Fuel cell assembly and method of making the same
View Patent ↗A fuel cell assembly in accordance with a present invention includes a substrate including a reactant-permeable region and a non-permeable support region and a fuel cell carried by the substrate.
1. A fuel cell assembly, comprising:
a substrate including a reactant-permeable region with a plurality of apertures and a non-permeable support region; and
a fuel cell, including first and second electrodes, carried by the substrate such that at least a portion of the fuel cell is positioned over the reactant permeable region and portions of the first electrode are located within the apertures.
2. A fuel cell assembly as claimed in claim 1 , wherein the substrate defines a thickness, the fuel cell defines a thickness, and the substrate is substantially thicker than the fuel cell.
3. A fuel cell assembly as claimed in claim 2 , wherein the substrate is at least 5 times as thick as the portion of the fuel cell positioned over the reactant permeable region.
4. A fuel cell assembly as claimed in claim 1 , wherein the non-permeable support region surrounds the reactant permeable region.
5. A fuel cell assembly as claimed in claim 1 , wherein the substrate is a unitary structure.
6. A fuel cell assembly as claimed in claim 1 , wherein the first electrode is in contact with reactant permeable region.
7. A fuel cell assembly as claimed in claim 1 , wherein
the first and second electrodes comprise first and second electrode films,
an electrolyte film is positioned over at least a portion of the first electrode film, and
the second electrode film is positioned over at least a portion of the electrolyte film.
8. A fuel cell assembly, comprising:
a substrate including a reactant-permeable region, with a plurality of apertures and defining a top surface and a bottom surface, and a non-permeable support region; and
a fuel cell, including first and second electrodes, carried by the substrate such that at least a portion of the fuel cell is positioned over the reactant permeable region, and the first electrode covers a portion of the top surface of the reactant permeable region, is located within at least some of the apertures, and covers a portion of the bottom surface of the reactant permeable region.
9. A fuel cell assembly as claimed in claim 8 , wherein the substrate defines a thickness, the fuel cell defines a thickness, and the substrate is substantially thicker than the fuel cell.
10. A fuel cell assembly as claimed in claim 9 , wherein the substrate is at least 5 times as thick as the portion of the fuel cell positioned over the reactant permeable region.
11. A fuel cell assembly as claimed in claim 8 , wherein the non-permeable support region surrounds the reactant permeable region.
12. A fuel cell assembly as claimed in claim 8 , wherein the substrate is a unitary structure.
13. A fuel cell assembly as claimed in claim 8 , wherein
the first and second electrodes comprise first and second electrode films,
an electrolyte film is positioned over at least a portion of the first electrode film, and
the second electrode film is positioned over at least a portion of the electrolyte film.
14. A fuel cell system, comprising:
a fuel cell stack including a plurality of fuel cell assemblies arranged in spaced relation to one another;
each fuel cell assembly including a substrate, having a reactant-permeable region with a plurality of apertures and a non-permeable support region, and a fuel cell, including first and second electrodes, carried by the substrate such that at least a portion of the fuel cell is over the reactant permeable region and portions of the first electrode are located within the apertures;
a fuel source operably connected to the stack; and
an oxidant source operably connected to the stack.
15. A fuel cell system as claimed in claim 14 , the fuel cell assemblies are arranged such that at least two of the substrates face one another and define a reactant passage therebetween.
16. A fuel cell system as claimed in claim 14 , wherein the substrates define a thickness, the fuel cells define a thickness, and the substrates are substantially thicker than the fuel cells.
17. A fuel cell system as claimed in claim 16 , wherein the substrates are at least 5 times as thick as the fuel cells.
18. A fuel cell system as claimed in claim 14 , wherein the non-permeable support region of each substrate surrounds the reactant permeable region.
19. A fuel cell system as claimed in claim 14 , wherein the substrates are unitary structures.
20. A fuel cell system as claimed in claim 14 , wherein the first electrode of each fuel cell is in contact with reactant permeable region of the associated substrate.
21. A fuel cell system as claimed in claim 14 , wherein
the first and second electrodes of each fuel cell comprise first and second electrode films,
an electrolyte film is positioned over at least a portion of the first electrode film in each fuel cell, and
the second electrode film is positioned over at least a portion of the electrolyte film in each fuel cell.
22. A fuel cell system, comprising:
a fuel cell stack including a plurality of fuel cell assemblies arranged in spaced relation to one another;
each fuel cell assembly including a substrate, having a reactant-permeable region with a plurality of apertures and defining a top surface and a bottom surface, and a non-permeable support region, and a fuel cell including first and second electrodes, carried by the substrate such that at least a portion of the fuel cell is over the reactant-permeable region and the first electrode covers a portion of the top surface of the reactant permeable region, is located within at least some of the apertures, and covers a portion of the bottom surface of the reactant permeable regions;
a fuel source operably connected to the stack; and
an oxidant source operably connected to the stack.
23. A fuel cell system as claimed in claim 22 , the fuel cell assemblies are arranged such that at least two of the substrates face one another and define a reactant passage therebetween.
24. A fuel cell system as claimed in claim 22 , wherein the substrates define a thickness, the fuel cells define a thickness, and the substrates are substantially thicker than the fuel cells.
25. A fuel cell system as claimed in claim 24 , wherein the substrates are at least 5 times as thick as the fuel cells.
26. A fuel cell system as claimed in claim 22 , wherein the non-permeable support region of each substrate surrounds the reactant permeable region.
27. A fuel cell system as claimed in claim 22 , wherein the substrates are unitary structures.
28. A fuel cell system as claimed in claim 22 , wherein
the first and second electrodes of each fuel cell comprise first and second electrode films,
an electrolyte film is positioned over at least a portion of the first electrode film in each fuel cell, and
the second electrode film is positioned over at least a portion of the electrolyte film in each fuel cell.
29. A fuel cell assembly produced by a process comprising the step of:
providing a substrate having a reactant permeable region, defining a top surface and a bottom surface, and a non-permeable support region; and
forming a fuel cell, on the substrate over the reactant permeable region, that includes a first electrode that covers a portion of the top surface of the reactant permeable region, extends through the substrate, and covers a portion of the bottom surface of the reactant permeable region.
30. A fuel cell assembly as claimed in claim 29 , wherein the step of providing a substrate comprises the steps of:
providing a sheet of substrate material; and
removing portions of the substrate material from the sheet to form a plurality of apertures that define the reactant-permeable region.
31. A fuel cell assembly as claimed in claim 30 , wherein the step of removing portions of the substrate material from the sheet comprises punching apertures into the sheet of substrate material.
32. A fuel cell assembly as claimed in claim 29 , wherein the step of providing a substrate comprises molding a substrate with a plurality of apertures in the reactant permeable region.
33. A fuel cell assembly as claimed in claim 29 , wherein the step of forming a fuel cell on the substrate comprises the steps of:
forming a first electrode film over the top and bottom surfaces and within the apertures of the reactant-permeable region;
forming an electrolyte film over at least a portion of the first electrode film; and
forming a second electrode film over at least a portion of the electrolyte film.