# US 7,407,636 B2 · Reformer for fuel cell system and method of manufacturing reaction substrate used for the same

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- Number: US 7,407,636 B2
- Document ID: US7407636B2
- Status: Granted
- Kind: B2
- Application number: 11/123,345
- Filed: 2005-05-07
- Published: 2005-11-17
- Granted: 2008-08-05
- Earliest claimed: 2004-05-14
- Assignees: Samsung SDI Co., Ltd.
- Inventors: Ju-Yong Kim; Ho-Jin Kweon; Jae-Jeong Kim; Oh-Joong Kwon
- Web page: https://patentgrep.com/patent/US7407636B2

## CPC

- H01M 8/0631: {Reactor construction specially adapted for combination reactor/fuel cell (hydrogen C01B3/00; reactors for physicochemical processes B01J19/00)}
- H01M 8/0668: Removal of carbon monoxide or carbon dioxide
- H01M 2008/1095: {Fuel cells with polymeric electrolytes}
- Y02E 60/50: Fuel cells
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

There is provided a reformer for a fuel cell system, the reformer comprising: a reforming unit having a reaction substrate in which a catalyst layer is formed in a plurality of flow channels for allowing fuel to flow and for generating hydrogen through a reformation reaction of the fuel using thermal energy. When viewing a cross-section perpendicular to the flow direction of the flow channels, the reaction substrate defines each flow channel by a bottom portion and a pair of wall portions extending from the sides of the bottom portion, and a joint between the bottom portion and the wall portion is formed in a rounded shape. There is also provided a method of manufacturing a reaction substrate used for a reformer for a fuel cell system, the method comprising: (a) preparing a substrate; (b) anisotropically etching the upper surface of the substrate and forming a channel pattern of which a bottom portion and a wall portion are perpendicular to each other; (c) isotropically etching the channel pattern and forming a flow channel of which the joints between the bottom portion and the wall portions are rounded; (d) forming a support layer on the surface of the flow channel; and (e) forming a catalyst layer on the support layer.

## Claims

### Claim 1

A reformer for a fuel cell system, the reformer comprising a reforming unit comprising:
a reaction substrate defining a plurality of flow channels, each flow channel defined by a generally planar bottom portion and a pair of corresponding generally planar wall portions, wherein the intersection of the bottom portion and each corresponding wall portion defines a rounded joint having a radius of curvature ranging from 10 to 20 μm; and catalyst layers formed in a plurality of the flow channels.

### Claim 2 (depends on 1)

The reformer for a fuel cell system of claim 1, wherein the bottom portion and each corresponding wall portion defines an obtuse angle.

### Claim 3 (depends on 2)

The reformer for a fuel cell system of claim 2, wherein the obtuse angles range from 120 to 130°.

### Claim 4 (depends on 1)

The reformer for a fuel cell system of claim 1, wherein a plurality of ribs protruding from a surface of the reaction substrate define the plurality of flow channels.

### Claim 5 (depends on 4)

The reformer for a fuel cell system of claim 4, further comprising a cover plate disposed in close contact with one surface of the reaction substrate.

### Claim 6 (depends on 1)

The reformer of a fuel cell system of claim 1, wherein a support layer is provided between each flow channel and each catalyst layer.

### Claim 7 (depends on 6)

The reformer of a fuel cell system of claim 6, wherein the reaction substrate comprises a material selected from the group consisting of silicon, glass, and stainless steel.

### Claim 8 (depends on 7)

The reformer of a fuel cell system of claim 7, wherein the support layer comprises a material selected from the group consisting of alumina, silica, and titania.

### Claim 9 (depends on 1)

The reformer of a fuel cell system of claim 1 wherein the reaction substrate is a first reaction substrate, the plurality of flow channels are a first plurality of flow channels, and the catalyst layer is a reforming catalyst layer, the reformer further comprising a heat source unit adjacent the reforming unit, the heat source unit comprising:
a second reaction substrate defining a second plurality of flow channels; and
a heat source catalyst layer formed in at least one of the second plurality of flow channels.

### Claim 10 (depends on 9)

The reformer of a fuel cell system of claim 9, further comprising a carbon monoxide reducing unit comprising:
a third reaction substrate defining a third plurality of flow channels; and
a carbon monoxide reducing catalyst layer formed in at least one of the third plurality of flow channels.

### Claim 11 (depends on 10)

The reformer of a fuel cell system of claim 10, wherein the first reaction substrate, the second reaction substrate and the third reaction substrate are stacked adjacent one another and a cover plate is disposed in close contact with the uppermost reaction substrate.