Abstract: A gas recycling system for a controlled atmosphere furnace includes a controlled atmosphere furnace having a product entry, a product exit, a process gas inlet adjacent said product exit, and a spent gas outlet adjacent said product entry. A spent gas recycler is operationally connected to the spent gas outlet. The recycler produces a recycled process gas stream and a waste gas stream. The recycled process gas stream is returned to the controlled atmosphere furnace. The waste gas stream is returned to the controlled atmosphere furnace at a point downstream from the spent gas outlet.

Abstract: A hydrogen recycling system for a controlled atmosphere unit operation with an exhaust vent and an inlet port includes: a hydrogen recycle unit in fluid communication with the exhaust vent and in fluid communication with the inlet port; and an oxygen reactor being located between the controlled atmosphere unit operation and said hydrogen recycle unit and in fluid communication with the controlled atmosphere unit operation and said hydrogen recycle unit.

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 conformable fuel cell is provided which includes a basic structure that provides flexibility while providing a high compression along the active surface of the fuel cell's membrane electrode assembly, which can be achieved by an injection-molded frame. A suitable fuel is delivered to the anode aspect of the fuel cell. Effective water management could also be provided by appropriate diffusion layers. The fuel cell can be contour-molded to a desired shape, or can be constructed of an array of flexibly connected individual fuel cells that overall have a curvilinear shape, or can be constructed as a pliable fuel cell that can be incorporated into an application device or an article of clothing.

Abstract: A passive direct oxidation fuel cell system, which uses a high concentration fuel such as neat methanol as a direct feed to an anode aspect of the fuel cell, is provided. The fuel cell includes a passive water management capability, achieved by the combined functions of controlled fuel dosing, effective push back of liquid water from the cathode through the membrane electrolyte by a hydrophobic microporous layer well bonded to the cathode catalyst and the use of a thin ionomeric membrane. The rate of fuel delivery is controlled by a passive fuel transport barrier. Carbon dioxide management techniques are also provided.

Abstract: The present invention provides a fuel efficient membrane electrode assembly that substantially resists methanol from “crossing over” by sealing the anode diffusion layer and catalyst layer, and by preventing fluids from passing across at least a portion of the membrane electrolyte. The efficiency of the fuel cell is maintained because essentially all of the fuel is reacted on the catalyst layers creating electricity, which is transferred to the fuel cell load. The temperature of the fuel cell is also maintained as the uncatalyzed reaction that produces heat is prevented.

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: The present invention provides a fuel efficient membrane electrode assembly that substantially resists methanol from “crossing over” by sealing the anode diffusion layer and catalyst layer, and by preventing fluids from passing across at least a portion of the membrane electrolyte. The efficiency of the fuel cell is maintained because essentially all of the fuel is reacted on the catalyst layers creating electricity, which is transferred to the fuel cell load. The temperature of the fuel cell is also maintained as the uncatalyzed reaction that produces heat is prevented.

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 system and method for removal or oxidative decomposition of fuel from a fuel storage container for use in a direct oxidation fuel cell and direct oxidation fuel cell system wherein the fuel permeates through a material and can be exposed to a catalyst/enzyme which oxidizes the fuel as it leaves the storage container. The system includes a fuel storage container provided with a catalyst-coated material. An airtight seal is provided over the catalyzed area, which seal is broken to allow oxygen access, and consequently the catalytic reaction. The airtight seal may be broken by simple manual methods or automatic methods on removal of the container from the fuel cell system.

Abstract: An improved fuel delivery system and fuel cell system is provided which includes a component, which delivers fuel from the fuel cartridge by connecting with a corresponding component in the anode chamber of the fuel cell. Liquid fuel is transported into the anode area via an action in which fuel is drawn through the material which may be substantially comprised of a foam-based substance. Gases, including carbon dioxide, that are produced in the anodic reaction can be removed because the foam is gas permeable. Electrons produced in the reaction are collected by a wire mesh that lies between the foam and the membrane electron assembly. The flow of fuel between the foam and the fuel cartridge and the foam and the anode can be interrupted by breaking the connection between the cartridge and the cell, or the cartridge can be pulled away from the fuel cell to break the connection between the foam components. The invention may be employed with a fuel cell stack, or with an enclosed, refillable fuel cell system.

Abstract: A fuel cell system including an anode chamber having a fuel mixture comprising methanol and water, and a diffusion layer, a fuel source in fluid communication with the anode chamber via a conduit, a cathode chamber having a cathode and a diffusion layer, wherein the diffusion layer is in fluid communication with an oxidizer, and a proton conducting, electrical non-conducting membrane electrolyte separating the chambers and positioned substantially adjacent to said diffusion layers. The membrane includes a catalyst exposed to each of the chambers for initiating chemical reactions to produce electricity. The system also includes a first valve for automatically controlling a flow of fuel from the fuel supply cartridge, where the first valve includes a shape memory alloy.

Abstract: An adjustable fuel delivery regulation assembly is provided which can be disposed within a direct oxidation fuel cell system, or the fuel reservoir or fuel tank that supplies such a system. One embodiment of the fuel delivery regulation assembly is a shutter assembly, which includes two correspondingly perforated components. The two components can be positioned relative to one another such that the apertures in each component are aligned in certain ways. In an open position, the apertures are substantially fully aligned to permit full fuel flow. In a closed position, the apertures are offset such that there is no opening; thereby fuel flow is restricted. Intermediate positions allow adjustments in the amount of fuel flow proportional to the size of the openings. In accordance with another embodiment of the invention, a set of rotatably mounted slotted rods is inserted into a housing through which fuel can flow through openings in the housing.

Abstract: The present invention provides a fuel efficient membrane electrode assembly that substantially resists methanol from “crossing over” by sealing the anode diffusion layer and catalyst layer, and by preventing fluids from passing across at least a portion of the membrane electrolyte. The efficiency of the fuel cell is maintained because essentially all of the fuel is reacted on the catalyst layers creating electricity, which is transferred to the fuel cell load. The temperature of the fuel cell is also maintained as the uncatalyzed reaction that produces heat is prevented.

Abstract: An enclosed direct oxidation fuel cell system is provided. The system is sealed with one or more layers of a plastic enclosure that conforms directly to the shape of the fuel cell system. The enclosure is substantially comprised of one or more layers of materials that are non-reactive with the fuel substance used in the fuel cell. In accordance with one aspect of the invention, one of the materials is a plastic film material that provides a good seal to substantially prevent liquids from escaping from the system. Yet, the enclosure is lightweight and conforms substantially to the exterior body of the fuel cell system so that it adds little or no bulk to the fuel cell system. The enclosure also prevents water from leaking out of the system. The enclosure materials may include color-changing properties so that in the event of a leak, it is visually apparent that liquid is in contact with the enclosure.

Abstract: A passive direct oxidation fuel cell system, which uses a high concentration fuel such as neat methanol as a direct feed to an anode aspect of the fuel cell is provided. The fuel cell includes a passive water management capability, achieved by the combined functions of controlled fuel dosing, effective bucking of liquid water from the cathode into the membrane electrolyte by a hydrophobic microporous layer well bonded the cathode catalyst and the use of a thin ionomeric membrane. These functions maintain water within the membrane and at the anode portion of the fuel cell even when only neat methanol is fed to, or contained in the anode chamber. One embodiment of the fuel cell system includes a methanol delivery film, which effects a phase change from the liquid fuel contained within a fuel reservoir to a vaporous fuel that is presented to the anode aspect of the catalyzed membrane electrolyte. Alternatively, liquid fuel delivery is controlled by a hydrophilic microporous layer.

Abstract: An adjustable fuel delivery regulation assembly is provided which can be disposed within a direct oxidation fuel cell system, or the fuel reservoir or fuel tank that supplies such a system. One embodiment of the fuel delivery regulation assembly is a shutter assembly, which includes two correspondingly perforated components. The two components can be positioned relative to one another such that the apertures in each component are aligned in certain ways. In an open position, the apertures are substantially fully aligned to permit full fuel flow. In a closed position, the apertures are offset such that there is no opening; thereby fuel flow is restricted. Intermediate positions allow adjustments in the amount of fuel flow proportional to the size of the openings. In accordance with another embodiment of the invention, a set of rotatably mounted slotted rods is inserted into a housing through which fuel can flow through openings in the housing.

Abstract: A system and method for removal or oxidative decomposition of fuel from a fuel storage container for use in a direct oxidation fuel cell and direct oxidation fuel cell system wherein the fuel permeates through a material and can be exposed to a catalyst/enzyme which oxidizes the fuel as it leaves the storage container. The system includes a fuel storage container provided with a catalyst-coated material. An airtight seal is provided over the catalyzed area, which seal is broken to allow oxygen access, and consequently the catalytic reaction. The airtight seal may be broken by simple manual methods or automatic methods on removal of the container from the fuel cell system.

Abstract: A passive fluid management component for a direct oxidation fuel cell is provided. It enables the introduction of highly concentrated methanol solutions, including neat methanol, directly into the anode, eliminating the need of mechanical modes of dosing and/or mixing a methanol/water solution to control the local concentration at the anode. The fluid management of the present invention can be based on pores formed in the component of a specific size and spacing to allow anode reactants to flow through the component towards the anode face of the membrane electrolyte of the fuel cell at a controlled rate. The pore size can be adjusted to allow the highest concentrations possible of methanol, including neat methanol, to be introduced in direct contact with the outer face of the component, said component being capable of lowering, under current, the local concentration of methanol at the anode face of the membrane electrolyte to the level required to minimize methanol loss.