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.

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: Fuel cell components provide fuel cells on a flexible sheet that defines a wall of a flexible plenum. An external support structure limits expansion of the plenum in response to forces exerted by a pressurized reactant. The external support structure may comprise a portion of a housing of a portable device. Cathodes of the fuel cells may be accessible from an outside of the flexible sheet and exposed to ambient air while anodes of the fuel cell are accessible from an inside of the flexible sheet and exposed to a fuel, such as hydrogen gas.

Abstract: Methods, articles, and systems for controlling the internal operating temperature of fuel cell systems, such as planar fuel cell arrays. The heat management system conducts heat away from the fuel cell without disturbing the flow of gases around the fuel cell layer and without the need for the equipment to disturb the flow of gases around the fuel cell layer. The present invention also provides a heat transfer system that has a low thermal mass relative to the fuel cell layer or is thermally isolated from the fuel cell layer such that the heat transfer system will not remove substantial amounts of heat from a fuel cell layer during star-up and can be activated to dissipate heat from the fuel cell only as needed.

Abstract: A fuel cell layer includes a plurality of membrane electrode assemblies disposed in a planar array arrangement and an interconnector for electrically coupling an anode catalyst layer of one of adjacent membrane electrode assemblies to a cathode catalyst layer of the other of the adjacent membrane electrode assemblies. Each membrane electrode assembly includes an electrolyte membrane, the anode catalyst layer provided on one face of the electrolyte member and the cathode catalyst layer provided on the other face of the electrolyte membrane in such a manner that at least part of which is disposed counter to the anode catalyst layer. The interconnector is formed of at least one of a material constituting the anode catalyst layer and a material constituting the cathode catalyst layer.

Abstract: A fluidic control system includes featured layers. The featured layers include two or more features which collectively form at least one functional component.

Abstract: Described herein are fuel cell systems that include fuel cell covers, as well as electronic systems and methods for optimizing the performance of a fuel cell system. In the various embodiments, a fuel cell cover includes an interface structure proximate to one or more fuel cells. The interface structure is configured to affect one or more environmental conditions proximate to the one or more fuel cells. An electronic system includes an electronic device, one or more fuel cells operably coupled to the electronic device, and an interface structure proximate to the one or more fuel cells. The interface structure affects one or more environmental conditions near or in contact with the one or more fuel cells. A method includes providing a fuel cell layer, and positioning an interface layer proximate to the fuel cell layer.

Abstract: Described herein are fuel cell systems that include a cover affecting reactant flow into an electrochemical cell array of the system. The cover includes one or more transport barrier regions and one or more opened regions. The transport barrier regions are in proximity to active regions of the electrochemical cell array.

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: 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: 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: Methods, articles, and systems for controlling the internal operating temperature of fuel cell systems, such as planar fuel cell arrays. The heat management system conducts heat away from the fuel cell without disturbing the flow of gases around the fuel cell layer and without the need for the equipment to disturb the flow of gases around the fuel cell layer. The present invention also provides a heat transfer system that has a low thermal mass relative to the fuel cell layer or is thermally isolated from the fuel cell layer such that the heat transfer system will not remove substantial amounts of heat from a fuel cell layer during star-up and can be activated to dissipate heat from the fuel cell only as needed.

Abstract: A method for operating a passive, air-breathing fuel cell system is described. In one embodiment, the system comprises one or more fuel cells, and a closed fuel plenum connected to a fuel supply. In some embodiments of the method, the fuel cell cathodes are exposed to ambient air, and the fuel is supplied to the anodes via the fuel plenum at a pressure greater than that of the ambient air.

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: Various embodiments of the present invention provide a fuel cell connection component, including an interconnect or a current collector. The fuel cell connection component includes conductive fibers oriented at an angle of less than about 90° to at least one electrode in the fuel cell. The fuel cell connection component provides an electrically conductive pathway from the at least one electrode of the fuel cell to an external circuit or to an electrode of a different fuel cell. Embodiments of the present invention also provide fuel cells that include the fuel cell connection component, including fuel cell layers, and methods of making the same.

Abstract: A fuel cell system including, among other things, one or more of a fuel cell, a fuel reservoir, a current collecting circuit, a plenum, or a system cover. The fuel reservoir is configured to store fuel, and may include a regulator for controlling an output fuel pressure and a refueling port. A surface of the fuel reservoir may be positioned adjacent a first fuel cell portion. The current collecting circuit is configured to receive and distribute fuel cell power and may be positioned adjacent a second fuel cell portion. The plenum may be formed when the fuel reservoir and the first fuel cell portion are coupled or by one or more flexible fuel cell walls. The system cover allows air into the system and when combined when a fuel pressure in the plenum, may urge contact between the fuel cell and the current collecting circuit.

Abstract: Embodiments of the present invention relate to a portable fuel cell power source including an expandable enclosure, a first reactant contained within the enclosure, one or more fuel cells and a fluid port positioned in the expandable enclosure and adapted to be in fluidic communication with the one or more fuel cells. The enclosure may also include an opening to insert a second reactant. When the first reactant is contacted with the second reactant a fuel is generated for use with one or more of the fuel cells. The volume of the portable fuel cell power source in a collapsed state may be smaller than the volume of the amount of first reactant and second reactant needed to substantially consume the first reactant in a fuel generation reaction.

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.

Abstract: A fluidic control system includes featured layers. The featured layers include two or more features which collectively form at least one functional component.