods are discussed. The fluid coupling assemblies include a first coupling member, a second coupling member magnetically engageable with the first coupling member, and a seal member disposed between a portion of the first coupling member and a portion of the second coupling member. A magnetic engagement of the first coupling member and the second coupling member unseals a fluid flow path therebetween. In certain examples, the first coupling member is sealed by a valve member and the second coupling member includes an activation member. When engaged, the valve member is moved from a closed position to an open position by the activation member, thereby unsealing the fluid flow path. A magnetic force between the first coupling member and the second coupling member can be chosen such that the members disengage when a predetermined fluid flow path pressure is reached.

Abstract: An electrochemical cell system includes a fluid manifold having a layered structure. The fluid manifold includes at least one conduit layer having a first side and a second side. The at least one conduit later has at least one conduit channel.

Abstract: A electrochemical cell system includes a fluid manifold having a layered structure. The fluid manifold includes at least one conduit layer having a first side and a second side. The at least one conduit layer has at least one conduit channel.

Abstract: Embodiments of the present invention relate to a fluid distribution system. The system may include one or more electrochemical cell layers, a bulk distribution manifold having an inlet, a cell layer feeding manifold in direct fluidic contact with the electrochemical cell layer and a separation layer that separates the bulk distribution manifold from the cell feeding manifold, providing at least two independent paths for fluid to flow from the bulk distribution manifold to the cell feeding manifold.

Abstract: Embodiments relate to a composite for a fuel cell layer including a plurality of electron conducting components, a plurality of ion conducting components each having a first surface and a second surface and wherein each ion conducting component is positioned between two electron conducting components. The electron conducting components and the ion conducting components form a layer and at least one of the ion conducting components or the electron conducting components is geometrically asymmetric in one or more dimensions.

Abstract: Embodiments of the present invention relate to a fluid distribution system. The system may include one or more electrochemical cell layers, a bulk distribution manifold having an inlet, a cell layer feeding manifold in direct fluidic contact with the electrochemical cell layer and a separation layer that separates the bulk distribution manifold from the cell feeding manifold, providing at least two independent paths for fluid to flow from the bulk distribution manifold to the cell feeding manifold.

Abstract: Methods of manufacturing electrochemical cells having a current collector which, at least in part, underlies a catalyst layer are discussed. A method comprises patterning a current collector to have at least one electrolyte opening, disposing an electrolyte into or through the at least one opening, and disposing a catalyst, at least in part, over the disposed electrolyte. Optionally, the method comprises pattering a substrate and attaching a patterned current collector to each side thereof. Patterning of the current collector can include patterning a continuous sheet, which comprises at least a first and a second separable current collector. In one such example, a continuous carbon-fiber sheet impregnated or laminated with a non-porous material is patterned. In another such example, a continuous plastic material sheet impregnated with one or more electrical conductive particles is patterned. Among other things, the pattern of the current collector can include an extruded slot or adjacently-disposable strips.

Abstract: A complete fuel cell system (10) is described. The fuel cell system (10) comprises at least two fuel precursors (16, 18) that react to create hydrogen. A solid fuel precursor (18) can be carried in disposable fuel cartridges (100). A passive pressure control system including a dose pump (22) and a pressure equalization system (24, 300, 504) is provided to dose a liquid fuel precursor (16) to the solid fuel precursor (18) in the fuel cartridge (100). An outer wall (102) of the fuel cartridge can form a part of the passive pressure control system. The solid fuel precursor may include larger metallic particles coated by another fine metallic particles such that multiple micro galvanic cells are formed on the surface of the larger metallic particles. The fuel cell system may also include a gas buffer (40) that stores produced hydrogen that in unneeded by the fuel cell, and a water trapping mechanism (604). The fuel cell system may also have an electronic vent (46) that consumes unneeded hydrogen.

Abstract: An electrochemical cell structure has an electrical current-carrying structure which, at least in part, underlies an electrochemical reaction layer. The cell comprises an ion exchange membrane with a catalyst layer on each side thereof. The ion exchange membrane may comprise, for example, a proton exchange membrane. Some embodiments of the invention provide electrochemical cell layers which have a plurality of individual unit cells formed on a sheet of ion exchange membrane material.