Abstract: A simplified direct oxidation fuel cell system is disclosed. The fuel cell is constructed in such a manner that fuel is added to the cell anode as it is consumed and water is evaporated off at cell cathode so that there is no need for recirculation of unreacted fuel at the cell anode or water at the cell cathode. In addition, carbon dioxide generated from the anodic reaction is passively vented out of the system by using a CO2 gas permeable membrane material integrated as part of the anode chamber construction. It is thus possible that, the CO2 separation from the anode fluid occurs without the recirculation of the anode fluid outside the anode chamber. In one embodiment, the simplified direct oxidation fuel cell includes a gas permeable, liquid impermeable membrane placed in close proximity to the anode to perform the carbon dioxide separation.

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: 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 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: Methods for conditioning the membrane electrode assembly of a direct methanol fuel cell (“DMFC”) are disclosed. In a first method, an electrical current of polarity opposite to that used in a functioning direct methanol fuel cell is passed through the anode surface of the membrane electrode assembly. In a second method, methanol is supplied to an anode surface of the membrane electrode assembly, allowed to cross over the polymer electrolyte membrane of the membrane electrode assembly to a cathode surface of the membrane electrode assembly, and an electrical current of polarity opposite to that in a functioning direct methanol fuel cell is drawn through the membrane electrode assembly, wherein methanol is oxidized at the cathode surface of the membrane electrode assembly while the catalyst on the anode surface is reduced. Surface oxides on the direct methanol fuel cell anode catalyst of the membrane electrode assembly are thereby reduced.

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.

Abstract: A fuel cell diffusion layer for delivering a fuel mixture to the anode face of a catalyzed membrane and for resisting flow of carbon dioxide produced in the anodic reaction back into the associated fuel chamber. The diffusion layer contains either conduits or channels on one aspect thereof to redirect the carbon dioxide generated at the anode in the fuel cell reaction away from the catalyzed membrane and away from the fuel chamber. This avoids the volume replacement by carbon dioxide of fuel mixture in the anode chamber and enhances the concentration of methanol that can be used in the fuel mixture. It also serves to allow only that fuel that is consumed in the reaction to enter the space between the anode face of the catalyzed membrane and the diffusion layer adjacent thereto. The diffusion layer further includes perforations to increase the ability to deliver fuel to the anode aspect of the membrane electrode assembly of the fuel cell.

Abstract: Inks are formulated for forming anode and cathode catalyst layers and applied to anode and cathode sides of a membrane for a direct methanol fuel cell. The inks comprise a Pt catalyst for the cathode and a Pt—Ru catalyst for the anode, purified water in an amount 4 to 20 times that of the catalyst by weight, and a perfluorosulfonic acid ionomer in an amount effective to provide an ionomer content in the anode and cathode surfaces of 20% to 80% by volume. The inks are prepared in a two-step process while cooling and agitating the solutions. The final solution is placed in a cooler and continuously agitated while spraying the solution over the anode or cathode surface of the membrane as determined by the catalyst content.

Abstract: A simplified direct oxidation fuel cell system is disclosed. The fuel cell is constructed in such a manner that fuel is added to the cell anode as it is consumed and water is evaporated off at cell cathode so that there is no need for recirculation of unreacted fuel at the cell anode or water at the cell cathode. In addition, carbon dioxide generated from the anodic reaction is passively vented out of the system by using a CO2 gas permeable membrane material integrated as part of the anode chamber construction. It is thus possible that, the CO2 separation from the anode fluid occurs without the recirculation of the anode fluid outside the anode chamber. In one embodiment, the simplified direct oxidation fuel cell includes a gas permeable, liquid impermeable membrane placed in close proximity to the anode to perform the carbon dioxide separation.

Abstract: A fuel cell diffusion layer providing a preferential path by which liquid reactants or byproducts may be supplied to or removed from a direct oxidation fuel cell is described. The modified diffusion layer will be typically on the cathode side of the fuel cell and its use is to eliminate or minimize flooding of the cathode diffusion layer area, which is a performance limiting condition in direct methanol fuel cells. In accordance with one embodiment of the invention, the diffusion layer includes a substrate that is coated with a microporous layer. A pattern may be embossed into the diffusion layer, to create preferential flow paths by which water will travel and thereby be removed from the cathode catalyst area. This avoids cathode flooding and avoids build up of potentially destructive pressure by possible cathodic water accumulation.

Abstract: A method for activating a membrane electrode assembly for a direct methanol fuel cell is disclosed. The method comprises operating the fuel cell with humidified hydrogen as the fuel followed by running the fuel cell with methanol as the fuel.

Abstract: An air breathing direct methanol fuel cell is provided with a membrane electrode assembly, a conductive anode assembly that is permeable to air and directly open to atmospheric air, and a conductive cathode assembly that is permeable to methanol and directly contacting a liquid methanol source.

Abstract: Metallic layer components for use in a direct oxidation fuel cell are disclosed. A direct oxidation fuel cell includes a membrane electrode assembly having an anode face and a cathode face. An anodic diffusion layer is associated with the anode face and a cathodic diffusion layer is associated with the cathode face. The metallic diffusion layers, in accordance with one embodiment of the invention include pores formed in the diffusion layer to allow substances to flow through the diffusion layer to the membrane electrolyte and back out again. Another embodiment of the invention incorporates metallic layer components that are formed using particle diffusion bonding techniques and are then coated with hydorphilic or hydrophobic substances to control reactant flow and transport. The metallic layers may also perform the function of flow field plates that not only direct the flow of substances to and from the membrane, but also conduct the electrons and thus the electricity generated by the cell.

Abstract: An air breathing direct methanol fuel cell is provided with a membrane electrode assembly, a conductive anode assembly that is permeable to air and directly open to atmospheric air, and a conductive cathode assembly that is permeable to methanol and directly contacting a liquid methanol source.

Abstract: A sensor outputs a signal related to a concentration of methanol in an aqueous solution adjacent the sensor. A membrane electrode assembly (MEA) is included with an anode side and a cathode side. An anode current collector supports the anode side of the MEA and has a flow channel therethrough for flowing a stream of the aqueous solution and forms a physical barrier to control access of the methanol to the anode side of the MEA. A cathode current collector supports the cathode side of the MEA and is configured for air access to the cathode side of the MEA. A current sensor is connected to measure the current in a short circuit across the sensor electrodes to provide an output signal functionally related to the concentration of methanol in the aqueous solution.

Abstract: An air breathing direct methanol fuel cell is provided with a membrane electrode assembly, a conductive anode assembly that is permeable to air and directly open to atmospheric air, and a conductive cathode assembly that is permeable to methanol and directly contacting a liquid methanol source. Water loss from the cell is minimized by making the conductive cathode assembly hydrophobic and the conductive anode assembly hydrophilic.

Abstract: An air breathing direct methanol fuel cell is provided with a membrane electrode assembly, a conductive anode assembly that is permeable to air and directly open to atmospheric air, and a conductive cathode assembly that is permeable to methanol and directly contacting a liquid methanol source.

Abstract: A sealed ultracapacitor assembly is formed with first and second electrodes of first and second conducting polymers electrodeposited on porous carbon paper substrates, where the first and second electrodes each define first and second exterior surfaces and first and second opposing surfaces. First and second current collector plates are bonded to the first and second exterior surfaces, respectively. A porous membrane separates the first and second opposing surfaces, with a liquid electrolyte impregnating the insulating membrane. A gasket formed of a thermoplastic material surrounds the first and second electrodes and seals between the first and second current collector plates for containing the liquid electrolyte.

Abstract: The fuel utilization of a direct methanol fuel cell is enhanced for improved cell efficiency. Distribution plates at the anode and cathode of the fuel cell are configured to distribute reactants vertically and laterally uniformly over a catalyzed membrane surface of the fuel cell. A conductive sheet between the anode distribution plate and the anodic membrane surface forms a mass transport barrier to the methanol fuel that is large relative to a mass transport barrier for a gaseous hydrogen fuel cell. In a preferred embodiment, the distribution plate is a perforated corrugated sheet. The mass transport barrier may be conveniently increased by increasing the thickness of an anode conductive sheet adjacent the membrane surface of the fuel cell.