fuel cells

Abstract

This disclosure provides a fuel cell comprising at least one fuel cell board. Each fuel cell board comprises at least one first insulating layer, at least one ion-permeable membrane, a plurality of anodes, and a plurality of cathodes. All cathodes are arranged across the entire first surface of the ion-permeable membrane, and all anodes are arranged across the entire second surface opposite the first surface of the ion-permeable membrane. At least one material property of an anode or cathode, or the size of an anode or cathode, varies across the entire fuel cell board, and / or at least one material property of other components of the fuel cell board varies across the entire fuel cell board. A pair of anodes and cathodes flanking at least one ion-permeable membrane may be electrically connected in parallel with adjacent anode-cathode pairs.

Description

Technical Field

[0001] The present disclosure relates to a fuel cell, uses of a fuel cell, a method for controlling the voltage of a fuel cell, and a member for a fuel cell.

Background Art

[0002] A fuel cell (e.g., a solid polymer electrolyte fuel cell) is an electrochemical device that generates electrical energy and heat from a reactant or oxidant (e.g., pure oxygen or air) and a fuel (e.g., hydrogen or a hydrogen-containing mixture, or a hydrocarbon or hydrocarbon derivative). Fuel cell technology is used in stationary applications such as power plants, vehicles, laptop computers, and mobile applications.

[0003] Typically, a fuel cell includes two electrodes, an anode and a cathode, which are separated by an electrolyte membrane that allows ions (e.g., hydrogen ions) to pass from one electrode to the other but does not allow free electrons to pass. The catalyst on the electrodes promotes the reaction with the fuel on the anode to separate electrons and protons / cations, and promotes the reaction with the oxidant on the cathode to cause a reduction reaction to water. Then, a circuit can be formed between the anode and the cathode to generate a current that supplies power to a load such as an electrical device. A reaction fluid, e.g., oxygen or reaction air, is supplied to the cathode, and a fuel, e.g., hydrogen, is supplied to the anode.

[0004] A pair of electrodes separated by an electrolyte membrane is called a membrane electrode assembly (MEA). An MEA in a fuel cell operating at a moderate load produces an output voltage of approximately 0.7V, but this output voltage is often too low from many practical standpoints. To increase this voltage, MEAs are typically assembled in a stack, as shown in Figure 1. Each MEA has a layer of electrolyte membrane 1a (e.g., Nafion® membrane), which includes an ion-permeable membrane sandwiched between two electrode layers, with an anode 2 on one side of the electrolyte membrane and a cathode 3 on the other. Adjacent MEAs can be separated by a conductive bipolar separator plate 4, through which the fuel (e.g., hydrogen) 6 and oxidizer 5 (e.g., oxygen gas or "reaction air") flow through channels provided on opposite sides of the bipolar plate. The end plates 9 are connected to external circuits via electrical connectors 7 and 8. The number of these MEAs in the stack within the fuel cell determines the total output voltage, and the surface area of ​​each membrane electrode determines the total current that can be extracted / output. The catalyst layer adjacent to the electrode increases the rate and efficiency of the reaction at the electrode.

[0005] Figure 2 shows a fuel cell in the prior art (see, for example, International Publication No. 2012 / 117035) in which multiple fuel cell boards 22 are stacked between two end plates 21 to increase voltage and output. Electrode pairs are arranged in series along both sides of a single layer of polymer electrolyte 10, which is, for example, a Nafion® film. Anodes 11 are located on one surface of these films, and cathodes 12, separated by a gap, are located on the other opposing surface of these films. The anodes and cathodes of two adjacent electrode pairs may partially overlap. Through-film electrical connectors 13 connect the electrodes by penetrating the films in the overlapping region and may be formed by a uniform chemical deposition process. Catalysts on the electrodes facilitate the reaction at the electrodes. A fuel 17, such as hydrogen gas, flows along the surface of the fuel cell board 22 and is supplied to the anodes 11, and a reactant or oxidizer 16, such as oxygen gas or air, flows along the surface of the fuel cell board 22 and is supplied to the cathodes 12. One electrode located on the upper edge of the fuel cell board and another electrode located on the lower edge are connected to an external circuit via electrical connections 18 and 19. In this series arrangement, the surface area of ​​the electrode pair determines the magnitude of the current in the fuel cell board 22, while the voltage accumulates in proportion to the number of electrode pairs on the fuel cell board 22.

[0006] An electrically insulating spacer 20, which includes a spacer made of an electrically insulating material (e.g., plastic), can be incorporated into the stack between each fuel cell board.

[0007] The size of each individual cell (surface area of ​​the electrode pair) determines the magnitude of the current supplied to the fuel cell board. The total number of individual cells on the fuel cell board determines the voltage generated. The number of fuel cell boards in the stack determines the magnitude of the total current supplied to the fuel cell stack.

[0008] The end cathodes and anodes 11 on each fuel cell board are connected to the first and second output lines, respectively, via electrical connections 18 and 19. The connection between each fuel cell board in the stack and the second output line can be controlled by a switching mechanism, such as a field-effect transistor (FET) switch, which provides direct power processing and control in the cell. Each of these switches can be controlled by its own separate control line.

[0009] Numerous factors determine the performance and consistency of voltage / current output of a fuel cell. Maintaining the appropriate moisture content within the electrolyte membrane is crucial for optimizing and controlling fuel cell performance, as humidity on the fuel cell board can affect performance and control. The ion-permeable membrane of a fuel cell requires a certain level of moisture to operate efficiently and conduct ionic current efficiently without reducing fuel cell current. Water generated in the cell is removed by the fluid flow along the cathode or by capillary action. If the fuel cell board is too wet or too dry, performance during operation may be below optimal or fluctuate.

[0010] The temperature of the fuel cell or fuel cell stack, and the temperature variations across the fuel cell, cell, MEA, or individual fuel cell boards, can determine the performance of the fuel cell and the consistency of the voltage output / current of the fuel cell or subsequent fuel cell stack.

[0011] Variations in other factors between fuel cell boards, such as fuel concentration, pressure or partial pressure of fuel(s), and heat exchange fluid temperature (e.g., coolant temperature), can also affect fuel cell performance and the consistency of the fuel cell's voltage output / current.

[0012] Consistency in the voltage output / current of a fuel cell is crucial in most fuel cell applications. Excessive voltage fluctuations, unless specifically desired, can affect the performance of downstream operations. While varying the fuel cell voltage may be desirable in some cases, controlling this voltage, if possible, is important in fuel cell design.

[0013] In light of the circumstances described above, there is a need to improve the control of fuel cell voltage / current output through novel methods and new fuel cell designs. It is desirable to provide improved fuel cells, fuel cell applications, methods for controlling fuel cell voltage, and fuel cell components. [Prior art documents] [Patent Documents]

[0014] [Patent Document 1] International Publication No. 2012 / 117035 Pamphlet [Overview of the Initiative] [Means for solving the problem]

[0015] A first aspect of a preferred embodiment provides a fuel cell comprising at least one fuel cell board. Each fuel cell board comprises at least one first insulating layer, at least one ion-permeable membrane, a plurality of anodes, and a plurality of cathodes. All cathodes are arranged across the entire first surface of the ion-permeable membrane, and all anodes are arranged across the entire second surface of the ion-permeable membrane opposite the first surface. At least one material property of the anodes or at least one material property of the cathodes may vary across the fuel cell board. The size of the anodes and / or the size of the cathodes may vary or be changed for each anode across the fuel cell board. At least one material property of other components of the fuel cell board (for example, “other components” may be the ion-permeable membrane or the gas diffusion layer) may vary or be changed across the fuel cell board. Each anode may have different material properties / composition or size from at least one / any adjacent anode / other anode on the same fuel cell board, and / or each cathode may have different material properties / composition or size from at least one / any adjacent cathode / other cathode on the same fuel cell board. The size and / or material properties / composition of each anode may differ from at least one / any adjacent anode / other anode on the same fuel cell board, and / or the size and / or material properties / composition of each cathode may differ from at least one / any adjacent cathode / other cathode on the same fuel cell board. At least one anode or at least one cathode may have a different size (may be larger or smaller) or material properties / composition from other anodes on the same fuel cell board. The fuel cell board may have a plurality of ion-permeable films, in which case there may be one for each pair of anodes and cathodes. The MEA may be laminated on at least one first insulating layer, or may be attached or mounted in other ways.

[0016] As used herein, "across the fuel cell board" means a change from one side of the fuel cell board to the other side, for example, a change along the length of the fuel cell board or a change along the width of the fuel cell board.

[0017] Preferably, at least one anode-cathode pair sandwiching an ion-permeable membrane may be electrically connected in parallel with an adjacent anode-cathode pair.

[0018] The anodes and cathodes of the fuel cells described herein may be described or referred to as “segmented” throughout. A segmented anode or cathode is one which has a gap between adjacent anodes or cathodes. Segmented anodes and cathodes form a segmented membrane electrode assembly (MEA) or “cell.” Each MEA may be formed from one anode and one cathode, each positioned on opposite sides of an ion-permeable membrane. An ion-permeable membrane may have multiple anodes or cathodes or multiple MEAs across its entire surface. Multiple segmented MEAs may be arranged on a single fuel cell board of the present invention. In this specification, an MEA may also be referred to as a “cell.” Multiple ion-permeable membranes may be provided across the entire fuel cell board, and each ion-permeable membrane may have one or more anodes or cathodes. Each MEA may consist of one anode, one cathode, and one ion-permeable membrane. These are arranged such that each anode overlaps with at least one cathode via an ion-permeable membrane, and / or each cathode overlaps with at least one anode via an ion-permeable membrane. On the same fuel cell board, anodes and cathodes have gaps between adjacent anodes or cathodes.

[0019] Segmented anodes, cathodes, cells, or MEAs may have different, varied, or diverse properties (e.g., size, shape, or material properties / composition) than other anodes, cathodes, cells, or MEAs on the same fuel cell board. This may be the case where, across the entire first surface of the ion-permeable membrane, at least one material property / composition or property or size or shape of the anode varies for each anode, and / or, across the entire second surface of the ion-permeable membrane, at least one material property / composition or size or shape of the cathode varies for each cathode. Each anode may have a different material composition, size, or shape than at least one / any adjacent anode / other anodes on the same fuel cell board. Each cathode may have a different material property / composition or size or shape than at least one / any adjacent cathode / other cathodes on the same fuel cell board. The size, shape, and / or material properties / composition of each anode may differ from at least one / any adjacent anode / other anodes on the same fuel cell board. The size, shape, and / or material properties / composition of each cathode may differ from at least one / any adjacent cathode / other cathodes on the same fuel cell board.

[0020] Segmenting the MEA on the fuel cell board using the method described herein improves the overall performance and durability of the fuel cell board. Segmentation allows for adjustment of the voltage / current characteristics of a stack with fixed dimensions.

[0021] As described in the background section, MEAs are typically designed to operate under specific conditions and can be designed to accommodate various applications where increases or decreases in temperature or humidity are expected. However, the inventors have found advantages and possibilities in designing with varying MEAs across individual fuel cell boards, and in achieving this using PCB material-based fuel cell boards.

[0022] This specification describes a configuration that enhances the degree of adjustment and design of a fuel cell board such that the characteristics of the MEA, anode, cathode, or cell vary across the entire single fuel cell board. Different anodes or cathodes on the same surface of the fuel cell board may have different characteristics (e.g., size, shape, or material composition) from other anodes or cathodes on the same surface. These characteristics can be varied in consideration of the differences in MEA performance across the entire fuel cell board, as described in this specification. These characteristics can be varied in consideration of the changes in current density across the entire fuel cell board.

[0023] Variations in the conditions to which the fuel cell board is exposed, such as temperature, humidity, and fuel concentration, can be compensated for by individually varying the characteristics of the individual cells, as described in more detail in this specification. These variations result in fluctuations in current density across the entire fuel cell board. By design, variations across the entire fuel cell board that can occur depending on the fuel flow path across the board can be considered. By adjusting the MEA in consideration of the variations in the conditions to which the board is exposed, variations in potential across the board can be reduced. The reduction of variations in potential across the board can be referred to as voltage flattening (i.e., maintaining the voltage within a predetermined range while reducing variations in potential across the board).

[0024] By reducing variations in potential across the board, the performance of the fuel cell board is improved and the efficiency of the fuel cell board is increased. The fuel cells and fuel cell boards described in this specification can be adjusted such that the same output can be obtained at different voltages.

[0025] This is uniquely possible in the PCB fuel cell board described in this specification due to its insulation characteristics and manufacturing method, for example, as compared to a metal or graphite fuel cell board.

[0026] The PCB is an insulating material and is different from prior art metal or graphite-based fuel cell boards where the entire board is conductive. Thus, the fuel cell board described herein can be designed such that current flows only to specific locations, such as through-hole plating, plating of a conductive material (e.g., copper) in a selected area of the PCB board, or electrical connection tabs at the edges of the MEA. These can be connected such that the connections can be dynamically changed to maintain a desired voltage range (while keeping the kW output constant) and can provide a constant output as needed. This is technically impossible, for example, in a metal fuel cell board.

[0027] Furthermore, the adjusted and diverse segmentation described herein can reduce the impact of transient phenomena that occur during startup and / or shutdown of the fuel cell. The gas front passing through or traveling along the board can create high potentials that can damage the fuel cell board, especially one containing a catalyst. By segmenting the cell into smaller areas, the duration of these high potentials can be shortened and degradation can be minimized. This is particularly useful in a segmented fuel cell board where the cell characteristics vary across the board. For example, a corrosion-resistant catalyst can be used in areas where high potentials are likely to occur, and an inversion-resistant material can be used in areas where voltage inversion can occur.

[0028] Furthermore, segmenting the MEA on a fuel cell board with varying characteristics reduces the likelihood that parts of the fuel cell will remain at relatively low potentials during operation. This is advantageous because large variations in potential can accelerate the degradation of the fuel cell board. Thus, the fuel cell board described herein has improved degradation resistance and a longer lifespan.

[0029] A second aspect of a preferred embodiment provides a fuel cell comprising at least one fuel cell board. Each fuel cell board comprises at least one first insulating layer, at least one ion-permeable membrane, a plurality of anodes, and a plurality of cathodes. All cathodes are arranged across the entire first surface of the ion-permeable membrane, and all anodes are arranged across the entire second surface opposite the first surface of the ion-permeable membrane. They are arranged such that each anode overlaps with at least one cathode across the ion-permeable membrane, and / or each cathode overlaps with at least one anode across the ion-permeable membrane. Pairs of anodes and cathodes sandwiching at least one ion-permeable membrane are electrically connected in parallel with adjacent pairs of anodes and cathodes. Each individual cell has at least one anode and at least one cathode on opposite sides of at least one ion-permeable membrane, and the anodes and cathodes are able to exchange ions across the at least one ion-permeable membrane. Each individual cell is connected in parallel across the entire fuel cell board.

[0030] In a second embodiment, preferably, at least one material property of the anode or cathode or the size of the anode or cathode is varied or modified throughout the fuel cell board, and / or at least one material property of other components of the fuel cell board is varied or modified throughout the fuel cell board.

[0031] A pair of anodes or cathodes separated by at least one ion-permeable membrane may be referred to herein as an individual cell on a fuel cell board or an individual MEA on a fuel cell board, and may be electrically connected in parallel with other (i.e., adjacent) anode-cathode pairs on the same fuel cell board. These may be connected by any means known in the art, as described herein.

[0032] Connecting anode-cathode pairs, individual cells on the fuel cell board, or individual MEAs on the fuel cell board in parallel rather than in series reduces the overall voltage of the fuel cell and increases the amount of current drawn from the fuel cell board, which can be referred to as "flattening" the polarization / potential curve of the fuel cell. By operating in this manner, the polarization curve can be flattened.

[0033] A further advantage of connecting individual MEAs on a fuel cell board in parallel is the ability to bypass potentially faulty individual cells. In configurations where individual cells or MEAs on a fuel cell board are not connected in parallel, a faulty cell can potentially bring the entire board offline, and even the entire fuel cell stack offline. By bypassing a faulty cell allows the circuit to remain open, keeping the fuel cell board or fuel cell operational.

[0034] Operating individual MEAs on a fuel cell board in series can sometimes yield higher voltages than in parallel operation, which can be advantageous in certain situations. Therefore, a fuel cell board that can be switched between series and parallel operation may be more advantageous than one that can operate only in series or only in parallel.

[0035] Although described as "parallel connection," these can also be electrically connected in series, and the connection can be dynamically switched from parallel to series during fuel cell operation to accommodate various requirements in the fuel cell's operation. Being a "parallel connection" does not mean that it is not possible to electrically connect them in series or that it is not possible to switch between the two. By changing these connections, voltage flattening (i.e., maintaining the voltage within a specified range while reducing potential variations across the entire board) can also be achieved. This allows the fuel cell voltage to be adjusted to the desired application, and even with the same fuel cell, by changing the connection path, it can be operated at high voltage / low current or low voltage / high current, reducing the need for a DC-DC converter. This reduces power loss associated with conversion, or makes it possible to use less expensive system components (i.e., a smaller DC-DC converter).

[0036] The following preferred embodiments relate to both the first and second aspects of the present invention.

[0037] Preferably, at least one ion-permeable film is bonded to at least one insulating layer.

[0038] Preferably, gaps are provided between each anode across the entire first surface of the ion-permeable membrane. Preferably, gaps are provided between each cathode across the entire second surface of the ion-permeable membrane. These are referred to herein as "segmented". Preferably, the gaps between adjacent anodes and / or adjacent cathodes are 0.1 mm to 1.5 cm, more preferably 0.2 mm to 1 cm.

[0039] Preferably, the fuel cell board includes means configured to supply an oxidizing fluid to the cathode and means configured to supply a reducing fluid to the anode. Preferably, the means for supplying the oxidizing fluid to the cathode is an insulating layer having at least one first fluid path, and / or the means configured to supply a reducing fluid to the anode is a further / second insulating layer having at least one first fluid path. Preferably, at least one first insulating layer includes at least one first fluid path and is configured to supply the oxidizing fluid to the cathode or to supply the reducing fluid to the anode.

[0040] Preferably, one or more insulating layers are PCB boards. The insulating layers in the embodiments described herein may be printed circuit board (PCB) layers, as described herein. PCB boards containing insulating materials, such as FR-4 epoxy resin substrates with copper plating on one or more of their outer surfaces, have the advantage of being able to be manufactured in large quantities and at low cost. For example, multiple flow path field boards can be manufactured simultaneously by laminating thin laminate substrates and then routing or drilling them at the same time. Individually routed boards are then laminated. PCBs are lightweight yet have high mechanical strength and can provide a unified structure (if necessary) by lamination or mechanical pressure or compression while maintaining good contact between individual layers. The PCB insulating layer of the present invention may include multiple PCB layers, which are referred to as a single insulating layer. This results in a unified, lightweight, and completely sealed structure. By using insulating materials in such a fuel cell configuration, the fuel cell, fuel cell board, and components of the present invention can be constructed without the disadvantages of mass or size that may occur when using other materials, such as metal. The insulating material board described herein may be plated with a conductive material such as copper (e.g., PCB board), and / or conductive material may be plated or filled into through-holes or other means to conduct electrical current through or along the board. This eliminates the need for all boards, spacers, etc. to be conductive, as in the case where prior art dipole plates or conductive metal members are used in prior art stacks, thus allowing for better control of the current within the stack. Conductive features such as through-holes, e.g., copper-plated through-holes or conductive resin-filled through-holes, can be provided in specific regions, thereby enabling high-level control of the current passing through or along the fuel cell board / fuel cell stack. Preferably, multiple insulating material layers, e.g., multiple PCB board layers, may be provided to form a single layer, and only one or more of the outer layers of these multiple layers may be conductive.

[0041] Preferably, the anodes increase or decrease in size across the entire first surface of the ion-permeable membrane, and / or preferably, the cathodes increase or decrease in size across the entire second surface of the ion-permeable membrane. The anodes and / or cathodes may be substantially all the same length, but the width of the anode or cathode may increase or decrease across the entire first / second surface of the ion-permeable membrane. The size of the anode or cathode may include the width, height, length or thickness of the anode or cathode. At least one anode may be larger or smaller than the other anodes on the fuel cell board. At least one cathode may be larger or smaller than the other anodes on the fuel cell board.

[0042] Preferably, the material properties / composition or size change across the entire surface of the ion-permeable film only at the anode, or only at the cathode.

[0043] Preferably, the anode and / or cathode are smaller in size than other anodes / cathodes on the board in locations where the fuel cell board is exposed to more favorable conditions compared to other parts. For example, in locations where the fuel cell board has favorable humidity, temperature, fuel partial pressure (or other conditions as described herein), the anode and / or cathode may be smaller in size than other anodes / cathodes on the board. Preferably, the anode and / or cathode are larger in size than other anodes / cathodes on the board in locations where the fuel cell board is exposed to less favorable conditions compared to other parts. The size of the anodes and cathodes may be graded based on the conditions to which the board is exposed during operation. Other material properties of the anode may also be varied.

[0044] Preferably, in the edge or side of the fuel cell board where the reducing agent fluid is first supplied to the anode, the size or width of at least one anode (and optionally at least one cathode) is smaller than the size or width of the anode (and optionally cathode) in the edge or side where the reducing agent fluid is discharged from the fuel cell board.

[0045] Preferably, in the edge or side of the fuel cell board where the oxidizing fluid is first supplied to the cathode, the size or width of at least one cathode (and optionally at least one anode) is greater than the size or width of the cathode (and optionally anode) in the edge or side where the reducing fluid is discharged from the fuel cell board.

[0046] Preferably, in the edge or side of the fuel cell board where the reducing agent fluid is first supplied to the anode, the size or width of at least one anode (and optionally at least one cathode) is greater than the size or width of the anode (and optionally cathode) in the edge or side where the reducing agent fluid is discharged from the fuel cell board.

[0047] Preferably, in the edge or side of the fuel cell board where the oxidizing fluid is first supplied to the cathode, the size or width of at least one cathode (and optionally at least one anode) is smaller than the size or width of the cathode (and optionally anode) in the edge or side where the reducing fluid is discharged from the fuel cell board.

[0048] Preferably, in the edge or side of the fuel cell board having the highest humidity compared to other sides or edges, the size or width of at least one anode (and optionally at least one cathode) is smaller than the size or width of the cathode (and optionally anode) in the edge or side of the fuel cell board with lower humidity.

[0049] Preferably, at the edge or side of the fuel cell board where the partial pressure of the reducing agent fluid is highest, the size or width of at least one anode (and optionally at least one cathode) is smaller than the size or width of the anode (and optionally cathode) at the edge or side of the fuel cell board where the partial pressure of the reducing agent fluid is lower.

[0050] Preferably, at the edge or side of the fuel cell board where the partial pressure of the oxidizing fluid is highest, the size or width of at least one cathode (and optionally at least one anode) is smaller than the size or width of the cathode (and optionally anode) at the edge or side of the fuel cell board where the partial pressure of the reducing fluid is lower.

[0051] Preferably, the oxidizing fluid is initially supplied to the cathode of the fuel cell board in substantially the opposite direction to the direction in which the reducing fluid is initially supplied to the anode of the fuel cell board.

[0052] Preferably, the heat exchange fluid is initially supplied to the fuel cell board in substantially the same direction as the reducing agent fluid is initially supplied to the anode of the fuel cell board, or in substantially the same direction as the oxidizing agent fluid is initially supplied to the cathode of the fuel cell board.

[0053] Preferably, the material properties / composition of at least one anode and / or cathode (which vary throughout the fuel cell board) is at least one of the following: i) at least one of the materials constituting the anode and / or cathode, or at least one of the additive materials applied to or used together with the anode and / or cathode; ii) the coating of the anode and / or cathode; and / or iii) the composition, material properties, location, or size of the catalyst layer provided on or with each cathode and / or anode. Preferably, the composition of the catalyst layer includes at least one of the ionomer content, catalyst load, or catalyst type.

[0054] Preferably, two, three, four, five, six, seven, eight, nine, ten, or more than ten MEAs may be provided on a single fuel cell board. Preferably, 20, three, four, five, six, seven, eight, nine, ten, or more than ten MEAs may be provided on a single fuel cell board.

[0055] Preferably, if the fuel cell boards do not have MEAs connected in parallel with each other, the fuel cell boards include means for conducting electrical current from one side of the fuel cell board to the other. Preferably, these means are plated through-holes. These plated through-holes may penetrate the entire fuel cell board and can carry electrical current in series across the entire fuel cell board. Preferably, these means may conduct electrical current to or from the copper plating on the insulating layer.

[0056] Preferably, the fuel cell board may include a second insulating layer. Preferably, the fuel cell board includes means for conducting electrical current from the anode through at least one insulating layer to the surface of at least one first insulating layer, and means for conducting electrical current from the surface of at least one second insulating layer through at least one second insulating layer to the cathode. Preferably, these means are plated through holes. Preferably, the number or distribution frequency of the means for conducting electrical current varies throughout the fuel cell board. These can be varied to account for variations in the design of the anode and / or cathode throughout the fuel cell board. A higher number, concentration, or density may result in a higher current density throughout the fuel cell board. Preferably, these means may conduct electrical current to or from copper plating on the insulating layer.

[0057] Preferably, each anode may overlap with at least one cathode via an ion-permeable membrane, and / or each cathode may overlap with at least one anode via an ion-permeable membrane. "Overlapping" means that the body of an anode or cathode on one side of the ion-permeable membrane overlaps, at least partially, with the body of an anode or cathode on the other side of the ion-permeable membrane.

[0058] Preferably, the first insulating layer includes at least one first fluid path. Preferably, the first insulating layer includes a plurality of first fluid paths. Preferably, the plurality of first fluid paths are substantially parallel to each other.

[0059] Preferably, the fuel cell board includes a second insulating layer. The first insulating layer may include at least one first fluid path, and the second insulating layer may include at least one second fluid path. At least one ion-permeable membrane and a plurality of anodes and a plurality of cathodes may be arranged between the first insulating layer and the second insulating layer, so that at least one first fluid path is arranged to supply oxidizing fluid to one or more cathodes (all cathodes) of at least one fuel cell board, and at least one second fluid path is arranged to supply reducing fluid to one or more anodes (all anodes) of at least one fuel cell board. The MEA, the first insulating layer, and the second insulating layer may be laminated together to form a fuel cell board, or they may be mechanically compressed. Preferably, at least two layers of the fuel cell board are laminated together or mechanically compressed.

[0060] Preferably, the first insulating layer includes a plurality of first fluid paths, which are substantially parallel to each other. Preferably, the second insulating layer includes a plurality of second fluid paths, which are substantially parallel to each other.

[0061] Preferably, at least one of the at least one first fluid path has a different flow path / design from at least one second fluid path.

[0062] Preferably, the first insulating layer includes at least one fluid path for the heat exchange fluid. Preferably, the second insulating layer further includes at least one further or third fluid path for the heat exchange fluid. The at least one further / third fluid path is arranged so that the heat exchange fluid can control the thermal properties or temperature of the fuel cell board, preferably the thermal properties or temperature of at least one anode. The heat exchange fluid is separated from the oxidizing fluid, and these are different fluid flows. Preferably, the at least one further / third fluid path is provided on the side of the insulating layer opposite to the at least one first fluid path or the at least one second fluid path.

[0063] Preferably, the fuel cell includes a plurality of fuel cell boards. At least one fuel cell board may be arranged such that the first insulating layer and one or more cathodes of each fuel cell board face the second insulating layer and one or more anodes of an adjacent fuel cell board.

[0064] Preferably, at least one of the first fluid path, the second fluid path, or the third / further fluid path is substantially linear. Preferably, at least one of the first fluid path, the second fluid path, or the third / further fluid path is meandering.

[0065] Preferably, the fuel cell board includes a plurality of first fluid paths and / or a plurality of second fluid paths and / or a plurality of third / further fluid paths. Preferably, the fuel cell board includes at least one of the following: a plurality of first fluid paths substantially linear and substantially parallel to each other, a plurality of second fluid paths substantially linear and substantially parallel to each other, and / or a plurality of third / further fluid paths substantially linear and substantially parallel to each other.

[0066] Preferably, at least one further / third fluid path has a different flow path from at least one first fluid path or at least one second fluid path. For example, one flow path may be substantially linear and the other flow path may be meandering.

[0067] Preferably, the number of one of the multiple first fluid paths, multiple second fluid paths, and / or multiple third / further fluid paths is greater than the number of the other fluid paths, for example, there may be more third / further fluid paths than first fluid paths.

[0068] Preferably, the fuel cell further includes further means for controlling the temperature of at least one fuel cell board or adjacent fuel cell boards. The means for controlling the temperature of at least one fuel cell board includes at least one further insulating layer, which includes at least one further / fourth fluid path for heat exchange fluid. This at least one further insulating layer is positioned between the first insulating layer of the fuel cell board and the second insulating layer of the adjacent fuel cell board. This at least one further insulating layer includes means for conducting an electrical current from one side to the other. This allows the further insulating layer to function as a bipolar plate. This allows electrical contact between the anode and cathode of adjacent fuel cell boards, as described herein. The heat exchange insulating layer may be laminated on the first or second insulating layer of the fuel cell board, or it may be compressed. Preferably, this further means is laminated on the second insulating layer, i.e., adjacent to the anode side of the MEA. By laminating the further means on the fuel cell board, the energy density can be increased because this further means may consist of only one further layer, unlike the multi-layer or thick means described above. Furthermore, sealing the additional means plate to the fuel cell board simplifies the assembly of the fuel cell stack due to the reduced number of components and non-integrated seals in the stack. Preferably, this additional / fourth fluid path carries a cooling fluid to cool the fuel cell board or adjacent fuel cell boards. Preferably, this heat exchange fluid is identical to the heat exchange fluid in the third / further fluid path located in or on and / or in or on the second insulating layer. Preferably, this heat exchange fluid is different from the heat exchange fluid in the third / further fluid path located in or on and / or in or on the second insulating layer. This additional means for controlling the temperature of at least one fuel cell board or adjacent fuel cell boards may also be provided if neither the first nor the second insulating layer contains at least one additional / third fluid path for the heat exchange fluid (i.e., if at least one additional / third fluid path for the heat exchange fluid does not exist).Preferably, further means for controlling the temperature of at least one fuel cell board includes a second further insulating layer which seals or caps the flow paths of further / fourth fluid paths (functioning as in other embodiments described herein). The first insulating layer constituting the further means for controlling the temperature of at least one fuel cell board or adjacent fuel cell boards may be thicker than the second further insulating layer, or the second further insulating layer may be thinner than the first insulating layer constituting the further means for controlling the temperature of at least one fuel cell board or adjacent fuel cell boards. This further means for controlling the temperature of at least one fuel cell board or adjacent fuel cell boards may have a plurality of fluid paths for heat exchange fluid, which may carry fluids of different sizes, shapes and / or dimensions, different types of fluids, or fluids of different flow rates or temperatures. The fluids may be at different temperatures or flow rates for each different board, or at different temperatures or flow rates for each different flow path within the same board. This allows for accommodating differences in cooling requirements across the fuel cell. Preferably, if there are multiple further means for controlling the temperature of at least one fuel cell board or adjacent fuel cell boards within a single fuel cell stack, each further means for controlling the temperature of at least one fuel cell board or adjacent fuel cell boards may have different fluid paths, fluid paths of different sizes, shapes or dimensions, or may be designed to carry different fluids, fluids of different temperatures or fluids of different flow rates. This can accommodate differences in cooling requirements across the entire fuel cell. Further / fourth fluid paths can be formed within the insulating layer of the board by conventional routing or depth-controlled routing.

[0069] Fuel cell stacks with these additional heat exchange layers are advantageous because they do not need to be open to the introduction of cooling air as described in prior art systems, and are completely sealed to the atmosphere. While integrating the heat exchange fluid path within the first or second insulating layer is the most space-efficient, utilizing these additional heat exchange layers eliminates the need for non-functional spacer elements and allows for the supply of reaction gases at higher pressures, thereby increasing power density and reactant distribution on the electrodes compared to prior art stacks.

[0070] Preferably, in the fuel cell board, the surface of the first insulating layer adjacent to the cathode is a surface or surface that includes at least one first fluid flow path or channel, thereby allowing the oxidizing fluid to flow or diffuse to one or more cathodes (all cathodes) of the MEA. This may be done via a gas diffusion layer.

[0071] Preferably, in the fuel cell board, the surface of the second insulating layer adjacent to the anode is a surface or surface that includes at least one second fluid flow path or channel, thereby allowing the reducing agent fluid to flow or diffuse to one or more anodes (all anodes) of the MEA. This may be done via a gas diffusion layer.

[0072] Preferably, at least one of the first insulating layer, the second insulating layer, and / or the third / further insulating layer includes one or more means for conducting electrical current from one surface or face of the insulating layer to the other opposite surface or face of the insulating layer (first, second, and / or third / further). Preferably, the means for conducting electrical current is a plated through-hole. Preferably, the plated through-hole is a copper plated through-hole. Preferably, the surface or face of the insulating layer including these means also includes the first, second, or third / further fluid channels described herein. Preferably, the one or more means for conducting electrical current from one surface or face of the insulating layer to the other surface or face of the insulating layer (first, second, and / or third / further) is provided on the same surface or face of the insulating material layer adjacent to the anode or cathode, and these means (e.g., copper plated through-holes) can perform the function of carrying electrical current to and from the anode and / or cathode. Preferably, the means may conduct electrical current to or from the copper plating on the insulating layer, and this copper plating may also function to carry electrical current to or from the anode and / or cathode. The means for conducting electrical current as described herein may also function to carry electrical current to or from the adjacent fuel cell board or other components of the fuel cell.

[0073] Preferably, the membrane electrode assembly (MEA) further includes at least one gas diffusion layer. One or more gas diffusion layers may be located between at least one or all cathodes and the first insulating layer, and between at least one or all first fluid paths. One or more gas diffusion layers may be located between at least one or all anodes and the second insulating layer, and between at least one or all second fluid paths. The MEA may include multiple gas diffusion layers as described herein.

[0074] Preferably, the fuel cell includes means for air-cooling at least one fuel cell board.

[0075] Preferably, in any embodiment of the invention described herein, the oxidizing fluid is air and the reducing fluid is hydrogen gas.

[0076] Preferably, each fuel cell board may have a rated output of at least 10W. Preferably, each fuel cell board may have a rated output of up to 1000W. Preferably, each fuel cell board may have a rated output of 10W to 1000W. Preferably, a fuel cell comprising multiple fuel cell boards may have a rated output of at least 10kW. Preferably, each fuel cell comprising multiple fuel cell boards may have a rated output of up to 1000kW. Preferably, each fuel cell comprising multiple fuel cell boards may have a rated output of 10kW to 1000kW.

[0077] Preferably, one or more layers described herein are laminated together. This lamination may be achieved by chemical bonding by heating prepreg layers placed between insulating layers under pressure, as described herein. The use of epoxy resin prepregs also maintains compression of the gas diffusion layer of the MEA, which is an important factor in maintaining fuel cell performance by providing sufficiently low-resistance electrical paths without impairing the distribution of the reaction fluid. Preferably, one or more layers described herein may be mechanically pressurized or compressed within the fuel cell stack.

[0078] Preferably, an oxidizing fluid, a reducing fluid, and / or one or more heat exchange fluids flow into and out of the relevant fluid pathways described herein via inlets and outlets. These inlets and outlets may connect the fluid pathways to manifolds that supply the relevant fluids to the fluid pathways. These manifolds are described herein, but may also be openings in an insulating layer.

[0079] Preferably, in any embodiment of the invention described herein, each fuel cell board is connected to an electronic circuit that generates an electrical output, and the connection between each fuel cell board and the electronic circuit is individually switchable. Preferably, the connection between each fuel cell board in the fuel cell and the output line can be controlled by a switching mechanism such as a field-effect transistor (FET) switch that provides direct power processing and control in the cell. Each of these switches can be controlled by its own separate control line. This can be achieved by providing switches on each fuel cell board.

[0080] Preferably, one or more of the flow paths described herein are routed to penetrate the entire body of the layer. Preferably, the fluid path is routed within the insulating layer, and optionally, within the insulating layer before copper plating is applied to at least a portion of the insulating layer.

[0081] Preferably, one or more fluid channels are formed by routing or grooving within the insulating layer such that the routing or groove does not completely penetrate the insulating layer.

[0082] Preferably, the fluid channel is formed in or on the insulating layer by routing or grooving within or on a portion of the body of one or more faces or surfaces of the layer. In other words, the fluid channel is formed so that the routing or groove does not completely penetrate the layer. This may be done through one or more individual insulating material layers that make up the insulating layer. This may be done only through the copper layer and any other present layers (e.g., passivation layers, e.g., passivation ink layers), and the layers of the insulating material itself may not be penetrated. Preferably, any fluid channel described herein is provided inside or on the surface of the insulating layer. As shown in some figures herein, the fluid channel or so-called route may provide a channel for fluid within a single layer, in contrast to cases where one layer providing the channel and another layer providing a sealing surface to seal the fluid path are required. Depth-controlled routing may be made up to a maximum depth of 1 mm. Depth-controlled routing may be made up to a maximum depth of 3 mm, 2 mm, or 1 mm. Depth-controlled routing may be performed at depths of approximately 3 mm, 2 mm, 1 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm, or 0.1 mm. Depth-controlled routing may be performed in the range of 3 mm to 0.1 mm, or approximately 1 mm to 0.3 mm, or approximately 0.9 mm to 0.4 mm, or approximately 0.8 mm to 0.4 mm. Depth-controlled routing is available here because it is possible to maintain the sealing properties of any individual layer. Preferably, depth-controlled routing is routing that does not penetrate the entire layer (e.g., the PCB board), that is, only 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the layer's depth is penetrated by the routing. Preferably, only 10% to 90% of the layer depth is penetrated by routing, more preferably only 20% to 80% of the layer depth is penetrated by routing, and even more preferably only 50% to 75% of the layer depth is penetrated by routing. This may also be referred to as depth-controlled drilling or depth-controlled routing.Preferably, after depth-controlled drilling, a layer of at least 0.1 mm remains beneath the routed or drilled area. Preferably, after depth-controlled drilling, a layer of approximately 0.10 mm to 0.40 mm remains beneath the routed or drilled area.

[0083] Preferably, at least a portion of the insulating layer is copper-plated, and then at least one of the insulating layers is covered at least partially with a passivation layer.

[0084] One aspect of the present invention provides the use of any fuel cell described herein.

[0085] One aspect of the present invention is a component for an electrochemical device. The component may include any of the features described herein with respect to an insulating layer for a fuel cell board. This may include an insulating layer having at least one first fluid path on one side of the insulating layer and a second fluid path for a heat exchange fluid on the other or opposite side of the insulating layer. This may be a component for any type of electrochemical device in which an anode and cathode are arranged with a film in between, as described herein.

[0086] One aspect of the present invention is a method for controlling a fuel cell voltage, the method comprising operating a fuel cell comprising at least one fuel cell board, the at least one fuel cell board comprising a plurality of membrane electrode assemblies (MEAs). The fuel cell board has at least one insulating layer, at least one ion-permeable membrane, a plurality of anodes, and a plurality of cathodes. All cathodes are arranged across the entire first surface of the ion-permeable membrane, and all anodes are arranged across the entire second surface of the ion-permeable membrane. These may be arranged such that each anode overlaps with at least one cathode via the ion-permeable membrane, and / or each cathode overlaps with at least one anode via the ion-permeable membrane, thereby forming a plurality of MEAs on a single fuel cell board. Each MEA is electrically connected in parallel with each, both, or all adjacent MEAs, and the method comprises operating the fuel cell with each MEA electrically connected in parallel with each, both, or all adjacent MEAs.

[0087] Although described as "parallel connection," these can also be electrically connected in series, and the connection can be dynamically switched from parallel to series during fuel cell operation to accommodate various requirements in the fuel cell's operation. Being a "parallel connection" does not mean that they cannot be electrically connected in series or that they cannot be switched between the two. The ability to change these connections also allows for voltage flattening (i.e., maintaining the voltage within a specified range while reducing potential variations across the entire board). This allows the fuel cell voltage to be adjusted to the desired application, and even with the same fuel cell, changing the connection path allows for operation at high voltage / low current or low voltage / high current, reducing the need for a DC-DC converter. This reduces power loss associated with conversion, or allows for the use of less expensive system components (i.e., smaller DC-DC converters). These connections may be configured to dynamically change to maintain the desired voltage range (while keeping the kW output constant), and to provide a constant output as needed. This is technically impossible, for example, with a metal fuel cell board.

[0088] The fuel cell board of this method may include any of the features described herein with respect to the fuel cell board described above.

[0089] Preferably, at least one ion-permeable film is bonded to at least one insulating layer.

[0090] Preferably, the connections between each MEA can be individually switched between parallel and series connections.

[0091] Preferably, at least one material property of the anode or cathode, or the size of the anode or cathode, is varied or altered throughout the fuel cell board, and / or at least one material property of other components of the fuel cell board is varied or altered throughout the fuel cell board.

[0092] One aspect of the present invention is a method for controlling a fuel cell voltage, the method comprising operating a fuel cell including segmented MEAs on a single fuel cell board, wherein the segmented MEAs are connected in parallel to one another. Embodiments of the above-described aspect may also be applied to this method.

[0093] One aspect of the present invention involves the use of segmented MEAs on a single fuel cell board and the use of parallel connections between these segmented MEAs within the fuel cell. Embodiments of the aforementioned aspects may also be applied to this method.

[0094] The embodiments of this disclosure will be described below with reference to the attached drawings. [Brief explanation of the drawing]

[0095] [Figure 1] This figure shows a schematic side view of a stacked fuel cell relating to prior art. [Figure 2] This figure shows a cross-sectional view of a prior art fuel cell, including the stack of fuel cell boards. [Figure 3A] This is a schematic diagram showing how the size of the MEA can vary across one side of the fuel cell board. [Figure 3B] This is a schematic diagram showing how the size of the MEA can vary across one side of the fuel cell board. [Figure 3C] This is a schematic diagram showing how the size of the MEA can vary across one side of the fuel cell board. [Figure 3D] This is a schematic diagram showing how the size of the MEA can vary across one side of the fuel cell board. [Figure 3E] This figure shows a fuel cell board 50 with tabs 62, 63 that provide the possibility of connecting cells / MEAs in parallel. [Figure 4] This figure shows an expanded view of one embodiment of the fuel cell board of the present invention. [Figure 5]This figure shows an example of one electron path in the segmented active region of a fuel cell board. [Figure 6] This figure shows a fuel cell according to one embodiment. [Figure 7] This figure shows that the fuel cell stack can be adjusted to have different voltages while maintaining the same output, as required. [Figure 8A] This figure shows the modeling results for a segmented fuel cell board. [Figure 8B] This figure shows the modeling results for a segmented fuel cell board. [Figure 8C] This figure shows the modeling results for a segmented fuel cell board. [Figure 8D] This figure shows the modeling results for a segmented fuel cell board. [Modes for carrying out the invention]

[0096] The embodiments will be described in detail below with reference to the attached drawings. The same reference numerals indicate the same or similar features in different drawings and embodiments of the present invention; this is for convenience only and does not limit the invention. The following detailed description includes numerous specific examples to help the relevant teachings be fully understood. However, it will be obvious to those skilled in the art that the teachings of the present invention can be implemented without these specific examples.

[0097] A fuel cell can operate more efficiently if at least one material property / composition of the anode or the size of the MEA is varied or altered across the entire fuel cell board. For example, the size, shape, or material property / composition of the MEA, membrane, anode, or cathode can be varied based on its positional relationship to the flow paths that transport fuel and heat exchange fluid to or throughout the fuel cell board. Variations in the conditions to which the fuel cell board is exposed, such as temperature, humidity, and fuel concentration, can be compensated for by changing the characteristics of individual cells. These may be referred to herein as “preferred,” i.e., “more preferred,” or “less preferred.” By changing the cell design, it is possible to accommodate variations or preferences across the entire fuel cell board, which can typically occur depending on the fuel flow paths across the board. Adjusting the MEA to account for variations in the conditions to which the board is exposed means that variations in potential across the board are reduced.

[0098] The temperature of a fuel cell board can vary across the board due to several factors. For example, if a location on the fuel cell board is near the outlet of a heat exchange fluid (e.g., coolant) flow, the heat exchange fluid is likely to be warmer, and therefore that area of ​​the fuel cell board is likely to be hotter. Furthermore, if the ion-permeable film on the board adjacent to the problem area is locally dry, fuel cell performance will decrease, resulting in a lower voltage for the same current, which means more waste heat will be generated, and that area of ​​the fuel cell board may become hotter than other areas.

[0099] The humidity of a fuel cell board can vary across the board due to several factors. For example, areas of the fuel cell board with higher temperatures, as mentioned above, typically have lower humidity. Water is produced by the cathode of the fuel cell board, which can then diffuse to the anode. More water is typically produced at the inlet of the reducing agent fluid (e.g., H2 gas) because the fuel concentration is higher and the system is more humid. Furthermore, H2 may be recirculated within the fuel cell stack, and the recirculated H2 fluid may have a higher water content than the previously circulated H2. This can then diffuse to drier areas of the fuel cell board. Generally, a humid MEA has lower resistance and achieves a higher current density at the same voltage. Generally, the flow direction of the fuel and heat exchange fluids can influence humidity variations across the fuel cell board. However, under normal operation, some humidity variation is always present across the fuel cell board.

[0100] Fuel concentration or reactant partial pressure can vary across the fuel cell board due to several factors. For example, reactant concentrations in the fuel (reducing or oxidizing fluids, e.g., H2 and O2) decrease as the fuel reacts with the anode and cathode throughout the fuel cell board.

[0101] The pressure of the fluid supplied to the fuel cell board, i.e., the fuel (e.g., reducing fluid or oxidizing fluid) or the heat exchange fluid supplied to the fuel cell board (e.g., coolant), can vary throughout the fuel cell board due to several factors. For example, in any flow, pressure loss occurs as any fluid flows along the fluid path, so the pressure is likely to be highest at the fluid inlet. Furthermore, as the fluid concentration decreases (e.g., as fuel is consumed by the MEA on the fuel cell board) and as the overall system pressure decreases, the partial pressure decreases even more rapidly.

[0102] Known transient events, such as those occurring during fuel cell startup and / or shutdown, can also be taken into account by changes in fuel cell design. Gas fronts passing through or along the board can generate high potentials and may damage fuel cell boards, particularly those containing catalysts.

[0103] Figure 3A is a schematic diagram showing how the size of the MEA can vary across one entire surface of the fuel cell board 50. The fuel cell board 50 is shown having six rectangles 52, 54 across its entire surface. These rectangles represent the “active region” of the fuel cell board and may be anodes or cathodes, or may represent MEAs or cells. Figure 3A shows how the size of a cathode, anode, both, cell, or MEA can vary across a single surface of the fuel cell board 50. Here, the leftmost rectangle 52 is the smallest, and the rightmost rectangle 54 is the largest.

[0104] Figure 3B is a schematic diagram showing a fuel cell board 50 in which the segmented MEA 52 does not change (in size or characteristics) across the entire surface of the fuel cell board 50. The rectangles represent the "active region" of the fuel cell board, which may be the anode or cathode, or may represent the MEA or cells. On the left side of the board 50, there are inlets for flow channels that extend across the surface of the board 50 for air (O2, cathode reaction fluid) and coolant (heat exchange fluid). On the right side of the board 50, there is an inlet for a flow channel for H2 (anode reaction fluid). Here, parallel fluid paths carry all three fluids across the entire surface of each side (the coolant across the entire anode side) and lead them to outlets located on the opposite edge of the fuel cell board.

[0105] Figure 3C shows a fuel cell board 50 in which the size of the segmented MEA varies across the entire fuel cell board 50. The fuel cell board 50 is shown having 10 rectangles 54-52 across its entire surface. As in Figures 3A and 3B, these rectangles represent the “active regions” of the fuel cell board and may be anodes or cathodes, or may represent MEAs or cells. Figure 3C shows how the size of the cathode, anode, both, cells, or MEA can vary across a single surface of the fuel cell board 50. Here, the rightmost rectangle 52 is the smallest, and the leftmost rectangle 54 is the largest. The fluid inlet, outlet, and flow path are the same as in Figure 3B.

[0106] The anode may increase or decrease in size across the entire board. Alternatively, or in addition, the cathode may increase or decrease in size across the entire board. The size of the anode or cathode may include the width, height, length, or thickness of the anode or cathode. Both may increase or decrease in the same pattern on the other side of the PCB board. This may occur across at least one ion-permeable film, or multiple ion-permeable films may be provided across the entire board.

[0107] In particular, the anode and / or cathode may all be substantially the same length, but the width of the anode or cathode may increase or decrease across the entire ion-permeable membrane.

[0108] The shape of the segmented anode or segmented cathode may vary across the entire ion-permeable membrane. The shape may vary to conform to a particular fuel flow path design; for example, the anode shape may vary across the entire surface of the ion-permeable membrane to conform to the anode fuel (reducing agent fluid, e.g., H2) flow path in the anode (PCB) plate adjacent to the anode layer.

[0109] Figure 3C shows how segmented MEAs can be arranged in a relatively low-humidity, dry fuel cell system. Humidity can be a significant limiting factor in fuel cell board performance. Here, we discuss designs for low-humidity systems, particularly those where the cathode airflow has low or near-zero humidity.

[0110] When both boards in Figures 3B and 3C are in a low-humidity system, the leftmost MEA will have the lowest humidity because the O2 airflow enters the fuel cell board at low humidity. The rightmost MEA is exposed to a higher H2 concentration because it is closest to the inlet, and therefore generates a relatively larger amount of moisture. Furthermore, the air becomes more humid as it flows over the fuel cell board and is further humidified by the time it reaches the rightmost MEA. Therefore, the rightmost MEA has the highest humidity.

[0111] The MEA is designed to account for higher humidity on the far right of the board. Here, a smaller MEA can be said to decrease the reaction rate in the rightmost MEA, while conversely, placing a larger MEA on the left can increase the reaction rate in this MEA. This balances the mismatch in conditions experienced on different sides of the fuel cell board and equalizes the electrical properties (i.e., current density) of the fuel cell board.

[0112] Here, it is shown that the MEA is designed to account for variations associated with counterflow of the anode and cathode fluids (H2 and air are shown in counterflow in Figures 3B and 3C). Counterflow of H2 and air typically equalizes the current density experienced across the entire fuel cell board. However, the MEA can also be varied to accommodate co-flow (co-flow, i.e., an arrangement where the H2 and air inlets are on the same side of the fuel cell board) in addition to counterflow.

[0113] The fuel cell boards shown in Figures 3A, 3B, and 3C are suitable for parallel fuel channels in which fuel (reducing fluid or oxidizing fluid, e.g., H2 and air) flows in parallel channels on this surface of the fuel cell board. The MEA characteristics, shown here as size, can be varied to account for variations in the conditions to which the MEA is exposed on the fuel cell board.

[0114] The fuel cell board can have variations in its MEA design to accommodate various flow paths, not just parallel ones. Various flow path field patterns and inlet and outlet positions on the plate are well known to those skilled in the art. For example, the flow paths may be meandering, circular, or channels (i.e., parallel) that run linearly across the plate. The flow path fields may flow in and out from the same side of the plate, or from the opposite side or corner of the plate. For example, the MEA may have stepped variations in size or material properties to account for variations in reactants or reaction conditions (e.g., humidity) along meandering flow paths as well as the parallel flow paths shown herein.

[0115] By using PCB material in the construction of the fuel cell board, the MEA can be segmented into smaller regions without inter-plane conductivity. This is not possible with fuel cell boards formed from conductive materials such as metal or graphite. Therefore, the diverse MEA designs shown herein can be realized.

[0116] The number of anodes, cathodes, cells, or MEAs on a single fuel cell board is not limited to the numbers shown in the examples herein. There may be as few as two segmented MEAs on a single fuel cell board, and preferably, there may be two, three, four, five, six, seven, eight, nine, ten or more MEAs on a single fuel cell board. There may be more than ten MEAs on a single fuel cell board, for example, 20, 30, 40, 50, 60, 70, 80, 90, 100 or more MEAs depending on the size of the fuel cell board.

[0117] The fuel cell board may be constructed to any suitable and desired dimensions. In some embodiments, the thickness of the electrolyte membrane layer may be 1 to 200 μm, preferably 5 to 100 μm. The width of the electrode band / MEA may be 1 mm to 10 cm, preferably 2 mm to 5 cm. The electrode band / MEA may be up to 500 × 500 mm, preferably 300 × 100 mm, 300 × 200 mm, or 300 × 300 mm. The gap width between the electrode bands may be 0.1 mm to 1.5 cm, preferably 0.2 mm to 1 cm. The width of the through-membrane electrical connector may be 1 μm to 2 mm, preferably 10 μm to 1 mm.

[0118] The anode and cathode may have the same design pattern, geometric size, shape, or material properties on opposite sides of the ion-permeable membrane, or they may have different design patterns, geometric size, shape, or material properties on opposite sides of the ion-permeable membrane. This is insofar as all anodes and all cathodes overlap with at least one cathode or anode across the ion-permeable membrane, allowing for ion exchange for the operation of the fuel cell.

[0119] In addition to its size, as will be discussed later, MEA can change the material properties throughout the entire fuel cell board.

[0120] MEA can be designed to take into account various limiting factors, such as humidity, temperature, or partial pressure of the reaction fluid.

[0121] For example, if the partial pressure of H2 or O2 in the reaction flow is known to be a limiting factor in the design of a fuel cell stack, the MEA can be designed to take this into account. The anode (and optionally the cathode) may have a smaller size or width at the edges or sides where the fluid considered to be a limiting factor for the reaction on the fuel cell board is supplied to the fuel cell board. The anode (and optionally the cathode) may have a larger size or width at the edges or sides where the fluid considered to be a limiting factor for the reaction on the fuel cell board is discharged from the fuel cell board.

[0122] For example, the MEA on the board side of the anode flow (H2) inlet is exposed to the highest H2 concentration and therefore experiences a higher reaction rate. If this is the leftmost MEA, the rightmost MEA will experience the lowest H2 concentration and reaction rate. Therefore, when varying the size across the entire fuel cell board to account for partial pressure (e.g., H2 partial pressure), the smallest MEA can be placed at the board end on the anode inlet side, and the largest MEA at the opposite end of the board, i.e., the anode outlet side. This allows for equalization of the current density to account for the higher reaction rate at the anode inlet where the H2 partial pressure / concentration is higher. The same can be applied when O2 partial pressure / concentration is the limiting factor.

[0123] The oxidizing fluid may be initially supplied to the cathode of the fuel cell board in substantially the opposite direction to the direction in which the reducing fluid is initially supplied to the anode of the fuel cell board. The heat exchange fluid may be initially supplied to the fuel cell board in substantially the same direction as the reducing fluid is initially supplied to the anode of the fuel cell board, or in substantially the same direction as the oxidizing fluid is initially supplied to the cathode of the fuel cell board.

[0124] The material properties or composition of the anode or cathode can be varied throughout the fuel cell board or ion-permeable membrane. The anode can be designed to promote hydrogen oxidation (HOR), be robust against degradation (temperature cycling, voltage, acidic environment), and have a high electrochemically active surface area (ECSA). The same applies to the cathode, but with respect to oxygen reduction (ORR).

[0125] The anode and cathode may contain platinum on a carbon support. Other platinum group metals (Pt, Ir, Os, Rh, Ru, Pd) or non-precious metals with much lower electrochemical activity (NPMs, e.g., Ni, Fe, Co, Sn) can also be used.

[0126] These can be altered by changing the ionomer content, PTFE content, catalyst content, electrode composition, or coating on the electrode.

[0127] The materials constituting the anode and / or cathode body may be varied. This may be done by changing the materials constituting the electrodes, i.e., the electrodes may be composed of graphite, Pt, Ir, a mixture thereof, or different mixtures or materials across the entire surface of the fuel cell board. For example, to account for variations in conditions across the entire fuel cell board, the percentage of platinum in the graphite electrode may be varied across the entire fuel cell board.

[0128] The additive materials applied to or used with the anode and / or cathode may be varied. This may be done by adding iridium oxide, PTFE, or Ru in various concentrations throughout the fuel cell board.

[0129] A gas diffusion layer (GDL) may also be provided between the flow path and the anode / cathode. The MEA may include one or more gas diffusion layers. These may be Sigracet (SGL Carbon), Avcarb, or porous carbon paper such as Toray. They may also be metal foam or porous metal material (e.g., foam or felt). These may include aluminum, titanium, or stainless steel. This material structure can also be varied across the entire surface of the fuel cell board, and the "material composition of the MEA" as used herein also includes the composition of this GDL.

[0130] The electrolyte membrane may be a proton exchange membrane (PEMFC), also known as a polymer electrolyte membrane (PEM). This may be fluorinated (e.g., a sulfonated tetrafluoroethylene-based fluoropolymer copolymer, e.g., Nafion®), or a non-fluorinated membrane (e.g., a hydrocarbon membrane, e.g., an Ionomr PEMION® membrane). The membrane may be an Ionomr Pemion®, GORE-Select®, or Fumatech Fumapem® membrane. Alternatively, the electrolyte membrane may be an anion exchange membrane (e.g., a Fumatech Fumasep® FAA-3 membrane). Other suitable membranes known to those skilled in the art may also be used in conjunction with this embodiment. In some embodiments, a catalyst layer on the electrodes accelerates the reaction between the fuel (on the anode electrode) and the oxidizer (on the cathode electrode), generating or consuming ions and electrons. This layer may be formed from a catalyst material suitable for the reaction under consideration, as is generally understood by those skilled in the art of fuel cell manufacturing. For example, the catalyst layer may consist of platinum nanoparticles deposited on carbon and a proton-conducting polymer (e.g., Nafion®). The catalyst layer may be provided on or together with each cathode and / or each anode. The composition of the catalyst layer may vary from anode to anode or from cathode to cathode across the entire surface of the ion-permeable membrane. For example, at least one of the ionomer content, catalyst load, or catalyst type may vary across the entire fuel cell board.

[0131] The varied and adjusted segmentation described herein can also reduce the effects of transient events, such as those occurring during fuel cell startup and / or shutdown. Gas fronts passing through or along the board can generate high potentials that can damage fuel cell boards, particularly catalysts. By segmenting the cells into smaller areas, the duration of these high potentials can be reduced, minimizing degradation. This is particularly useful in segmented fuel cell boards where cell properties vary across the board; for example, corrosion-resistant catalysts can be used in areas prone to high potentials, and reversal-resistant materials can be used in areas where voltage reversals may occur. Relatively small areas for some anodes or cathodes mean that the degree of damage in each MEA can be balanced, reducing variations in MEA efficiency during operation.

[0132] In particular, the catalyst can be varied by changing the catalyst type or loading percentage across the entire anode and / or cathode. For example, in cases where conditions are less favorable for an anode (e.g., the anode furthest from the anode reactant inlet, or the anode closest to the anode reaction fluid outlet), iridium oxide, which can react with water to prevent damage to the catalyst support, can be added to the anode / anode catalyst. This may be applied only to anodes where the conditions are known to be less favorable. For example, anodes closer to the anode reactant inlet can be made more resistant to such conditions by adding a catalyst resistant to anode fuel poisoning (e.g., a PtRu catalyst resistant to CO poisoning of H2).

[0133] The number or distribution frequency of means for conducting electrical current to or from the anode, or the layout of means for conducting electrical current from one side of the fuel cell board to the other, can be varied to account for variations in anode and / or cathode design across the entire fuel cell board.

[0134] Figure 3D shows how the means for conducting electricity generated in the fuel cell board 50 may be arranged to accommodate changes in the size of the active region of the fuel cell board. Here, the means for conducting electricity 60 may be plated through-holes (PTHs) as described herein. These are shown as row 60 in Figure 3B. When the active region is small, increasing the density of PTHs 60 within the small active region allows for the extraction of more current as a result of a higher current density in a smaller and more efficient MEA. The PTHs 60 can also serve to dissipate heat, which is advantageous in MEAs with high reaction rates.

[0135] A means is required to conduct electrical current from one side of the plate or board to the other, such as "plated through-holes" (PTH) or conductive material-filled through-holes. This is because the plates and boards described herein contain electrical insulating material, and therefore such means must be introduced to make the copper surfaces on both sides of the insulating layer electrically conductive, allowing current to flow from the MEA to electrical connections elsewhere in the fuel cell, and enabling power output from the fuel cell.

[0136] The “means for conducting electricity” as used herein may be plated through-holes or conductive material-filled through-holes. A “plated through-hole” (PTH) is a hole that forms a conduit that penetrates one or more layers of insulating material, the conduit extending substantially perpendicular to the plane of the fuel cell board. These are plated with a conductive material, such as copper, and function as electrical conduits. Since the insulating material (e.g., FR-4) has an electrically insulating core, plated through-holes are necessary to allow electricity to pass from one side of the layer to the other as needed. These may be formed by drilling holes in a layer of insulating material (e.g., a PCB plate) and then coating the inner walls with a conductive material. For example, coating with a conductive material may be done by an electroplating immersion process, such that copper coats the edges of each hole. Optional additional steps may be performed after electroplating, in which case i) resin may be pressed onto the PCB layer to flow through existing holes and fill the remaining parts of the holes with resin, ii) the electroplating immersion process may be repeated to cap both sides of the resin-filled holes with copper, and iii) light milling may then be performed to ensure that the PCB surface is flat. If these penetrate the PCB layer, a continuity can be formed between the two copper layers on either side of the PCB. The PTH may be formed to penetrate only specific layers of the insulating material described herein, or only some layers of the fuel cell board described herein (e.g., penetrating only the anode plate and cathode plate, thereby allowing current to be carried from the anode / cathode to the outer surface of the insulating material layer, or vice versa). The PTH may be formed to penetrate the entire fuel cell board (e.g., penetrating both the anode plate and cathode plate with the same hole, thereby allowing current to be carried from one side of the fuel cell board to the other, or vice versa). Holes filled with conductive materials such as resin or copper may be used instead of or in addition to the PTH. Furthermore, the insulating layer may not have means for conducting current through the body of the layer.

[0137] Figure 3E shows a fuel cell board 50 with tabs 62, 63 that provide the possibility of connecting cells / MEAs in series or in parallel. MEA / cells 52, 54 are shown as being of different sizes, with the largest MEA 54 located on the far right of the board. Six MEA / cells are shown, with one tab 62, 63 on each side edge of each MEA / cell (a total of 12 tabs 62, 63 across all six MEAs).

[0138] Current from each MEA can be collected at tabs or connection points provided on the edge of each MEA, such as electrode tabs on the individual MEA. The tabs may, for example, be parts of a copper-plated PCB board electrically connected to a portion of the MEA, thereby allowing current to be drawn from the MEA. This may be done by copper plating, wires, or any suitable means known in the art for drawing current from planar MEAs. These tabs or connection points on the edge of each MEA can then be electrically connected to other tabs or connection points on other MEAs. These connections can be wired in series or parallel.

[0139] To illustrate the comparison of possible series and parallel connections of MEA / cells, two different connection / wiring types are shown on the same fuel cell board.

[0140] Figure 6e shows the upper group of tabs 62 connected in series with each other. Each MEA is connected in series with an adjacent MEA. These are also connected in series with the remaining tabs.

[0141] The lower tab group 63 in Figure 6e shows how they are connected in parallel, pair by pair. Each pair of MEAs / cells connected in parallel is then connected in series with the rest of the fuel cell stack.

[0142] Because the MEA (Mechanical Energy Adjuster) changes voltage as needed, it can be connected to other MEAs in either series or parallel, depending on the requirements of operation. This switching between series and parallel connections can be used to favorably flatten the fuel cell voltage as needed.

[0143] Figure 4 is a schematic diagram of the unfolded PCB fuel cell board 200 viewed from one viewpoint. In this figure, the fuel cell board 200 is shown unfolded to show that the membrane electrode assembly layer 103 is separated from the cathode plate 101 and the anode plate 102. The cathode plate may be the first insulating layer described herein. The anode plate may be the second insulating layer described herein.

[0144] The MEA layer 103 is provided with 10 cells or MEA113 visible in a planar arrangement. Each MEA113 includes an ion-permeable membrane, an anode, and a cathode. In Figure 4, two MEA113s are labeled, but all 10 are partially visible. In the MEA113 of this embodiment, all cathodes are located on the first surface of the ion-permeable membrane, and all anodes are located on the other surface of the ion-permeable membrane, opposite the cathodes. Only one membrane exists. In this embodiment, the MEA113 is stacked between the cathode plate 101 and the anode plate 102, but in this figure it is shown separated / unfolded to show its presence. The stacking process will be described later. Here, the anode faces the anode plate 102 (upward in Figure 4), and the cathode faces the cathode plate 101 (downward and not visible in Figure 4).

[0145] This shows one embodiment of the MEA suitable for use in the embodiments described herein. Other MEA designs, shapes, and orientations are known to those skilled in the art and are understood to be applicable to this embodiment. Variations in the MEA may be as described herein. In this embodiment, only the variation in the size of the MEA is visible. The MEA layer 103 comprises a seal / laminate material such as a prepreg, which is visible as a non-MEA 113 region within the MEA layer 103. 113 indicates an MEA which may include a gas diffusion layer. The ion-permeable film extends slightly beyond this region (approximately 0.2 mm to the edge of the module) and forms a seal with the prepreg. The ion-permeable film is sandwiched between the prepreg in this region.

[0146] Here, the cathode plate 101 and anode plate 102 are partially copper-plated printed circuit boards (PCBs), but in embodiments herein, they may be layers of any insulating material described herein. In the fuel cell board 200, the cathode plate 101 and anode plate 102 are laminated together with an MEA layer 103, and the MEA is placed between the cathode plate 101 and anode plate 102 to form the fuel cell board 200. In Figure 4, only the inner surface 101a of the cathode plate 101 and the outer surface 102b of the anode plate 102 are visible. The inner surfaces of both the cathode plate 101 (surface 101a shown in Figure 4) and the anode plate 102 are copper-plated, and the flow path fields 111 and 112 are routed therein. To prevent degradation, passivation ink is screen-printed on the flow path field surfaces on the inner surfaces of both plates 101 and 102. On the inner surface 101a of the cathode plate 101, only the flow path field 111 on the cathode side is visible (in Figure 4, one flow path field 111 is labeled, but multiple parallel flow path fields 111 are visible). In Figure 4, the flow path field of the anode plate 102 is not visible and is located on the invisible inner surface 102a of the cathode plate 102. The flow path field 111 on the cathode plate 101 may be the first fluid path described herein, and the flow path field on the anode plate 102 may be the second fluid path described herein.

[0147] In the specific embodiment shown in Figure 4, and generally in all embodiments, the flow path field is routed within the PCB, providing a path for supplying reactants (e.g., air, hydrogen) to the cathode and anode. The oxidizing fluid flows to only one or more cathodes of each fuel cell board, and the reducing fluid flows to only one or more anodes of each fuel cell board. As used herein, “oxidizing fluid” refers to the fluid that reacts at the cathode, e.g., air or oxygen. “Reducing fluid” refers to the fluid that reacts at the anode, e.g., hydrogen.

[0148] Here, the flow channels are channels routed within the surface of the PCB, but not through the entire body or volume of the board. They are routed only within one surface, and no flow channels or channels exist on the opposite surface from the surface to which the fields are routed. This configuration allows for effective separation of reactants for the anode and cathode. For example, as shown in Figure 4, the flow channel field 111 on the cathode plate 101 is routed only within the surface 101a of the anode plate 101, and not through the entire body of the plate to surface 101. The same applies to the flow channel field on the anode plate 102, which is not shown in Figure 4. Therefore, no flow channel field is visible on the outer surface 102b of the anode plate 102 (nor is a flow channel field visible on the outer surface 101b of the cathode plate 101). When the boards are stacked, the flow channel fields are located on the relevant parts of the MEA 113 (anode flow channel field on the anode and cathode flow channel field on the cathode), thereby directly supplying the relevant reactants to the anode and cathode. The pressure of the supplied reaction fluid ensures the reaction at the anode and cathode. In this embodiment, the reactants flow in from one side of the plate and out from the opposite side of the plate through a parallel flow field.

[0149] Various flow path field patterns and inlet and outlet positions on the plate are known to those skilled in the art. For example, the flow path may be meandering, circular, or a channel (i.e., parallel) that runs linearly across the plate. The flow path field may flow in and out from the same side of the plate, or from the opposite side or corner of the plate. It is advantageous to have the reactant flow in and out from the opposite side of the plate, thereby allowing for easy separation of the reactant manifold on the opposite side of the fuel cell.

[0150] The outer surfaces 101b and 102b of plates 101 and 102 are also copper-plated, and the desired copper patterns are routed. Subsequently, holes for various manifolds and flow fields are drilled into the plates.

[0151] After lamination, holes 103 and 104 are drilled or routed into the outer surfaces 101b and 102b of the cathode plate 101 and anode plate 102, respectively. These holes 103 and 104 provide access to the respective flow path fields 111, allowing reaction fluids (e.g., air and hydrogen) to be supplied from the manifold to the flow path fields 111 and to return from the flow path fields 111 to the manifold.

[0152] On the cathode plate 101, reaction air is supplied and discharged from the end of the cathode flow path field 111. The cathode manifold 105 supplies compressed reaction air, and the reaction air is discharged from the cathode plate 101 and the entire fuel cell board 200 via the cathode manifold 105. The air is supplied from the atmosphere, i.e., from outside the fuel cell, but flows into the fuel cell system via an air compressor (in contrast to a fan which may be used in later embodiments). This allows for higher air pressure to be achieved, although the parasitic energy cost required to operate the compressor is increased compared to using a fan.

[0153] Figure 4 also shows the heat exchange fluid manifold 107 and the anode manifold 109, which are also drilled or routed into the plate after lamination. The anode manifold 109 supplies reaction hydrogen, and the reaction hydrogen is discharged from the anode plate 102 and the entire fuel cell board 200 through the anode manifold 109. The heat exchange fluid manifold 107 and the cathode manifold 105 are also shown in Figure 4, which are also drilled into the plate after lamination. These supply the cathode reaction fluid and the heat exchange fluid (e.g., cooling fluid) to the fuel cell board 201.

[0154] In general, in all embodiments of this specification, manifolds of any suitable size, dimensions, and shape are used to supply and discharge reactants, heat exchange fluids, or other related substances to and from the inlet and outlet of the fuel cell board. A longitudinal channel running vertically through the fuel cell stack is connected to manifolds positioned along two opposite edges of the stack, which supply reactants, heat exchange fluids, etc., to and from the board.

[0155] The plate may have holes drilled or routed for bolt holes, and / or positioning pins may be inserted therein.

[0156] In this specification, the terms "fluid path," "fluid channel," "flow path," "fluid flow path," "fluid route," "flow path field," and "channel" are interchangeable and may be used interchangeably with each other. All of these refer to means through which a fluid can flow, move, or pass. The fluid is substantially guided along the fluid flow path, channel, etc., with or without assistance.

[0157] Figure 5 shows an example of one electron path in the segmented active region of the fuel cell board. This shows that the MEA can be connected in series across the entire fuel cell board 70. Such a PTH cannot be used when the MEAs are connected in parallel. Two MEAs are shown on the fuel cell board 70, each having an anode 72 and a cathode 74. Each fuel cell board can connect multiple MEAs in this manner, and this figure shows only two of the many possible configurations. The anode 72 and cathode 74 are separated by an ion-permeable film 71. Arrow 76 indicates the path of current flowing laterally across the entire fuel cell board 70. The current first flows from the anode 72 through the plating through-hole 80 to the copper plating 76 on the upper surface of the board 70. The current flows along the copper layer 76 on the upper surface of the board, then flows downward through the plating through-hole 82 and along the copper layer 76 on the lower surface of the board. The electrons then flow through the plating through-hole 80 to the cathode 74 on the right side of the board. For each MEA, a total of four plated through-holes 80 are labeled, two on each side of the ion-permeable film 71. Eleven plated through-holes 80 are shown for each MEA.

[0158] Figure 5 illustrates how current can flow laterally across the fuel cell board when the MEA is segmented as described herein. These MEAs are connected in series with each other.

[0159] Figure 5 shows two types of plated through-holes, indicated by reference numerals 80 and 82. Firstly, plated through-holes 80 penetrate only a portion or one layer of the insulating material (and provide a current path between them) from one side of the fuel cell board to the anode or cathode. These are indicated by reference numeral 80 in Figure 5. Secondly, plated through-holes 82 penetrate the entire fuel cell board from one side to the other (and provide a current path between them). These penetrate at least two insulating layers of the insulating material, namely both the anode plate and the cathode plate. In some configurations (not shown here), these may also penetrate the ion-permeable films of the anode, cathode, and MEA. These are indicated by reference numeral 82 in Figure 5.

[0160] During operation, the fuel cell may be housed within a housing and sealed from the atmosphere. Reactants are supplied to the fuel cell channels through sealed connections. The seals may be made from, for example, polydimethylsiloxane (PDMS). In particular, fuel (e.g., H2) and oxidizer (e.g., air) are supplied to appropriate fluid channels in the fuel cell stack, with the fuel supplied to the anode and the oxidizer to the cathode. The resulting electrical current can be directly extracted as the output of the fuel cell boards. A constant power output of the stack can be achieved in various ways. For example, all fuel cell boards may be constantly loaded. Alternatively, the fuel cell boards may be divided into groups, and these groups may be sequentially "turned on" in a synchronous manner (i.e., all fuel cell boards are switched at predetermined times). The fuel cell boards may also be switched asynchronously or quasi-asynchronously, i.e., each fuel cell board is connected to and disconnected from the load for individually defined periods and frequencies. The output power of the stack can be continuously adjusted by switching the fuel cell boards to be connected to the load for a portion of the time according to a duty cycle. For example, if only 50% of the fuel cell boards are connected to the load during a given sampling period, the output power of the fuel cell stack will be similarly reduced. There are many ways to achieve this 50%; for example, half of the fuel cell boards may be disconnected from the load for the entire sampling period, with the other half connected, or all fuel cell boards may be connected to the load, but each fuel cell board may be connected for only half the sampling period. Yet another method is to connect half of the fuel cell boards to the load for one-quarter of the sampling period, and the other half for three-quarters of the sampling period, and so on. The choice of the specific method or duty cycle used may depend on the performance of the individual fuel cell boards, the need to avoid localized heating or "hot spots," the need to avoid cathode site flooding by generated water, the need to prevent membrane dehydration, or the need to counteract electrode poisoning.It should be noted that the duty cycle may be predetermined or controlled in real time based on the monitored performance of the fuel cell within a closed-loop feedback system, for example, with a voltage measuring device. Partial use of fuel cell boards can improve efficiency because optimal load conditions and power conversion can be achieved for each individual fuel cell board rather than the entire fuel cell stack, which is a limitation in current designs. By providing additional switching and filtering components on the fuel cell board, it is possible to obtain smoothly changing outputs, such as a sinusoidal wave, in addition to simple "switching" or stepwise changes from one potential to another.

[0161] Each fuel cell board can have its own electronic circuitry, and each module supplies power to the electric bus. That is, each board contains its own power electronics and controller. The latter monitors the performance of the fuel cell electrodes, local humidity, and temperature. Also, as will be described later, it can control shape memory alloy (SMA) valves to restrict the reaction flow to the electrodes on each board. In this way, the power electronics can be directly placed on each horizontal board. This method allows monitoring of the degradation of each electrode. This information is used as feedback to modulate the electronic circuitry to reduce the frequency of use of a particular electrode board, thereby slowing down the degradation process or even shutting down the electrode board completely. This control protects faulty boards and thus extends the lifespan of the entire fuel cell stack.

[0162] Figure 7 shows that the fuel cell stack can be adjusted to have the same output but different voltages, as required. Figure 7 shows two system examples, based on experimental modeling, that supply the same maximum power with different configurations. System A (indicated by dots and ×s, with ×s representing voltage and dots representing power) has an area of ​​100 cm². 2 This is a fuel cell stack containing 20 cells, while system B (shown by squares and triangles, with voltage indicated by triangles and power by squares) has an area of ​​200 cm².2 This is a fuel cell stack having a fuel cell board containing 10 cells. In System A, when a higher voltage is required for the application, the fuel cells are connected in series to maximize the cumulative voltage to 18V and supply a maximum stack current of 100A. In contrast, in System B, the cumulative voltage of the stack is reduced to 10V by switching the fuel cell connection from series to parallel, while the current is increased to 210A to maintain a constant power. System A has a high voltage but a low supply current, while System B has a low voltage but a high supply current. This illustrates how the electrical characteristics of the fuel cell stack are affected by changing the cell segmentation.

[0163] Figures 8A, 8B, 8C, and 8D show the modeling results for a segmented fuel cell board. In all figures, the x-axis represents the spatial coordinates across the entire modeled fuel cell board, and 10 individual MEAs can be seen in each of the four graphs, with each line representing a different MEA of 0.1 A / cm². 2 ~1.6A / cm 2 This is shown using eight different currents.

[0164] These figures compare the cathode potentials of two different segmented MEA fuel cell boards operating at relatively low humidity, with all other conditions being identical. The anode inlet is at 50% relative humidity, and the cathode inlet is at 10% humidity.

[0165] Figure 8A plots oxygen saturation (partial pressure) against spatial coordinates, and Figure 8B plots water activity (relative humidity) against spatial coordinates; both values ​​are for the cathode catalyst layer. These two graphs are for a segmented module where all segments are the same size and therefore all segments experience the same current density.

[0166] The figure shows a predictable distribution, illustrating a predictable decrease in oxygen saturation and a predictable increase in humidity across the entire fuel cell board.

[0167] Figure 8C plots the potential against spatial coordinates, and Figure 8D also plots the potential against spatial coordinates; both show values ​​at the cathode catalyst layer. Both graphs are for segmented modules, but Figure 8C is for a fuel cell module where all segments of the fuel cell are the same size, while Figure 8D is for a fuel cell module where the segment sizes differ across the entire fuel cell board, resulting in all segments experiencing different current densities.

[0168] Figure 8D shows that, compared to Figure 8C, when the MEA segmentation varies across the entire fuel cell board, the potential variation across the fuel cell board is significantly smaller. This indicates that by changing the size of the MEA, the potential variation across the fuel cell board can be reduced, flattening the voltage and making it more predictable. A more consistent voltage is maintained across the entire segmented fuel cell board with varying sizes.

[0169] Comparing Figures 8C and 8D, we see that 1.6 A / cm² is particularly noteworthy. 2 In this case, it can be seen that the performance has improved (from 4.60V to 4.65V).

[0170] In this specification, the configuration of fuel cell boards and fuel cell stacks will be described in terms of "horizontal" and "vertical" planes, according to the embodiments shown in the figures. However, these terms are used for clarity of explanation only and do not limit the scope of the invention. It will be apparent to the reader that fuel cell boards are not limited to horizontal planes but can be arranged in any plane. Furthermore, the term "directly opposite" is not limited to cases where the electrodes are perfectly aligned. The anode is located on one surface of the polymer electrolyte and is directly opposite the cathode, which is located on the opposite surface of the same electrolyte membrane layer.

[0171] Figure 6 shows a fuel cell stack 30-1 as an example of an embodiment. The fuel cell stack 30-1 is housed in a fuel cell casing, and the end plates 31 are visible. This embodiment is provided with 11 liquid cooling plates 300 and 10 fuel cell boards 200. This fuel cell has two cathode inlets / outlets 32, two coolant inlets / outlets 33, and two anode inlets / outlets 34.

[0172] The cathode inlet 32 ​​is connected to a compressed air cylinder or air compressor to supply compressed air, which acts as an oxidizer that reacts at the cathode during fuel cell operation. The cathode outlet 32 ​​is connected to an exhaust system to the atmosphere. In some cases, the cathode outlet 32 ​​is connected to the exhaust system via a humidifier, and the water produced by the fuel cell can be used to humidify the air flowing into the stack. This is achieved by passing the inflow and outflow fluids over a water-permeable membrane.

[0173] The anode inlet 34 is connected to a hydrogen cylinder and supplies hydrogen reactants to the anode, which act as a reducing gas and supply fuel for the fuel cell operation. The anode outlet 34 is connected to an exhaust system to the atmosphere or an anode recirculation system.

[0174] The anode recirculation system may include a water trap (for removing accumulated water) and a hydrogen pump or orifice that increases the pressure so that unused hydrogen can be returned to the stack.

[0175] The end plate 32 compresses and seals the fuel cell, preventing fluid leakage during operation. The fuel cell is bolted in place to ensure proper compression.

[0176] By using sealing materials such as prepregs and insulating plates such as PCBs, it is ensured that the MEA is sealed from sources other than those intentionally guided to the MEA components by channels in adjacent boards (e.g., anode and cathode plates). This is an advantage of the technology described herein, enabling the rapid, simple, and low-cost construction of such structures. For example, by using lamination with epoxy resin prepregs, the compression of the gas diffusion layer of the MEA is also maintained, which is an important factor in maintaining fuel cell performance by providing sufficiently low-resistance electrical paths without impairing the distribution of the reaction fluid.

[0177] The boards are laminated through a specific lamination process that involves careful pre-cutting and alignment of the materials, as well as specially configured heating, cooling, pressure, and cleaning cycles.

[0178] The boards or layers of boards may be mechanically compressed or pressurized by appropriate means to form a single unit. This may be done when the entire fuel cell stack is compressed as a whole. This means that lamination is not necessarily required in all embodiments. This may be done using layers of prepreg or other sealing material types.

[0179] Once the fuel cell boards 200 of this embodiment are configured, they can be assembled into a fuel cell stack. These are modular and consist of two components: fuel cell boards 200 and thermal management plates 300. The stack begins and ends with end plates, which provide compression throughout the stack and sealed ports for connecting fuel, oxidizer, and thermal management fluid. If necessary, excess current removal means for extracting significantly large currents may be provided at either or both ends of the stack. The stack can be constructed in a configuration of repeated fuel cell boards 200, with additional thermal exchange plates 300 as needed. The stacks described herein may be held together by bolts or compression bands, which also provide compression for sealing between modules, but any means for holding the stack in a compressed state, or any means for sealing the fuel cell boards, optionally the thermal exchange plates or modules together, and any type of end plate known in the art may be used. Gaskets for sealing the manifold or other parts of the fuel cell stack together may be used if necessary, but they may not be necessary in such stacks.

[0180] In this specification, the terms “heat exchange fluid,” “thermal control fluid,” or “temperature control fluid” (as used interchangeably herein) refer to a fluid that can be used in a fuel cell or fuel cell component or other such electrochemical device and that flows in the vicinity of, adjacent to, or in contact with one or more parts of a fuel cell board, fuel cell, fuel cell component, or fuel cell stack described herein. For example, by the systems and methods described herein, a heat exchange fluid can be flowed in a channel adjacent to or near the anode of a fuel cell board, thereby cooling or heating these anodes. These can serve to cool various components, for example, by cooling the anode of a fuel cell while the fuel cell is operating. Such a heat exchange fluid can also serve to heat or warm components and can be used to raise the temperature of a fuel cell anode component, for example, during fuel cell startup, in the initial stages of the fuel cell's operating timeline / program, or in a low-temperature environment. The heat exchange fluid may be a liquid or a gas, as with other suitable fluids described herein. Heat or temperature can be added to or removed from various parts of a fuel cell board, fuel cell, fuel cell component, or fuel cell stack described herein.

[0181] The heat exchange fluid may be in contact with one or more parts of the fuel cell board, fuel cell, fuel cell components, or fuel cell stack described herein. For example, the systems and methods described herein can be used to flow the heat exchange fluid into a channel adjacent to or near the anodes of the fuel cell board, thereby cooling these anodes.

[0182] Thermal management or heat exchange may be performed for the purpose of maintaining the fuel cell board or stack at a predetermined operating temperature, operating the system in a more energy-efficient manner, extending the operating life of the system, and / or providing more efficient fuel cell operation (e.g., operating the fuel cell within set parameters and preventing excessive or insufficient power generation).

[0183] All heat exchange fluids known to those skilled in the art are suitable for the purpose of thermally managing or controlling the temperature of fuel cell boards, fuel cells, fuel cell components, or fuel cell stacks described herein.

[0184] In particular, the heat exchange fluid may be deionized water, water, or a mixture of water or deionized water with glycol to prevent freezing of the water. Other suitable heat exchange fluids are also conceivable and will be known to those skilled in the art. For example, a fluid may be used in which the ratio of deionized water to glycol (e.g., ethylene glycol or propylene glycol) is 1:1, or the ratio may be 2:1, 3:1, 4:1, or 5:1. The solution may contain up to 10%, 1%, 2%, 5%, 10%, 20%, 30%, 40%, or 50% glycol in the deionized water. Alternatively, the heat exchange fluid may be a mixture of deionized water with another type of alcohol (e.g., methanol, ethanol, isopropyl alcohol). The solution may contain up to 10%, 1%, 2%, 5%, 10%, 20%, 30%, 40%, or 50% alcohol in the deionized water. The cooling fluid may contain one or more perfluoroamines, such as Fluorinert®. Throughout this specification, water referred to as deionized water may also include non-deionized water, and vice versa.

[0185] Within an insulating layer, i.e., a single insulating layer, multiple different fluid paths or channels of different sizes, shapes, and / or dimensions, or paths for fluids of different flow rates or different fluid temperatures may be provided. The fluids may be at different temperatures or flow rates in different plates, or at different temperatures or flow rates in different paths within the same plate. If multiple thermal management plates are present in a fuel cell stack, each plate may have different fluid paths, fluid paths of different sizes, shapes, or dimensions, or may be designed to carry different fluids. Depending on the differences in the thermal management fluid requirements throughout the stack, different plates may carry fluids of different temperatures or fluids of different flow rates.

[0186] The reaction fluid may be oxygen gas, air, pressurized air, or any other suitable fluid that can react in the cathode. As mentioned above, the reaction fluid for the cathode may be air taken in from the atmosphere outside the fuel cell by a fan or air compressor.

[0187] In this specification, “fuel cell board” or “group of fuel cell boards” refers to a membrane electrode assembly (MEA) 113 sandwiched between a cathode plate 101 and an anode plate 102. In this embodiment, these three layers are laminated integrally. Some fuel cell boards may further have a cap layer 150 as part of the laminated structure. A fuel cell board may also be referred to as a fuel cell module in this specification. The use of the term “fuel cell board” is not intended to limit the size, shape, or arrangement of the MEA or other components of the board. “Fuel cell board” is not intended to limit the size, shape, or dimensions of the board, but is merely a term in the art referring to the MEA and plates described herein.

[0188] The fuel cell, fuel cell board, and components may consist of an insulating layer, such as a printed circuit board (PCB). Individual layers can be bonded together using epoxy-containing glass fiber composites ("prepregs") to form a single, integrated structure. The MEA may be laser-bonded onto the insulating layer, and then, to fabricate the fuel cell board, multiple boards may be laminated, for example, or mechanically compressed with or without the help of a sealing or adhesive material such as a prepreg. Gaps between electrodes and seals achieved within these gaps by epoxy resin prevent mixing of individual flows, i.e., mixing of the air-cooling flow, reaction flow, and fuel flow. Simple PCBs may also be used as end boards or end plates in the stack described herein.

[0189] As used herein, the term “insulating layer” may refer to an insulating core alone, or an insulating core comprising a conductive material and a passivation layer. The insulating layer in the embodiments herein may be a printed circuit board (PCB). The PCB for these embodiments may be manufactured by known methods. As used herein, the term “printed circuit board” or “PCB” refers to one or more layers of insulating material including one or more types of dielectric substrates such as epoxy resin, such as FR-1, FR-2, FR-3, FR-4, FR-5, FR-6, CEM-1, CEM-2, CEM-3, CEM-4, CEM-5, polytetrafluoroethylene, and G-10, and preferably the insulating layer includes FR-4. Multiple layers or boards may be laminated using, for example, an epoxy resin prepreg. A plate or board may contain one or more layers of these insulating materials, or one or more PCB boards may constitute a single “insulating layer” as used herein. The PCB board includes areas plated with a conductive material. To obtain a conductive region, a thin layer of a conductive material (e.g., metal, e.g., copper) may be deposited, plated, or coated onto the entire surface of the insulating substrate, and then etched (e.g., using a mask) to give a desired conductive pattern. The conductive material may also be applied by electroplating. The PCB described throughout this specification may or may not have copper plating on each part of the PCB board. The insulating layer, e.g., the PCB, may be a flexible PCB and have, for example, the thinner end of the thickness range shown in Table 1 above.

[0190] In this specification, a passivation layer or passivated layer means an additional layer deposited on a copper or other conductive metal layer. The passivation layer may be a passivation ink, which may refer to a conductive ink, and in particular may have a carbon-based functional conductive component. The ink serves to provide a low-surface-resistance conductive path between the electrode and the current collector while protecting the copper from the corrosive environment of the fuel cell. This is achieved by passivating mobile copper, which would otherwise cause irreversible damage to the electrolyte / membrane. Furthermore, the ink may be a carbon ink, or a silver paste and polyurethane-based ink in which conductive elements such as carbon nanotubes or gold / silver nanoparticles are dispersed. These and other inks will be known to those skilled in the art. The passivation layer may contain gold, silver or nickel, and / or may be an electroless nickel-plated gold (ENIG) layer, an organic solderable preservative layer or a silver-plated layer, or any other passivation treatment known in the art.

[0191] The reaction fluid may be oxygen gas, air, pressurized air, or any other suitable fluid that can be oxidized at the cathode. As mentioned above, the reaction fluid for the cathode may be air taken in from the atmosphere outside the fuel cell by a fan or air compressor.

[0192] In this specification, the term "passivated ink" may refer to conductive ink, which may in particular have a carbon-based functional conductive component. This ink serves to provide a low-surface-resistance conductive path between the electrode and the current collector while protecting the copper from the corrosive environment of the fuel cell. This is achieved by passivating mobile copper, which would otherwise cause irreversible damage to the electrolyte / membrane. Furthermore, this ink may be a carbon ink, or a silver paste and polyurethane-based ink in which conductive elements such as carbon nanotubes or gold / silver nanoparticles are dispersed. These and other inks will be known to those skilled in the art.

[0193] During operation, the fuel cell is housed within a housing and sealed from the atmosphere. Reactants are supplied to the fuel cell channels through sealed connections. The seals may be formed from, for example, polydimethylsiloxane (PDMS). In particular, the fuel (e.g., H2) and oxidizer (e.g., O2) are supplied to appropriate channels in the fuel cell stack, with the fuel supplied to the anode and the oxidizer to the cathode. The resulting electrical current can be taken directly, or the output of the fuel cell boards can be modulated using the aforementioned switches. A constant power output from the stack can be achieved in various ways. For example, all fuel cell boards may be constantly loaded. Alternatively, the fuel cell boards may be divided into groups, and these groups may be sequentially "turned on" in a synchronous manner (i.e., all fuel cell boards are switched at predetermined times). The fuel cell boards may also be switched asynchronously or quasi-asynchronously, i.e., each fuel cell board is connected to and disconnected from the load for individually defined periods and frequencies. The output power of the stack can be continuously adjusted by switching the fuel cell boards so that they are connected to the load for a portion of the time according to a duty cycle. For example, if only 50% of the fuel cell boards are connected to the load during a given sampling period, the output power of the fuel cell stack will be similarly reduced. There are many ways to achieve this 50%; for example, half of the fuel cell boards may be disconnected from the load for the entire sampling period, with the other half connected, or all fuel cell boards may be connected to the load, but each fuel cell board may be connected for only half the sampling period. Yet another method is to connect half of the fuel cell boards to the load for one-quarter of the sampling period, and the other half for three-quarters of the sampling period, and so on. The choice of the specific method or duty cycle used may depend on the performance of the individual fuel cell boards, the need to avoid localized heating or "hot spots," the need to avoid cathode site flooding by generated water, the need to prevent membrane dehydration, or the need to counteract electrode poisoning.It should be noted that the duty cycle may be predetermined or controlled in real time based on the monitored performance of the fuel cell within a closed-loop feedback system, for example, with a voltage measuring device. Partial use of fuel cell boards can improve efficiency because optimal load conditions and power conversion can be achieved for each individual fuel cell board rather than the entire fuel cell stack, which is a limitation in current designs. By providing additional switching and filtering components on the fuel cell board, it is possible to obtain smoothly changing outputs, such as a sinusoidal wave, in addition to simple "switching" or stepwise changes from one potential to another.

[0194] It will be understood that each aspect of the present invention can be used interchangeably or in parallel as appropriate. The fuel used is not limited to hydrogen, but may be any suitable fuel. For example, the novel fuel cell stack configuration described herein is also applicable to methanol used in direct methanol fuel cells. Other types of fuel cells are known in the art and can be used with the configurations and components described herein, and are not limited to hydrogen fuel cells.

[0195] In the present invention as an example, hydrogen (i.e., a reducing gas for the anode) is used as the reaction fuel, but the fuel cell can be used with any suitable pressurized fluid. As used herein, “fluid” refers to a substance that does not have a fixed shape and readily conforms to external pressure, such as a gas or a liquid. The fuels used in the systems and methods described herein are fluids. These fuels may be hydrogen or a hydrogen-containing mixture, or hydrocarbons or hydrocarbon derivatives. The fuel may also be other gaseous fuels such as methane or propane. The fuel may also be other gaseous fuels such as methane or propane, and the fluid may also include an oxidizing agent such as air or oxygen.

[0196] The fuel cells and fuel cell boards described herein can be designed to accommodate any power output expected in a fuel cell stack. Each fuel cell board may have a rated output of at least 100 W. Each fuel cell board may have a rated output of up to 1000 W. Each fuel cell board may have a rated output of 10 W to 1000 W. A fuel cell comprising multiple fuel cell boards may have a rated output of at least 10 kW. Preferably, each fuel cell comprising multiple fuel cell boards may have a rated output of up to 1000 kW. Preferably, each fuel cell comprising multiple fuel cell boards may have a rated output of 10 kW to 1000 kW. However, any rated output values ​​shown are merely illustrative of the current embodiments, and rated outputs may differ from these exemplary values.

[0197] This system and method can be used in conjunction with pressurized fuel storage units or containers well known in the art. The fuel can be stored in pressurized storage units such as bottles or canisters, which may be at a pressure of, for example, 700 to 300 bar.

[0198] This system and method can be used in conjunction with pressurized fuel storage units or containers well known in the art. Fuel can be stored in pressurized storage units such as bottles or canisters. These may be at pressures of, for example, 700 to 10 bar. In particular, the fuel storage unit is suitable for use in the fuel cell described herein, i.e., at pressures of 150 to 350 bar.

[0199] It will be apparent to those skilled in the art that numerous improvements and modifications can be made to the above embodiments without departing from the scope of this disclosure.

Claims

1. A fuel cell comprising at least one fuel cell board, Each fuel cell board is At least one first insulating layer, At least one ion-permeable membrane, It includes multiple anodes and multiple cathodes, All of the cathodes are arranged across the entire first surface of the ion-permeable membrane, and all of the anodes are arranged across the entire second surface of the ion-permeable membrane facing the first surface. The material properties of at least one of the anode or cathode, or the size of the anode or cathode, change or are altered throughout the entire fuel cell board, and / or The material properties of at least one of the other components of the fuel cell board change or are altered throughout the entire fuel cell board. fuel cell.

2. A fuel cell comprising at least one fuel cell board, Each fuel cell board is At least one first insulating layer, At least one ion-permeable membrane, It includes multiple anodes and multiple cathodes, All of the cathodes are arranged across the entire first surface of the ion-permeable membrane, and all of the anodes are arranged across the entire second surface of the ion-permeable membrane facing the first surface. The anode-cathode pairs sandwiching the at least one ion-permeable membrane are electrically connected in parallel with adjacent anode-cathode pairs. fuel cell.

3. The anode-cathode pairs sandwiching the at least one ion-permeable membrane are electrically connected in parallel with adjacent anode-cathode pairs. The fuel cell according to claim 1.

4. The material properties of at least one of the anode or cathode, or the size of the anode or cathode, change or are altered throughout the entire fuel cell board, and / or The material properties of at least one of the other components of the fuel cell board change or are altered throughout the entire fuel cell board. The fuel cell according to claim 2.

5. The fuel cell board includes means configured to supply an oxidizing agent fluid to the cathode and means configured to supply a reducing agent fluid to the anode, Optionally, the means for supplying an oxidizing fluid to the cathode is an insulating layer including at least one first fluid path, and / or optionally, the means configured to supply a reducing fluid to the anode is an insulating layer including at least one first fluid path. Optionally, the means configured to supply an oxidizing fluid to the cathode or a reducing fluid to the anode, wherein the at least one first insulating layer includes at least one first fluid path. A fuel cell according to any one of claims 1 to 4.

6. The size of the anode increases or decreases across the entire first surface of the ion-permeable film, and / or The size of the cathode increases or decreases across the entire second surface of the ion-permeable membrane. A fuel cell according to any one of claims 1 to 5.

7. The anode and / or the cathode have smaller dimensions at a location where the fuel cell board is exposed to more favorable conditions, and / or The anode and / or cathode are larger in the location where the fuel cell board is exposed to more unfavorable conditions. A fuel cell according to any one of claims 1 to 6.

8. At least one of the cathodes has a small size at the edge of the fuel cell board where the oxidizing fluid is first supplied to the cathode, and / or At least one of the anodes has a larger size at the edge of the fuel cell board where the reducing agent fluid is first supplied to the anode. The fuel cell according to claim 6 or 7.

9. The oxidizing fluid is initially supplied to the cathode of the fuel cell board in substantially the opposite direction to the direction in which the reducing fluid is initially supplied to the anode of the fuel cell board. A fuel cell according to any one of claims 1 to 8.

10. The material properties of the at least one anode and / or cathode that change are at least, i) at least one of the materials constituting the anode and / or the cathode, or at least one of the additive materials applied to or used together with the anode and / or the cathode, ii) Coating of the anode and / or the cathode, and / or iii) The composition, material properties, position, or size of any catalyst layer provided on or together with each cathode and / or anode, wherein the composition of the catalyst layer includes at least one of the ionomer content, catalyst load, or catalyst type. A fuel cell according to any one of claims 1 to 9.

11. The fuel cell board includes means for conducting current from one side of the fuel cell board to the other side, optionally the means being a plated through-hole and / or The fuel cell board includes means for conducting an electrical current from the anode through the at least one insulating layer to the surface of the at least one first insulating layer, Optionally, the means is a plated through-hole or a conductive material-filled hole. A fuel cell according to any one of claims 1 to 10.

12. The first insulating layer includes at least one first fluid path, A fuel cell according to any one of claims 1 to 11.

13. The first insulating layer includes a plurality of first fluid paths, and the plurality of first fluid paths are substantially parallel to each other. The fuel cell according to claim 12.

14. The fuel cell board includes a second insulating layer, The first insulating layer includes at least one first fluid path, The second insulating layer includes at least one second fluid path, The at least one ion-permeable membrane and the plurality of anodes and cathodes are arranged between the first insulating layer and the second insulating layer, so that the at least one first fluid path is configured to supply an oxidizing fluid to one or more of the cathodes of the at least one fuel cell board, and the at least one second fluid path is configured to supply a reducing fluid to one or more of the anodes of the at least one fuel cell board, and The MEA, the first insulating layer, and the second insulating layer are integrally laminated to form the fuel cell board. A fuel cell according to any one of claims 1 to 13.

15. The first insulating layer includes a plurality of first fluid paths, and the plurality of first fluid paths are substantially parallel to each other, and / or The second insulating layer includes a plurality of second fluid paths, and the plurality of second fluid paths are substantially parallel to each other. The fuel cell according to claim 14.

16. The first insulating layer is a printed circuit board (PCB), and optionally, a further insulating layer is also a PCB. A fuel cell according to any one of claims 1 to 15.

17. The fuel cell includes a plurality of fuel cell boards, Each of the fuel cell boards is arranged such that the cathode of each fuel cell board faces the anode of an adjacent fuel cell board, and each of the fuel cell boards is arranged such that the anode of each fuel cell board faces the cathode of an adjacent fuel cell board. A fuel cell according to any one of claims 1 to 16.

18. The fuel cell board has a rated output of 10W to 1000W, and / or the fuel cell has a rated output of 10kW to 1000kW. A fuel cell according to any one of claims 1 to 17.

19. Use of a fuel cell according to any one of claims 1 to 18.

20. A method for controlling fuel cell voltage, comprising operating a fuel cell including at least one fuel cell board, wherein the at least one fuel cell board includes a plurality of membrane electrode assemblies (MEAs), and the fuel cell board is At least one insulating layer, At least one ion-permeable membrane, It includes multiple anodes and multiple cathodes, All of the cathodes are arranged across the entire first surface of the ion-permeable membrane, and all of the anodes are arranged across the entire second surface of the ion-permeable membrane, forming the plurality of MEAs on a single fuel cell board. Each of the aforementioned MEAs is electrically connected in parallel with each, both, or all of the adjacent aforementioned MEAs. The method includes operating the fuel cell while each of the MEAs is electrically connected in parallel with each, both, or all of the adjacent MEAs. method.

21. The connection between each of the aforementioned MEAs can be individually switched between parallel and series connections. The method according to claim 20.

22. The material properties of at least one of the anode or cathode, or the size of the anode or cathode, change or are altered throughout the entire fuel cell board, and / or The material properties of at least one of the other components of the fuel cell board change or are altered throughout the entire fuel cell board. The method according to claim 20 or 21.

23. A method for controlling fuel cell voltage, comprising operating a fuel cell including segmented MEAs on a single fuel cell board, wherein the segmented MEAs are connected in parallel with each other. method.

24. The use of segmented MEAs on a single fuel cell board and the use of parallel connections between the segmented MEAs within the fuel cell.

Images