System for generating electric power with micro fuel cells and corresponding process

Abstract

Embodiment of a system for generating electric power with micro fuel cells comprising at least one first micro cell and at least one second micro cell, each micro cell having an anode and a cathode with a membrane being sandwich-wise interposed, the system comprising a spacer element having an annular element that surrounds a cavity, said spacer element being associated with said anode of said first micro cell and with said anode of said second micro cell to realize a common diffusion chamber for the fuel of said first micro cell a of said second micro cell.

Claims

1. A system comprising: a first hydrogen fuel cell comprising an anode, a cathode, and a membrane between the anode and the cathode; a second hydrogen fuel cell comprising an anode, a cathode, and a membrane between the anode and the cathode; a spacer element comprising an annular element surrounding a cavity between the first hydrogen fuel cell and the second hydrogen fuel cell, the annular element having a single inlet port and a single outlet port in an opposite side of the single inlet port; and a common output connector coupled between the single outlet port and a collecting tank, wherein the anode of the first hydrogen fuel cell and the anode of the second hydrogen fuel cell are exposed to the cavity.

2. The system of claim 1, wherein: the anode of the first hydrogen fuel cell and the anode of the second hydrogen fuel cell comprise a first plate; and the cathode of the first hydrogen fuel cell and the cathode of the second hydrogen fuel cell comprise a second plate.

3. The system of claim 2, wherein the first plate and the second plate each comprise a layer of frame retardant of the 4 type (FR4) material.

4. The system of claim 2, wherein the first plate and the second plate each comprise a plurality of passing grooves interspaces by wings.

5. The system of claim 2, wherein the first plate and the second plate each have a hole in a peripheral edge of the respective plate.

6. The system of claim 5, further comprising a connection pin coupled to the peripheral edge of the first plate.

7. The system of claim 1, wherein the membrane of the first hydrogen fuel cell and the membrane of the second hydrogen fuel cell each comprises solid electrolyte sandwich-wise interposed between two carbon layers.

8. A system comprising: a first fuel cell comprising an anode, a cathode, and a membrane between the anode and the cathode; a second fuel cell comprising an anode, a cathode, and a membrane between the anode and the cathode; a spacer element comprising an annular element surrounding a cavity between the first fuel cell and the second fuel cell, the annular element having a single inlet port and a single outlet port in an opposite side of the single inlet port; and a common output connector coupled to the single outlet port, wherein the anode of the first fuel cell and the anode of the second fuel cell are exposed to the cavity.

9. The system of claim 8, wherein the cavity comprises methanol (CH.sub.3OH).

10. A system comprising: a first fuel cell comprising an anode, a cathode, and a membrane between the anode and the cathode; a second fuel cell comprising an anode, a cathode, and a membrane between the anode and the cathode; a spacer element comprising an annular element surrounding a cavity between the first fuel cell and the second fuel cell, the annular element having a single inlet port and a single outlet port in an opposite side of the single inlet port; and a common output connector coupled to the single outlet port, wherein the anode of the first fuel cell and the anode of the second fuel cell are exposed to the cavity, the first fuel cell and the second fuel cell being configured to receive a first reactant in a gaseous state into the cavity, and a second reactant in a gaseous state, and generate a product in a liquid state.

11. A system comprising: a plurality of modular fuel cell structures coupled to one another and each comprising a first micro fuel cell comprising a first plurality of electrodes, a second micro fuel cell spaced apart from the first micro fuel cell and comprising a second plurality of electrodes, and an annular spacer defining a cavity between the first micro fuel cell and the second micro fuel cell and an inlet and an outlet to the cavity, the inlets and outlets of the plurality of modular fuel cells being interconnected so that the cavities define a common diffusion chamber for supplying fuel to all of the modular fuel cell structures simultaneously; a common input connector coupling an input of the plurality of modular fuel cell structures to a fuel stocking tank; and a common output connector coupled between a single common output of the plurality of modular fuel cell structures and a collecting tank.

12. The system of claim 11 further comprising a plurality of conductive pins electrically connecting each first micro fuel cell in series with the corresponding second micro fuel cell.

13. The system of claim 11 further comprising a plurality of conductive pins electrically connecting each first micro fuel cell in parallel with the corresponding second micro fuel cell.

14. The system of claim 11 wherein each first micro fuel cell further comprises a first spacer layer, and wherein the first electrodes of each first micro fuel cell are arranged on opposing sides of the first spacer layer; and wherein each second micro fuel cell further comprises a second spacer layer, and wherein the second electrodes of each second micro fuel cell are arranged on opposing sides of the second spacer layer.

15. The system of claim 11 wherein the plurality of first electrodes and the plurality of second electrodes have grooves therebetween to permit the inflow of oxygen to the common diffusion chamber.

16. The system of claim 11, wherein: the plurality of modular fuel cell structures comprises a single common input; and the common input connector is coupled between the single common input of the plurality of modular fuel cell structures and the fuel stocking tank.

17. The system of claim 11, wherein the common diffusion chamber comprises hydrogen (H.sub.2).

18. The system of claim 11, wherein anodes of the plurality of modular fuel cell structures comprise a first plate.

19. The system of claim 18, wherein the first plate comprises a first layer of non conductive compound material covered by a second layer of conductive material.

20. The system of claim 19, wherein the first layer comprises frame retardant of the 4 type (FR4) material.

21. The system of claim 19, wherein the second layer comprises gold (Au).

22. The system of claim 19, wherein the first plate comprises conductive tracks.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Characteristics and advantages of an embodiment will be apparent from the following description, which is given by way of indicative and non limiting example with reference to the annexed drawings.

(2) FIGS. 1A and 1B show a section of a micro fuel cell, realized according to the prior art.

(3) FIG. 2 shows a perspective view of a stack system of micro fuel cells realized according to the prior art.

(4) FIGS. 3A and 3B respectively show a perspective view and an exploded view of a planar system of two micro fuel cells realized in PCB technology, according to the prior art.

(5) FIG. 4 shows a section view of a system for the generation of electric power with micro fuel cells realized according to an embodiment.

(6) FIGS. 5A-5F show perspective views of some components of the system of FIG. 4 according to an embodiment.

(7) FIGS. 6A and 6B show a perspective view, respectively from above and from the bottom, of the system shown in FIG. 4 with a series connection between the micro cells of the system according to an embodiment.

(8) FIG. 6C, shows a perspective view of the system shown in FIG. 4 with a parallel connection between the micro cells of the system according to an embodiment.

(9) FIGS. 7 and 8 respectively show in a section view and in a perspective view, a system realised according to an embodiment.

(10) FIGS. 9 and 10 show a perspective view of a system realized according to respective embodiments.

(11) FIGS. 11 and 12 show two perspective views of a prototype realized according to an embodiment of FIG. 4.

(12) FIG. 13 shows a diagram that compares the electric power curves of a system according to an embodiment shown in FIG. 4 and of a system with a single micro cell realized according to the prior art.

(13) FIG. 14 shows a diagram that reports the biasing and electric power curves of a system realized according to an embodiment with two micro fuel cells in comparison with a similar system realized according to the prior art shown in FIG. 3A.

DETAILED DESCRIPTION

(14) With reference to these figures, 1 globally and schematically indicates an embodiment of a system for generating electric power of the modular type with two or more bi-planar micro fuel cells able to supply an electric power according to the request of a connected electronic application/load.

(15) It is noted that the figures showing schematic views of portions of the micro cells may not be drawn to scale, but may instead be drawn so as to emphasize important characteristics of an embodiment.

(16) Referring to FIG. 4, the system 1 comprises a first micro cell 2 and a second micro cell 3 supplied by fuel such as, for example, gaseous hydrogen H.sub.2, and coupled to each other.

(17) The first micro cell 2 and the second micro cell 3 may be identical with respect to each other and of the passive type and each substantially comprise: an anode, respectively 2A and 3A, defined by a first plate 4 realised in PCB technology, which is supplied, as a reactant, with gaseous hydrogen H.sub.2; a cathode, respectively 2C and 3C, defined by a further plate 4 realized in PCB technology, which is supplied, as a reactant, with oxygen O.sub.2 taken directly from the environment air surrounding the micro cell itself, to form a micro cell of the air-breathing type; a membrane MEA comprising a solid electrolyte realized by means of a polymeric membrane PEM being sandwich-wise interposed between two carbon layers.

(18) The system 1 also comprises a spacer element 5 defined by an annular element 7 that surrounds a cavity 6a.

(19) In particular, the spacer element 5 is associated with the anode A2 of the first micro cell 2 and with the anode A3 of the second micro cell 3 so that the cavity 6a realizes a common diffusion chamber 6 for simultaneously supplying the fuel to the first micro cell 2 and to the second micro cell 3.

(20) According to an embodiment, shown in FIG. 4, the cavity 6a of the spacer element 5 is passing the fuel and the annular element 7 is interposed and peripherally surrounds the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 3. The anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 3 thus face the cavity 6a and each other.

(21) The plates 4 and 4, which define the anode A2, A3, and the cathode C2, C3 of each micro cell 2, 3 are substantially identical with respect to each other and, according to the PCB technology, they comprise one or more thin layers of non conductive compound material, for example FR4 (Frame Retardant of 4 type), covered by one or more layers of conductive material, for example gold (Au) and are suitably micro-treated. In particular, as shown respectively in FIGS. 5A and 5B, the plates 4 and 4 have on the surface a plurality of passing grooves 4a which are interspaced by suitable wings 4b. The grooves 4a allow the inflow of the reactants into the membrane MEA.

(22) The grooves 4a of the plate 4 that defines the anode A2 and A3, and the grooves 4a of the plate 4 that defines the cathode C2 and C3 of each micro cell 2, 3 may be different from each other according to the stoichiometry of the reactions that occur respectively at the anode A and at the cathode C of the same micro cell.

(23) Naturally, the plates 4 and 4 may comprise conductive metallic tracks, vias, or passages suitable for allowing the electric connection between the micro cells and with discrete electronic components suitable for the management and the control of the electric power generated by the system 1.

(24) The membrane MEA, shown in FIG. 5C, is sandwich-wise interposed between the anode A2, A3 and the cathode C2, C3 of each micro cell 2, 3, and is assembled in a single step by means of the interposition of solid glue layers 11. The glue layers 11, shown in FIGS. 5E and 5F, are suitably shaped so as to maintain the grooves 4b free on the plates 4, 4. The wings 4b on the plates 4, 4 allow sustaining the interposed membrane MEA.

(25) Suitably, the cavity 6a of the spacer element 5, as shown in FIG. 5D, has such dimensions as to contain the grooves 4a when the annular element 7 is peripherally associated with the anode A2 of the first micro cell 2 and with the anode A3 of the second micro cell 3. In this way, the first micro cell 2 and the second micro cell 3 are stack-wise arranged in an arrangement defined as bi-planar with the diffusion chamber 6 interposed.

(26) The electric connection between the first micro cell 2 and the second micro cell 3 is provided by the introduction of connection pins 15, realised with small shafts of conductive material, that passes across the system 1 and are inserted and fixed in correspondence with prearranged holes 4c realized in correspondence with the peripheral edge of the plates 4 and 4. As shown in FIGS. 6A and 6B, the series electrical coupling between the first micro cell 2 and the second micro cell 3 is obtained with a connection pin 15 that couples the cathode C2 of the first micro cell 2 to the anode A3 of the second micro cell 3.

(27) The conductive coating material of the plates 4, 4 allows realizing a conveyor of electrons that are made to flow, always through further connection pins 15, to the management and control circuitry of the electric power generated.

(28) In a similar way, with a different arrangement of the connection pins 15 it may be possible to realize a bi-planar stack system 1 with the first micro cell 2 associated in electrical parallel with the second micro cell 3, as shown in FIG. 6C. This parallel coupling is obtained with a connection pin 15 that couples to each other the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 2 and a second connection pin 15 that couples to each other the cathode C2 of the first micro cell 2 to the cathode C3 of the second micro cell 3.

(29) The spacer element 5 comprises an input hole or inlet 8, realized in correspondence with the annular element 7 in flow communication with the cavity 6a for the coupling to a stocking tank of the gaseous hydrogen H.sub.2 by means of the interposition of a connector 10.

(30) Moreover, the spacer element 5 comprises an output hole or outlet 9 realized in correspondence with the annular element 7, on the opposite part with respect to the input hole 8, in flow communication with the cavity 6a to allow the coupling to a stocking tank of the reaction by-products, by means of the interposition of a further connector 10.

(31) Suitably, the connectors 10 may be of the pneumatic type or of other type while the stocking tank of the gaseous hydrogen H.sub.2 may be alternatively a high pressure cylinder or a cryogenic container.

(32) Moreover, the spacer element 5 is realized with any material compatible with the process of hot gluing of the FR4 of the plates 4 and 4.

(33) As regards the operation of the system 1, according to an embodiment, after having assembled the first micro cell 2 and the second micro cell 3, the spacer element 5 is sandwich-wise interposed. The cavity 6a interposed between the anode A2 of the first micro cell 2 with the anode A3 of the second micro cell 3 realizes the common diffusion chamber 6 for the first micro cell 2 and the second micro cell 3. In this way, the first micro cell 2 and the second micro cell 3 have the respective cathodes C2 and C3 arranged on the external surfaces of the system 1 which take oxygen O.sub.2 from the environment surrounding the system 1 itself through the grooves 4a.

(34) As shown in FIGS. 6A, 6B and 6C, the electric coupling is realized, and may be of the series or parallel type, between the first micro cell 2 and the second micro cell 3 with the external circuitry through respective connection pins 15. Also the fluhydric coupling is realized, through the interposition of connectors 10, with the stocking tank of the gaseous hydrogen H2 and with the collecting tank of the reaction by-products.

(35) At the activation of the system 1, the gaseous hydrogen H2 is introduced into the cavity 6a through the connector 10 associated with the input hole 8 and the diffusion chamber 6, according to an embodiment, simultaneously supplies the anode A2 of the first micro cell 2 and the anode A3 of the second micro cells 3 facing each other.

(36) The diffusion chamber 6, single for the system 1, may allow considerably improving the distribution of the gaseous hydrogen H.sub.2 in the whole cavity 6, thus improving the performances of the system 1.

(37) Thanks to the presence of the catalyst, finely dispersed in the membrane MEA, in the respective anodes A2 and A3 of the micro cells, the reactions of oxide-reduction are activated. While the gaseous hydrogen H2 is resolved into protons of hydrogen and electrons, the protons of hydrogen pass through the membrane MEA of each micro cell and are combined with the oxygen O.sub.2 in the cathode C2 of the first micro cell 2 and of the cathode C3 of the second micro cell 3, to form water and heat.

(38) The electrons freed are conveyed through the connection pins 15 to the conditioning and control circuitry of the electric power generated by the system 1 and thus to the load.

(39) According to an embodiment, the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 3 thus have a double function: they allow collecting the free electrons for generating electric power, the plates 4, 4 being coated with a conductive layer; they allow diffusing the gaseous hydrogen H.sub.2, i.e. the reactant, making it reach the membrane MEA through the grooves 4a.

(40) As it may be understood from the curves reported in the diagram shown in FIG. 13, by comparing the bi-planar stack system 1 with two micro cells couple in series, according to an embodiment, with a system comprising a micro fuel cell in PCB technology realized according to the prior art, the space surface occupied being identical and having a limited increase in thickness, due to the presence of the spacer element 5, a gain factor 2:1 is obtained, i.e. there is the possibility to generate a double electric power having an identical occupied surface.

(41) A second embodiment of a system 1 for the generation of electric power is shown in FIG. 7 and comprises a first micro cell 2 and a second micro fuel cell 3 that are arranged side by side and coupled in a contiguous way, supplied with gaseous hydrogen H.sub.2.

(42) As regards details and cooperating parts having the same structure and function as previously described, they will be indicated with the same reference numbers and acronyms.

(43) According to an embodiment, the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 3 as well as the respective cathodes, C2 and C3 are arranged side by side on parallel planes. The plates 4 and 4 that define the anodes A2 and A3 and the cathodes C2 and C3 are substantially equal to each other and comprise a central portion provided with a plurality of grooves 4a alternated with a plurality of wings 4b, according to what has been previously described.

(44) The system 1 comprises a spacer element 5, which is provided with a plate 16 substantially U-like shaped with an annular element 17 projecting from a same side with respect to said plate 16 to define a cavity 16a. The annular element 17 is peripherally associated with the respective anode A2 of the first micro cell 2 and with the anode A3 of the second micro cell 3 and connected in a per se known way through one or more layers of glue 11 or other technique. The cavity 16a of the spacer element 5 defines with the first micro cell 2 and the second micro cell 3 a common diffusion chamber 6 of the system 1 for supplying simultaneously with gaseous hydrogen H.sub.2 the first micro cell 2 and the second micro cell 3.

(45) The plate 16 comprises an input hole or inlet 8 and an output hole or outlet 9 both in flow communication with the cavity 16a and suitable for allowing respectively the coupling to a stocking tank of the gaseous hydrogen H.sub.2 and to a collection tank of the reaction by-products, possibly through the interposition of corresponding connectors 10.

(46) The diffusion chamber 6 allows, in particular, to make uniform the distribution of the gaseous hydrogen H.sub.2 in the cavity 16a supplying simultaneously the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 3, improving in a considerable way the performances of the system 1. This arrangement is indicated as a planar system of the bi-planar type.

(47) Naturally, further realization layouts may be obtained by suitably combining the implementations indicated in two or more of the above-described embodiments.

(48) For example, a third embodiment is shown in FIG. 9. The implementation provides a bi-planar stack system 1 comprising a spacer element 5 being sandwich-wise interposed between an anode of a first modular structure 22 and an anode of a second modular structure 23.

(49) The first modular structure 22 and the second modular structure 23 comprise an equal number of micro cells which have the respective anodes A and the respective cathodes C arranged side by side and on parallel planes.

(50) The spacer element 5 thus has an annular element 7 that surrounds a cavity 6a which defines with the anode A22 of the first modular structure 22 and the anode A23 of the second modular structure 23 a common diffusion chamber 6 for supplying the gaseous hydrogen H.sub.2 simultaneously to the whole system 1.

(51) This implementation, that constitutes an integration of embodiments previously described, allows further increasing the electric power and thus the electric power generated by the system 1.

(52) An embodiment is shown in FIG. 10. The embodiment provides the overlapping of two systems 1 independent from each other, that as shown, in an indicative and non-limiting manner, are realized according to the embodiment of FIG. 9. These systems 1 are suitably spaced by spacer elements 30 that define a gap for allowing the respective cathodes C, facing each other, to take oxygen in a passive way from the surrounding environment air. The separating elements 30 are small cylinders arranged in correspondence of the faced edges of each system 1 inserted in counter-shaped seats 31. FIGS. 11 and 12 show a prototype realized of an embodiment of a system of micro fuel cells according to an embodiment shown and described above with reference to FIG. 4.

(53) The prototype system 1 comprises a first micro cell 2 and a second micro cell 3 realized in PCB technology of active area equal to approximately 3.6 cm.sup.2. The prototype system 1 may be electrically characterized by means of a FCTS (Fuel Cell Test Station), by sending hydrogen to the anode A2 of the first micro cell 2 and to the anode A3 of the second micro cell 3 and making the oxygen being taken in a passive way from the environment air surrounding the respective cathodes C2 and C3.

(54) In the diagram shown in FIG. 14, with the light color a biasing curve of the prototype system 1 is reported when the load applied in a decreasing way varies from the starting conditions of open circuit. In particular, the diagram of FIG. 14 compares the voltage and electric power curves between the prototype system 1 and a similar system, also realized in PCB technology, but realized according to the prior art. Even more in particular, an improvement may be observed of the performances of the system 1 according to an embodiment with respect to the prior art system in terms of maximum power reached, approximately 1.54 W compared to 1.29 W. This is mainly due to the better distribution of the gaseous hydrogen H.sub.2 that, in the case of the system according to an embodiment, is introduced in the common diffusion chamber 6 for all the micro cells of the whole system 1 before reaching the respective membranes MEA.

(55) Moreover, considering a surface occupied by the system of approximately 3.6 cm.sup.2 the power density of the system, realized according to an embodiment, takes a value of approximately 213 mW/cm.sup.2 while for a system according to the prior art it is of approximately 178 mW/cm.sup.2.

(56) The system, according to an embodiment, does not preclude in any way the possibility to use other types of fuel such as for example methanol (CH.sub.3OH) instead of gaseous hydrogen H.sub.2.

(57) An embodiment also relates to a process for generating electric power by means of a system with micro fuel cells as previously described for which details and cooperating parts having the same structure and function will be indicated with the same reference numbers and acronyms.

(58) The system 1 comprising at least one first micro cell 2 and at least one second micro cell 3 that may be associated with each other. The first micro cell 2 and the second micro cell 3 are realized by sandwich-wise interposing a polymeric membrane MEA between an anode A2, A3 and a cathode C2, C3 of the respective micro cell.

(59) The process provides prearranging a spacer element 5 comprising an annular element 7 that surrounds a cavity 6a.

(60) The process thus provides a common diffusion chamber 6 by facing the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 3 with the cavity 6a. This common diffusion chamber 6 being suitable for simultaneously supplying the fuel, i.e. the gaseous hydrogen H.sub.2, to the first micro cell 2 and to the second micro cell 3.

(61) The process also provides an input hole 8 and an output hole 9 in said spacer element 5 for the coupling respectively to a stocking tank of the gaseous hydrogen H.sub.2 and to a collecting tank of the reaction by-products.

(62) Moreover, the process provides electrically coupling the first micro cell 2 and the second micro cell 3, according to a series or parallel arrangement, by associating and fixing to the respective prearranged anodes and/or cathodes connection pins 15.

(63) In an embodiment shown in FIG. 4, the cavity 6a of the passing type is realized and the process provides to sandwich-wise interpose the annular element 7 between the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 3 to define said common diffusion chamber 6 for the whole system 1.

(64) In an embodiment shown in FIG. 7, the process provides to realize the hidden cavity 16a in said spacer element 5. In particular, the process provides to realise the spacer element 5 by prearranging a plate 16 substantially U-like shaped with an annular element 17 projecting from a same side with respect to said plate 16 so as to define inside said cavity 16a.

(65) The process also provides to prearrange, side by side, the first micro cell 2 and the second micro cell 3 by associating the anode A2 of the first micro cell 2 and the anode A3 of the second micro cell 9 with the annular element 7 so as to define with the cavity 16a the single diffusion chamber 6 for the whole system 1.

(66) An advantage of a system according to an embodiment lies in its remarkable compactness and in its assembling simplicity. In fact, the common and single diffusion chamber for the whole system allows simultaneously supplying the gaseous hydrogen H.sub.2 to the anodes of the micro cells substantially reducing by almost a half the space surface of systems that generate similar electric power but are realized by means of the prior art.

(67) A further advantage of a system according to an embodiment is the versatility of the same that allows implementing solutions that have, the electric power produced being identical, a layout and thus space dimensions that may be defined according to the needs of the load: physical dimensions and requested electric power.

(68) An advantage of a process according to an embodiment is the significant simplification of the assembling operations that allow realizing systems with compact architectures, with good mechanical resistance, and contained weight.

(69) Another advantage of a system and of a process according to an embodiment is the reduction in the overall realization costs. The system in fact does not require the use of special packages for the containment of the electrodes, it has a direct interfacing of the micro cells with the external environment and for the introduction of the reactants and also for the coupling to the management and control circuitry of the electric power generated.

(70) From the foregoing it will be appreciated that, although one or more specific embodiments have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the disclosure. Furthermore, where an alternative is disclosed for a particular embodiment, this alternative may also apply to other embodiments even if not specifically stated.