Direct methanol fuel cell including a water management system and method of fabrication

A fuel cell device comprising:

• a base portion, formed of a singular body, and having a major surface, the base portion formed or a material selected from the group consisting of ceramic, plastic, glass, and silicon;
• at least one fuel cell membrane electrode assembly formed on the major surface of the base portion, the at least one fuel cell membrane electrode assembly including a first electrode, a film formed of a protonically conductive electrolyte, a second electrode, and a plurality of hydrophilic threads positioned to absorb reaction water at the second electrode;
• a fluid supply channel defined in the base portion and communicating with the at least one fuel cell membrane electrode assembly for supplying a fuel-bearing fluid to the at least one fuel cell membrane electrode assembly, the fluid supply channel further including a first fuel-bearing fluid inlet, and a second fuel-bearing fluid inlet, and a mixing chamber;
• an exhaust channel defined in the base portion and communicating with the at least one fuel cell membrane electrode assembly, the exhaust channel spaced apart from the fluid supply channel for exhausting fluid from the at least one spaced apart fuel cell membrane electrode assembly, the exhaust channel further including a water recovery and recirculation channel in fluidic communication with the at least one fuel cell membrane electrode assembly, and the plurality of hydrophilic threads, wherein the water recovery and recirculation channel provides for the recovery and recirculation from the fuel cell back to the mixing chamber, a spent water and ethanol mixture and reaction water collected from the plurality of hydrophilic threads, in combination the at least one fuel cell membrane electrode assembly and the cooperating fluid supply channel and cooperating exhaust channel forming a single fuel cell assembly;
• and
• a top portion including a plurality of electrical components for electrical integration of the plurality of formed fuel cell assemblies.

A method of fabricating a fuel cell device comprising the steps of:

• providing a base portion formed of a material selected from the group consisting of ceramic, plastic, glass, and silicon;
• forming a fluid supply channel in the base portion for supplying a fuel-bearing fluid to at least one fuel cell membrane electrode assembly, the fluid supply channel further including a mixing chamber and a methanol concentration sensor;
• forming an exhaust channel in the base portion, the exhaust channel spaced apart from the fluid supply channel for exhausting fluid from the at least one spaced apart fuel cell membrane electrode assembly, the exhaust channel further including a water recovery and recirculation channel for the recovery and recirculation of a spent fuel-bearing fluid and a reaction water;
• forming the at least one fuel cell membrane electrode assembly on the major surface of the base portion, the step of forming the at least one spaced apart fuel cell membrane electrode assembly including the steps of providing for a first electrode on a major surface of the base portion, providing for a film formed of a protonically conductive electrolyte in contact with the first electrode, providing for a second electrode in contact with the film, and providing for a plurality of hydrophilic threads positioned to absorb reaction water at the second electrode, thereby providing for the recovery and recirculation from the fuel cell back to the mixing chamber, the spent fuel-bearing fluid and reaction water collected from the plurality of hydrophilic threads, the at least one spaced apart fuel cell membrane electrode assembly and the cooperating fluid supply channel and cooperating exhaust channel forming a single fuel cell assembly;
• and
• forming a top portion including a plurality of electrical components for electrical integration of the formed fuel cell assembly.