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US20060088744A1 - Electrochemical cells - Google Patents

Electrochemical cells Download PDF

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Publication number
US20060088744A1
US20060088744A1 US11/228,453 US22845305A US2006088744A1 US 20060088744 A1 US20060088744 A1 US 20060088744A1 US 22845305 A US22845305 A US 22845305A US 2006088744 A1 US2006088744 A1 US 2006088744A1
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United States
Prior art keywords
electrode
fuel
channel
porous separator
electrochemical cell
Prior art date
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Abandoned
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US11/228,453
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English (en)
Inventor
Larry Markoski
Dilip Natarajan
Alex Primak
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INI Power Systems Inc
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Individual
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Priority to US11/228,453 priority Critical patent/US20060088744A1/en
Assigned to INI POWER SYSTEMS, INC. reassignment INI POWER SYSTEMS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MARKOSKI, LARRY J., NATARAJAN, DILIP, PRIMAK, ALEX
Publication of US20060088744A1 publication Critical patent/US20060088744A1/en
Priority to US12/813,432 priority patent/US8119305B2/en
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1007—Fuel cells with solid electrolytes with both reactants being gaseous or vaporised
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0258—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/023—Porous and characterised by the material
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0247—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the form
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0258—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant
    • H01M8/026—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant characterised by grooves, e.g. their pitch or depth
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04082—Arrangements for control of reactant parameters, e.g. pressure or concentration
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/08—Fuel cells with aqueous electrolytes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1009—Fuel cells with solid electrolytes with one of the reactants being liquid, solid or liquid-charged
    • H01M8/1011—Direct alcohol fuel cells [DAFC], e.g. direct methanol fuel cells [DMFC]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H01M50/491—Porosity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/36—Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells

Definitions

  • the present invention relates to electrochemical devices for electrochemical energy conversion (e.g., fuel cells and batteries). More specifically, the present invention teaches a variety of electrochemical devices utilizing channels contiguous to a porous separator, gas diffusion electrodes, and laminar flow.
  • Fuel cell technology shows great promise as an alternative energy source for numerous applications.
  • Several types of fuel cells have been constructed, including: polymer electrolyte membrane fuel cells, direct methanol fuel cells, alkaline fuel cells, phosphoric acid fuel cells, molten carbonate fuel cells, and solid oxide fuel cells.
  • polymer electrolyte membrane fuel cells direct methanol fuel cells
  • alkaline fuel cells alkaline fuel cells
  • phosphoric acid fuel cells molten carbonate fuel cells
  • solid oxide fuel cells solid oxide fuel cells.
  • operating temperatures can vary from room temperature to about 1000° C.
  • mobile applications for example, vehicular and/or portable microelectronic power sources
  • a fast-starting, low weight, and low cost fuel cell capable of high power density is required.
  • PEFCs polymer electrolyte fuel cells
  • FIG. 1 shows a cross-sectional schematic illustration of a polymer electrolyte fuel cell 2 .
  • PEFC 2 includes a high surface area anode 4 that acts as a conductor, an anode catalyst 6 (typically platinum), a high surface area cathode 8 that acts as a conductor, a cathode catalyst 10 (typically platinum), and a polymer electrolyte membrane (PEM) 12 that serves as a solid electrolyte for the cell.
  • the PEM 12 physically separates anode 4 and cathode 8 .
  • Fuel in the gas and/or liquid phase (typically hydrogen or an alcohol) is brought over the anode catalyst 6 where it is oxidized to produce protons and electrons in the case of hydrogen fuel, and protons, electrons, and carbon dioxide in the case of an alcohol fuel.
  • the electrons flow through an external circuit 16 to the cathode 8 where air, oxygen, or an aqueous oxidant (e.g., peroxide) is being constantly fed.
  • Protons produced at the anode 4 selectively diffuse through PEM 12 to cathode 8 , where oxygen is reduced in the presence of protons and electrons at cathode catalyst 10 to produce water.
  • GDE gas diffusion electrode
  • a GDE typically includes a porous conductor (such as carbon), allowing the gas to reach the electrode as well as the catalyst. Often, the catalyst is bound to the PEM, which is in contact with the GDE. Examples of GDEs and fuel cell systems which include GDEs, are describe in U.S. Patent Application Publication 2004/0209154, published 21 Oct. 2004, to Ren et al.
  • FIG. 2 shows a cross-sectional schematic illustration of a direct methanol fuel cell (DMFC) 18 .
  • DMFC direct methanol fuel cell
  • the cell utilizes methanol fuel directly, and does not require a preliminary reformation step.
  • DMFCs are of increasing interest for producing electrical energy in mobile power (low energy) applications.
  • several fundamental limitations have impeded the development and commercialization of DMFCs.
  • methanol liquid fuel feed
  • gaseous oxidant feed i.e., oxygen
  • PEM stationary polymer electrolyte membrane
  • methanol crossover takes place, whereby methanol travels from the anode to the cathode catalyst through the membrane where it reacts directly in the presence of oxygen to produce heat, water, carbon dioxide and no useable electric current.
  • methanol crossover also causes depolarization losses (mixed potential) at the cathode and, in general, leads to decreased cell performance.
  • LFFC laminar flow fuel cell
  • IDCI dynamic conducting interface
  • a fuel cell 20 embodying features of this type of flow cell design is shown in Prior Art FIG. 3 .
  • both the fuel input 22 e.g. an aqueous solution containing MeOH and a proton electrolyte source
  • the oxidant input 24 e.g., a solution containing dissolved oxygen, potassium permanganate or hydrogen peroxide and a proton electrolyte source
  • the fuel input 22 e.g. an aqueous solution containing MeOH and a proton electrolyte source
  • the oxidant input 24 e.g., a solution containing dissolved oxygen, potassium permanganate or hydrogen peroxide and a proton electrolyte source
  • the IDCI is established between anode 30 and cathode 32 and thus completes the electric circuit while keeping the fuel and oxidant streams from touching the wrong electrode.
  • the electrodes are in a side-by-side configuration.
  • a fuel cell may have a face to face LFFC design.
  • both the fuel input e.g. an aqueous solution containing a fuel and a proton electrolyte source
  • the oxidant input e.g., a solution containing dissolved oxygen, potassium permanganate or hydrogen peroxide, and a proton electrolyte source
  • the two solutions are in liquid form.
  • parallel laminar flow induces a dynamic conducting interface that is maintained during fluid flow between the anode and the cathode and thus completes the electric circuit while keeping the flowing fuel and oxidant streams from touching the wrong electrode. If the fuel and oxidant flow rates are the same, the IDCI will be established directly in the middle of the flow channel.
  • the face to face LFFC offers significant operational flexibility as a result of the ability to position the IDCI flexibly between the electrodes without experiencing significant cross-over effects and offers significant performance capabilities due the potential for lower internal cell resistance because of the relatively short and uniform electrode to electrode distances not afforded with the side by side design.
  • This face to face design there exist a number of potential flow geometries that could be used.
  • LFFCs with identical cross-sectional areas, but having different channel widths and heights and electrode-electrode distances are possible, however the best choice in design has the lowest electrode to electrode distance and the highest active area to volume ratio. In general a relatively short height and broad width is preferred and will provide the best overall performance under cell operation when positioned orthogonal to the gravitational field.
  • the present invention teaches a variety of electrochemical devices for electrochemical energy conversion.
  • the present invention teaches an electrochemical cell, comprising a first electrode, a second electrode, a porous separator, between the first and second electrodes, a first channel, having an inlet and an outlet, and a second channel, having an inlet and an outlet.
  • the first channel is contiguous with the first electrode and the porous separator
  • the second channel is contiguous with the second electrode and the porous separator.
  • the present invention teaches a method of generating electricity, comprising flowing a first liquid through a first channel; and flowing a second liquid through a second channel.
  • the first channel is contiguous with a first electrode and a porous separator
  • the second channel is contiguous with a second electrode and the porous separator
  • the first liquid is in contact with the first electrode and the porous separator
  • the second liquid is in contact with the second electrode and the porous separator
  • complementary half cell reactions take place at the first and second electrodes.
  • the present invention teaches an electrochemical cell, comprising a first electrode, a second electrode, a first channel, contiguous with the first and second electrodes.
  • the first electrode is a gas diffusion electrode, such that when a first liquid flows through the channel in contact with the first electrode and a second liquid flows through the channel in contact with the second electrode, laminar flow is established in both the first and second liquids.
  • the present invention teaches a method of generating electricity, comprising flowing a first liquid through a channel; and flowing a second liquid through the channel.
  • the channel is contiguous with a first electrode and a second electrode, the first liquid is in contact with the first electrode, the second liquid is in contact with the second electrode, the first electrode is a gas diffusion electrode, and complementary half cell reactions take place at the first and second electrodes.
  • the present invention is an electrochemical cell, comprising a first electrode, and a second electrode.
  • the first electrode is a gas diffusion electrode, and ions travel from the first electrode to the second electrode without traversing a membrane.
  • FIG. 1 shows a cross-sectional schematic illustration of a polymer electrolyte fuel cell.
  • FIG. 2 shows a cross-sectional schematic illustration of a direct methanol fuel cell.
  • FIG. 3 shows a schematic illustration of a direct methanol fuel cell containing a laminar flow induced dynamic interface in a side by side electrode configuration
  • FIG. 3A shows a schematic illustration of a direct liquid fuel cell containing a laminar flow induced dynamic interface in a face to face electrode configuration.
  • FIG. 4 illustrates an embodiment of a fuel cell including a porous separator.
  • FIGS. 5 and 5 A illustrate an embodiment of a fuel cell including a porous separator.
  • FIGS. 6 and 6 A illustrate an embodiment of a fuel cell using gaseous oxygen.
  • FIG. 7 illustrates an embodiment of a system including a fuel cell.
  • FIG. 8 is a graph of transport limited load curves for individual LFFCs with recycle capability.
  • FIG. 9 is a graph of cell potential versus current density for a 1 ⁇ 5 LFFC array.
  • FIG. 10 is a graph of polarization curves for a LFFC operated at room temperature at different fuel concentrations.
  • FIG. 11 is a graph comparing performance of a commercially available DMFC and a 1 ⁇ 5 LFFC array, both operated at 50° C.
  • the present invention teaches that inclusion of a porous separator (also referred to as a porous plate) between the flowing streams of a laminar flow fuel cell (hereinafter “LFFC”) allows the stream position to be stabilized, defined, and maintained under most conditions. This stabilization also provides a reliable mechanism so that individual streams can be separated and recycled.
  • the porous separator does not significantly impede ion conduction between the streams.
  • inclusion of a porous separator reduces fuel crossover, even allowing for turbulent flow and even two-phase gas/liquid plug flow within the individual streams.
  • inclusion of an electrolyte stream, between the fuel stream and the cathode, or between the oxidant stream and the anode allows for incorporation of a gas diffusion electrode as the cathode or anode, respectively.
  • electrochemical cell is to be understood in the very general sense of any seat of electromotive force (as defined in Fundamentals of Physics, Extended Third Edition by David Halliday and Robert Resnick, John Wiley & Sons, New York, 1988, 662 ff.).
  • electrochemical cell refers to both galvanic (i.e., voltaic) cells and electrolytic cells, and subsumes the definitions of batteries, fuel cells, photocells (photovoltaic cells), thermopiles, electric generators, electrostatic generators, solar cells, and the like.
  • the phrase “complementary half cell reactions” is to be understood in the very general sense of oxidation and reduction reactions occurring in an electrochemical cell.
  • FIG. 4 illustrates an embodiment of a fuel cell including a porous separator.
  • the fuel cell includes a track etch separator 1625 (the porous separator), allowing for separation of the fuel stream 1670 and oxidant stream 1660 flowing into the fuel cell.
  • the fuel stream 1670 flows past anode 1620 and the oxidant stream 1660 flows past cathode 1610 , allowing for diffusion of ions between the streams (especially across diffusion zone 1640 ) and depletion of fuel and oxidant (especially along depletion zones 1650 ).
  • Depleted oxidant stream 1680 and depleted fuel stream 1690 then exit the fuel cell.
  • the porous separator separates different streams, allowing them to be easily directed in different direction, and is particularly useful for keeping oxidant, fuel, and/or electrolyte streams separate for subsequent recycling.
  • the porous separator achieves this goal without interfering significantly with ion transport between the streams.
  • the porous separator is hydrophilic, so the fluid within the streams is drawn into the pores by capillary action, and therefore the two streams of fluid on either side of the separator are in contact, allowing ion transport between the two streams.
  • the thickness of the porous separator, diameter of the pore size, pore density and porosity can be any measurement suitable for implementation, an example of some possible ranges is useful.
  • the porous separator can have a thickness of 0.5 to 1000 microns, 1 to 100 microns, or 6 to 25 microns.
  • the average diameter of the pores (pore size) of the porous separator can be, for example, 1 nm to 100 microns, 5 nm to 5 microns, or 10 to 100 nm.
  • the diameter of any individual pore is the diameter of a circle having the same area as the pore, as directly observed under a microscope.
  • the pore density can be, for example, 10 4 to 10 12 pores/cm 2 , 10 6 to 10 11 pores/cm 2 , or 10 7 to 10 10 pores/cm 2 .
  • Pore density can be determined by counting the number of pores in a sample portion of the porous separator, as directly observed under a microscope.
  • the porous separator can be made of any suitable material, such as a material which is inert to the fluids it will come into contact with during operation within the electrochemical cell, at the temperature at which it will operate.
  • a material which is inert to the fluids it will come into contact with during operation within the electrochemical cell at the temperature at which it will operate.
  • metals, ceramics, semiconductors including silicon, organic materials including polymers, plastics and combinations, as well as natural materials and composites may be used. Polymers, plastics and combinations are particularly preferred.
  • commercially available track etched filters which are polymers films that have been bombarded with ions, and then chemically etched to form thru-pores along the track traveled by the ions.
  • FIGS. 5 and 5 A illustrate an embodiment of a fuel cell including a porous separator.
  • a layer or film 1745 for example, Kapton or etched glass
  • a second film 1755 for example, Kapton, etched glass or platinum
  • catalyst 1740 for example, platinum foils, or a conductor such as graphite or highly doped silicon with a catalyst on the surface.
  • porous separator 1775 Between the two films 1745 and 1755 is porous separator 1775 , which together help define the oxidant stream channel 1760 and fuel stream channel 1750 .
  • a film permeable to ions such as NAFION
  • the porous separator 1775 defines the channels for the two streams 1750 and 1760 , and still allows for ion transport through the pores.
  • Contact pads (not illustrated), such as gold, may be formed on the outside of the electrodes to aid in electrically connecting the electrochemical cell to other devices. Also shown in FIG. 5A is the catalyst layer 1735 .
  • FIGS. 6 and 6 A illustrates an embodiment of an electrochemical cell using a gaseous oxidant, such as O 2 or air.
  • the fuel cell includes an optional porous separator 1825 , allowing for separation of the fuel 1870 and electrolyte 1835 flowing into the fuel cell.
  • Electrolyte 1835 flows along an optional film permeable to ions 1845 , or when the film permeable to ions is absent, along the cathode 1810 , which is a GDE.
  • Gaseous oxidant 1860 flows along the GDE 1810 which receives oxygen molecules.
  • gaseous oxidant 1860 is provided at a pressure such that the same type of laminar flow may be observed between gaseous oxidant 1860 and electrolyte 1835 as is observed in the fuel and electrolyte streams along porous separator 1825 . While pressure drop-off varies differently in a channel for liquids and gases, maintaining an adequate pressure where the depleted oxidant 1880 exits will result in sufficient pressure of gaseous oxidant 1860 to cause essentially one-way diffusion of oxidant through the GDE (cathode) 1810 . Thus, under such conditions, the electrolyte 1835 may only minimally diffuse into the gaseous oxidant 1835 creating a three-phase interface within the catalyst layer.
  • the channel through which the oxidant flows may be closed off or having a dead end near the bottom of the cathode 1810 .
  • the electrodes with catalyst 1840 for example, a graphite plate with catalyst
  • a layer or film 1845 for example, Kapton
  • another electrode 1830 for example, graphite
  • Depleted gaseous oxidant 1880 , electrolyte 1835 and depleted fuel 1890 then exit the fuel cell.
  • the electrolyte 1835 may be recycled and returned to the fuel cell, and any fuel remaining in the depleted fuel 1890 may also be recycled and returned to the fuel cell.
  • GDEs include a porous conductor and, preferably a catalyst, so that a complementary half cell reaction may take place on the conductor, between gaseous oxidant and ions in a liquid (for example, H + ions in the electrolyte).
  • a porous hydrophobic layer is present on the GDE, on which the catalyst is present.
  • the GDE is a porous conductor with catalyst on the conductor, and has a hydrophilic surface, allowing liquid to wet the porous conductor and water produced at the GDE to spread out along the surface of the GDE and evaporate into the gaseous oxidant or flow into the circulating electrolyte.
  • the GDE may include a porous carbon substrate, such as teflonized (0-50%) Torray paper of 50-250 micron thickness (a porous conductor available from SGL Carbon AG, Wiesbaden, Germany) onto which is bonded the catalyzed (e.g. 4 mg/cm 2 Pt black) surface of a film permeable to ions or porous layer, such as NAFION 112 or expanded polyethylene, having a total thickness of 50 microns or less.
  • the circulating electrolyte may be, for example, 0.5-2.0 M sulfuric acid.
  • the film used with a GDE in the present invention typically will not have catalyst on both sides of the film; rather catalyst will only be present on one side of the film.
  • the fuels cells can produce, for example, at least 50 mA/cm 2 . In an alternate embodiment, the fuels cells can produce, for example, at least 400 mA/cm 2 . Further, in other embodiments, the fuel cells can produce, for example, at least 1000 mA/cm 2 , including 100-1000 mA/cm 2 , 200-800 mA/cm 2 , and 400-600 mA/cm 2 .
  • Each fuel cell is likely to be incorporated into a module or component along with support technology to provide a power supply. As a result, it may be useful to provide a power supply implementation using such fuel cells.
  • FIG. 7 illustrates an embodiment of a power system including a fuel cell.
  • the power system uses a fuel cell and supporting components to produce power.
  • Those supporting components include fuel and electrolytes, a pump and a blower, a power regulator, a battery power supply and various control components.
  • a power system includes fuel cell stack 1910 , which may be a stack of fuel cells such as those of the present invention. Coupled to fuel cell stack 1910 is dual pump 1920 , which provides fuel from fuel mixing chamber 1950 and electrolyte from electrolyte reservoir 1940 . Dual pump 1920 may be replaced with two single pumps in alternate embodiments.
  • Mixing chamber 1950 receives depleted fuel from fuel cell stack 1910 (through its output) and fuel from fuel reservoir 1930 through control valve 1960 .
  • electrolyte reservoir 1940 receives electrolyte fluid from fuel cell stack 1910 and may also receive depleted oxidant (e.g. air depleted of oxygen) from fuel cell stack 1910 .
  • the depleted oxidant may also enter the electrolyte reservoir 1940 and then exit.
  • Fuel reservoir 1930 may be filled as required to provide fuel to the system.
  • carbon dioxide may fill an empty mixing chamber 1950 , and be forced into fuel reservoir 1930 as fuel fills mixing chamber 1950 . Excess carbon dioxide may be bled out of the system.
  • blower 1970 blows gaseous oxygen into fuel cell stack 1910 .
  • Blower 1970 , pump 1920 and control valve 1960 may all be powered by DC-DC converter 1980 , which in turn draws power primarily from fuel cell stack 1910 .
  • Converter 1980 potentially operates as a voltage or power regulator to provide an 18 W output in some embodiments.
  • an 18 W output may be predicated on a 20 W output from fuel cell 1910 , for example. This allows 2 W for overhead, namely running the blower 1970 , pump 1920 and control valve 1960 , which is a reasonable amount of power for such components.
  • battery 1990 is provided to power the system at startup and provide small amounts of power in undersupply situations. Battery 1990 may be rechargeable or non-rechargeable, and preferably will not need replacement except at rare intervals.
  • the electrochemical cell technology described herein is applicable to numerous systems including batteries, fuel cells, and photoelectric cells. It is contemplated that this technology will be especially useful in portable and mobile fuel cell systems and other electronic devices, such as in cellular phones, laptop computers, DVD players, televisions, palm pilots, calculators, pagers, hand-held video games, remote controls, tape cassettes, CD players, AM and FM radios, audio recorders, video recorders, cameras, digital cameras, navigation systems, wristwatches and other electronics requiring a power supply. It is also contemplated that this technology will also be useful in automotive and aviation systems, including systems used in aerospace vehicles.
  • a 25 um Pt layer provided the channel height for the anode and the Pt layer also served as the current collector for the catalyst layer above.
  • the catalyst layer was 4.0 mg/cm 2 Pt/Ru catalyst bonded to the surface of a NAFION 117 film.
  • a 25 um Kapton layer provided the channel height for the cathode and the 25 um Pt layer served as the cathode catalyst and current collector.
  • the electrode to electrode distance was 56 um and the porous layer used to separate the anode from the cathode was a 6 um thick polycarbonate track etched layer with 100 nm pores and 6 ⁇ 10 8 pores/cm 2 . This equates to approximately 2-4% porosity.
  • An externally manifold 1 ⁇ 5 LFFC array was fabricated.
  • a 25 um Kapton spacer layer plus a 25 um Pt layer provided the channel height for the anode and the Pt layer also served as the current collector (edge collection) for the catalyst layer above.
  • the anode catalyst layer was 4.0 mg/cm 2 Pt/Ru on a NAFION 117 film that was then thermally bonded (hot pressed) with a 3M thermal setting epoxy-type adhesive layer to a 125 um Kapton film to provide rigidity and mechanically integrity (flatness) to the catalyst layer.
  • a 50 um Kapton layer provided the channel height for the cathode and the 25 um Pt layer served as the cathode catalyst and current collector.
  • the electrode to electrode distance was 112 um and the porous layer used to separate the anode from the cathode was a 12 um thick Kapton film track etched with 100 nm pores and 1 ⁇ 10 9 pores/cm 2 . This equates to approximately 8% porosity. 50, 75, and 100 nm pore sizes with 1-15% porosity in film thickness of 7, 12 and 25 um were evaluated in order to optimize the track etch performance. Channel dimensions were 1.5 mm width, 112 micron height, and 30 mm length. If all of the Kapton layers, track etch layer, and current collectors were very flat and aligned, no external leak points were observed while held under an external compression field (100-500 lbs). Near even flow distribution was also observed with these un-bonded layers.
  • An externally manifold 1 ⁇ 5 LFFC array was fabricated.
  • a catalyzed graphite sheet (1 mm) was the anode.
  • a 50 um Kapton layer provided the channel height for the anode.
  • a 50 um Kapton layer provided the channel height for the electrolyte.
  • the porous layer separating the anode from the electrolyte was composed of a 6 um thick polycarbonate track etched layer with 100 nm pores and 6 ⁇ 10 8 pores/cm 2 . This equates to approximately 2-4% porosity.
  • Liquid channel dimensions were 1.5 mm width, 50 micron height, and 30 mm length.
  • the electrode to electrode distance was 130 um.
  • the cathode was composed of a 25 um NAFION 111 bonded to a pre-catalyzed 250 um GDE with the gas porous side exposed to 0.5 mm graphite gas flow channels and the NAFION side exposed to the electrolyte. If all of the Kapton layers, track etch layer, GDE, and current collectors were very flat and aligned, no external leak points were observed while held under an external compression field (100-500 lbs). Near even fluid distribution between the channels was also observed with these un-bonded layers.
  • FIG. 10 illustrates the room temperature performance improvements that occurred as a result of increasing fuel concentration of methanol in 1.0 M sulfuric acid for the fuel stream (4 mL/min total), 1.0 M sulfuric acid for the electrolyte stream (4 mL/min total), and ambient oxygen (1000 mL/min total).
  • the anode was 5 mg/cm 2 50/50 Pt/Ru black deposited onto a graphite plate, and the cathode was 2 mg/cm 2 50% Pt/C and 4 mg/cm 2 Pt black deposited onto a GDE.
  • high current densities were still achieved with multiple channels in parallel and CO 2 bubble formation could be observed only in the fuel effluent around and above 150 mA/cm 2 .

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