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US 5,631,099 AGranted
Surface replica fuel cell
OwnerRobert G. Hockadayinventor
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OwnerRobert G. Hockadayinventor
Estimating the term…
A compact, surface replica fuel cell has a fiber reinforced, porous central membrane and two porous outer membranes. Thin film catalyst and metal electrode materials are deposited on both sides of the central membrane. The electrodes are deposited using a variety of techniques, including ion or light bombardment, etching and vacuum thin film deposition. For compound fuels, two catalysts are deposited. The first catalyst forms the interior surface replica electrode. The second catalyst is positioned on the interior of the pores to scavenge hydrogen before the hydrogen is diffused out of the electrode and electrolyte. A hydrophobic film is deposited over the electrode films to control electrolyte positioning and to strengthen the electrodes. Catalyst surface active area is maximized by separating the catalyst film from the porous, non-electrolyte substrate and filling the voids between the substrate and the catalyst film with an electrolyte. The fuel cell operates by supplying fuel gas to one electrode and an oxidizer gas to the other electrode. The cell may also function as an electrolysis cell for generating reactant gases from the electrolyte. During operation of the present invention, water is captured on cooler outer gas manifold surfaces of the cell and recirculated through electrode vias. Water content is regulated by a coating on the outer porous membranes.
A fuel cell apparatus comprising a first, central fiber-reinforced membrane having an oxygen side and a hydrogen side, electrodes positioned on the hydrogen side and the oxygen side of the membrane, each electrode comprising a first catalyst film layer deposited on the central membrane, the catalyst film layers separated from the central membrane by voids, metal film layers deposited over the catalyst film layers, and hydrophobic film layers positioned on the metal film layers, electrolyte disposed in voids between the catalyst film layers through the central membrane, a first water circulating and regulating membrane positioned above the hydrogen side electrode, a fuel channel flow manifold positioned above the first water circulating and regulating membrane and sealed to the hydrogen side electrode, a fuel inlet connected to the fuel manifold for delivering fuel to a region between the fuel manifold and the first water circulating and regulating membrane, a second water circulating and regulating membrane positioned below the oxygen side electrode, an oxidizer gas manifold positioned below the second water circulating and regulating membrane and sealed to the oxygen side electrode, an oxidizer gas inlet connected to the oxidizer gas manifold for delivering oxidizer gas to a region between the oxidizer gas manifold and the second water circulating and regulating membrane, a first electrical contact connected to the hydrogen electrode and a second electrical contact connected to the oxygen electrode, and a sealing rim extending around and connected to outer edges of the cell.
A fuel cell assembly comprising a first pressure wall structure, a second pressure wall structure, a fuel cell stack sandwiched between the first and second pressure wall structures, the stack having at least one fuel cell, a fiber wrapped around the pressure wall structures, interconnector fittings positioned in the first and second pressure walls, the fittings having openings for receiving gas lines and water lines, a first foam end cap positioned between the fuel cell stack and the first peripheral wall structure, a second foam end cap positioned between the fuel cell stack and the second peripheral wall structure, and wherein each end cap having a mating electrical coating that matches an electrical contact electrode of the fuel cell stack.
A method for making a, surface replica fuel cell comprising the steps of constructing a substrate by impregnating a fiber matrix with a plastic, forming etch tracks in the substrate, etching penetration channels and overhang ledges from the etch tracks in the substrate, forming electrolyte pores through the substrate, coating the substrate and parts of interiors of the electrolyte pores of the substrate with a catalyst material, depositing a conductor film on the catalyst and thereby depositing a first electrode on a top of the substrate and a second electrode on a bottom of the substrate, depositing hydrophobic films on the first and second electrodes, separating the catalyst material layer from the plastic of the substrate by etching the plastic from the substrate where the catalyst contacts the substrate, flowing electrolyte into the voids and into the penetration channels from the top side of the substrate, positioning an upper porous membrane over the first electrode, positioning a lower porous membrane below the second electrode, positioning a fuel gas manifold above the upper porous membrane, positioning an oxidizer gas manifold below the lower porous membrane, connecting a seal around outer edges of the substrate, manifolds, membranes and electrodes, sealing outer surfaces thereof and connecting contacts to the electrodes outside seal surfaces.
A fuel cell apparatus comprising a central membrane having an oxygen side and a hydrogen side, the membrane being a porous dielectric membrane with pores collimated through the membrane, a solid electrolyte coating on and through the central membrane, electrodes positioned on the hydrogen side and the oxygen side of the central membrane, each electrode further comprising a first catalyst film layer deposited on the electrolyte coating the central membrane, metal film layers deposited over the catalyst film layers, and hydrophobic film layers positioned on the metal film layers, a first water circulating and regulating membrane positioned above the hydrogen side electrode, a fuel channel flow manifold positioned above the first water circulating and regulating membrane and sealed to the hydrogen side electrode, a fuel inlet connected to the fuel manifold for delivering fuel to a region between the fuel manifold and the first water circulating and regulating membrane, a second water circulating and regulating membrane positioned below the oxygen side electrode, an oxidizer gas manifold positioned below the second water circulating and regulating membrane and sealed to the oxygen side electrode, an oxidizer gas inlet connected to the oxidizer gas manifold for delivering oxidizer gas to a region between the oxidizer gas manifold and the second water circulating and regulating membrane, a first electrical contact connected to the hydrogen electrode and a second electrical contact connected to the oxygen electrode, and a sealing rim extending around and connected to outer edges of the cell.
Dependencies are inferred from the claim text.