Abstract: A spring loaded direct oxidation fuel cell assembly reduces the effects of precompression relaxation. A near flat spring and a distribution plate form a spring assembly that is disposed between a membrane electrode assembly and one of the current collectors in the fuel cell. The components are assembled into a fuel cell assembly and are precompressed, and a spring yielding process is performed. While precompression is being applied, a set of pins and a plastic frame are insert molded around the fuel cell assembly to hold the components in place. Subsequently, as the precompression relaxes, the spring assembly forces act to maintain an evenly distributed compression on the MEA, thereby compensating for the loss of precompression. A related method of manufacturing a fuel cell assembly is provided.

Abstract: A method for fabricating membrane electrode assembly includes providing an anode side diffusion layer structure and a cathode side diffusion layer structure with a layer of membrane electrolyte therebetween. The diffusion layer structures include diffusion segments, which are coupled to each other by a first engaging member having one or more portions configured for engagement with a feed or aligning mechanism. Also, one or more of the segments of the diffusion layer structures may be connected to other segments or the first engaging member by one or more bridges. Bridges of each diffusion layer structure may be offset to avoid electrical contact with each other in response to diffusion layer structures being assembled with each other and with the layer of membrane electrolyte.

Abstract: A spring loaded direct oxidation fuel cell assembly reduces the effects of precompression relaxation. A near flat spring and a distribution plate form a spring assembly that is disposed between a membrane electrode assembly and one of the current collectors in the fuel cell. The components are assembled into a fuel cell assembly and are precompressed, and a spring yielding process is performed. While precompression is being applied, a set of pins and a plastic frame are insert molded around the fuel cell assembly to hold the components in place. Subsequently, as the precompression relaxes, the spring assembly forces act to maintain an evenly distributed compression on the MEA, thereby compensating for the loss of precompression. A related method of manufacturing a fuel cell assembly is provided.

Abstract: A method for fabricating membrane electrode assembly includes providing an anode side diffusion layer structure and a cathode side diffusion layer structure with a layer of membrane electrolyte therebetween. The diffusion layer structures include diffusion segments, which are coupled to each other by a first engaging member having one or more portions configured for engagement with a feed or aligning mechanism. Also, one or more of the segments of the diffusion layer structures may be connected to other segments or the first engaging member by one or more bridges. Bridges of each diffusion layer structure may be offset to avoid electrical contact with each other in response to diffusion layer structures being assembled with each other and with the layer of membrane electrolyte.

Abstract: A sealed fuel cell is provided which has been manufactured with a lead frame assembly encompassing a first and second current collector adapted to serve as lead frame components in an associated mold device. Fuel cell components include a catalyzed protonically conductive, electronically non-conductive membrane that has first and second diffusion layers disposed on opposite sides thereof. The fuel cell components are arranged between the first and second current collectors, and the entire assembly is placed into an insert molding device. A moldable material is introduced into the insert molding device and is allowed to cure in order to seal the edges of the lead frame assembly against leaks to thereby form a sealed fuel cell.

Abstract: A method for fabricating membrane electrode assembly includes providing an anode side diffusion layer structure and a cathode side diffusion layer structure with a layer of membrane electrolyte therebetween. The diffusion layer structures include diffusion segments, which are coupled to each other by a first engaging member having one or more portions configured for engagement with a feed or aligning mechanism. Also, one or more of the segments of the diffusion layer structures may be connected to other segments or the first engaging member by one or more bridges. Bridges of each diffusion layer structure may be offset to avoid electrical contact with each other in response to diffusion layer structures being assembled with each other and with the layer of membrane electrolyte.

Abstract: A method for fabricating membrane electrode assembly includes providing an anode side diffusion layer structure and a cathode side diffusion layer structure with a layer of membrane electrolyte therebetween. The diffusion layer structures include diffusion segments, which are coupled to each other by a first engaging member having one or more portions configured for engagement with a feed or aligning mechanism. Also, one or more of the segments of the diffusion layer structures may be connected to other segments or the first engaging member by one or more bridges. Bridges of each diffusion layer structure may be offset to avoid electrical contact with each other in response to diffusion layer structures being assembled with each other and with the layer of membrane electrolyte.

Abstract: A process for fabrication and molding of a fuel cell, or an array of fuel cells is provided. The inventive process, in accordance with one aspect of the invention, includes diffusion layers being hot-press bonded onto current collectors. A catalyzed membrane is sandwiched between two current collectors integrated into the lead frames designed for use in a molding process. A raised surface on each current collector provides a means for shut off of the mold plates. A suitable moldable material is introduced into a mold cavity to form a frame around the current collectors, which provides a tight and secure seal, eliminating the need for gasketing, and which further also provides compression thus further eliminating screws, nuts and other fasteners.

Abstract: A modular DMFC array, and a related method of manufacturing such an array is provided. The modular DMFC array incorporates separately manufactured individual fuel cells that are connected after the manufacturing process. A locking mechanism incorporates the necessary electric connections. In one embodiment of the invention, the electrical connections also function as the locking mechanism. In such an embodiment, a separate mechanical fastening mechanism is not needed. In other embodiments of the invention, mechanical connections are provided to connect the individual fuel cells in the modular fuel cell array. Yet a further embodiment includes a carrier component on which the individual fuel cells are bonded. The electrical connections are provided either through the carrier component, or cell-to-cell.