Portable fuel cell systems and methods therefor

A method of fabricating a fuel cell system, the method comprising:

• forming a fuel reservoir configured to store fuel therein;
• forming a system cover having one or more air access ports;
• coupling the system cover with one or more portions of the fuel reservoir, including forming an enclosed region;
• and
• disposing at least one fuel cell in the enclosed region, including arranging one or more flexible fuel cell walls to form at least one reactant plenum;
• wherein forming the fuel reservoir and the system cover includes forming a support for the one or more flexible fuel cell walls.

A fuel cell system comprising:

• at least one fuel cell including an anode, a cathode, and an electrolyte interposed therebetween;
• a fuel or fuel storage material;
• a fuel reservoir including at least one surface positioned adjacent a first portion of the at least one fuel cell, the fuel reservoir configured to store the fuel or the fuel storage material;
• a current collecting circuit in contact with a second portion of the at least one fuel cell, the current collecting circuit configured to receive and distribute power generated by the fuel cell;
• and
• a fuel plenum interposed between the at least one fuel reservoir surface and the first portion of the at least one fuel cell.

A fuel cell system providing portable power, the system comprising:

• a fuel cell assembly, including at least one fuel cell including an anode on a first surface, a cathode on a second surface, and an electrolyte interposed therebetween;
• a protective porous member positioned near the fuel cell second surface;
• a current collecting circuit configured to receive and distribute power generated by the at least one fuel cell;
• a hydrogen reservoir including a surface positioned adjacent the fuel cell first surface, the hydrogen reservoir configured to store hydrogen fuel;
• a fuel plenum interposed between the hydrogen reservoir and the fuel cell first surface;
• and
• a system cover including at least one air access port, the system cover sized and shaped to house one or more of the protective porous member, the current collector circuit, the at least one fuel cell, the fuel plenum, or a portion of the hydrogen reservoir;
• wherein a fuel pressure in the plenum and a cover-generated pressure urge contact between the at least one fuel cell and the current collecting circuit.

A method of fabricating a portable fuel cell system, the method comprising:

• forming a fuel cell;
• coupling a fuel reservoir with a first portion of the fuel cell, including forming a fuel plenum therebetween;
• disposing a current collecting circuit adjacent a second portion of the fuel cell;
• disposing a system cover having at least one air access port over one or more of the current collecting circuit, the fuel cell, or a portion of the fuel reservoir, including positioning the at least one air access port near the second portion of the fuel cell;
• and
• coupling the system cover with the fuel reservoir.