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: Methods, systems, and articles relating to enhanced bonding of layers in a planar fuel cell. A planar fuel cell having a composite layer is bonded to an outer layer (e.g., a fuel or fluid manifold) using intrusions that extend through an electrolyte layer and into an underlying layer (e.g., a substrate component or a current-collector component).

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: 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: 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: 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: 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.