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: 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: 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 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 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: 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: 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 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 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 of the invention relate to electrochemical cell assemblies in which a region of discontinuity provides separation and insulation between adjacent cells in an array.

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: 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 of the invention relate to electrochemical cell assemblies in which a region of discontinuity provides separation and insulation between adjacent cells in an array.

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: 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: 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.