Abstract: Passive water management techniques are provided in an air-breathing direct oxidation fuel cell system. A highly hydrophobic component with sub-micrometer wide pores is laminated to the catalyzed membrane electrolyte on the cathode side. This component blocks liquid water from traveling out of the cathode and instead causes the water to be driven through the polymer membrane electrolyte to the cell anode. The air-breathing direct oxidation fuel cell also includes a layer of cathode backing and additional cathode filter components on an exterior aspect of the cell cathode which lessen the water vapor escape rate from the cell cathode. The combination of the well laminated hydrophobic microporous layer, the thicker backing and the added filter layer, together defines a cathode structure of unique water management capacity, that enables to operate a DMFC with direct, controlled rate supply of neat (100%) methanol, without the need for any external supply or pumping of water.

Abstract: A fuel cell system having a methanol vapor delivery component or film is provided. The component includes an evaporation pad. The evaporation pad is disposed within the fuel cell generally parallel to the anode diffusion layer, but with a vapor gap provided between the evaporation pad and the anode diffusion layer. A fuel delivery conduit having at least one injection port is provided through which liquid fuel is delivered from an associated source of highly concentrated fuel into the evaporation pad, at a controlled, adjustable rate. Multiple parallel liquid delivery points can also be provided. In order to ensure uniform delivery of fuel across the across the active area of the anode, one or more dispersion members are placed on the evaporation pad to effectively disperse the fuel laterally around each injection port.

Abstract: Fuel mixtures for direct methanol fuel cells are disclosed. The fuels include methanol and additives that react with water to produce methanol and other easily electro-oxidizable compounds including dimethyloxymethane, methylorthoformate, tetramethylorthocarbonate, trimethylborate, and tetramethylorthosilicate. Other additives to improve safety and efficiency of the fuel cell include sulfonated activated carbon particles and metal hydrides, such as LiAlH4, NaBH4, LiBH4, (CH3)2 NHBH3, NaAlH4, B2H6, NaCNBH3, CaH2, LiH, NaH, KH or sodium bis (2-methoxyethoxy) dihydridaluminate.