fuel cells

Abstract

This disclosure provides a fuel cell comprising at least one fuel cell substrate. Each fuel cell substrate comprises a MEA including an ion permeable membrane, an anode, and a cathode. The anode is located on a first surface of the ion permeable membrane, and the cathode is located on a second surface of the ion permeable membrane. Each fuel cell substrate comprises a first insulating layer having at least one first fluid path, and a second insulating layer having at least one second fluid path. The MEA is located between the first insulating layer and the second insulating layer such that at least one first fluid path is arranged to allow an oxidizing fluid to flow to one or more cathodes of at least one fuel cell substrate, and at least one second fluid path is arranged to allow a reducing fluid to flow to one or more anodes of at least one fuel cell substrate. The fuel cell substrate comprises at least one third fluid path for a heat exchange fluid.

Description

Technical Field

[0001] The present disclosure relates to fuel cells, the use of fuel cells, components for fuel cells, components for electrochemical devices, and methods for thermally managing fuel cells.

Background Art

[0002] Background Fuel cells (e.g., solid polymer electrolyte fuel cells) are electrochemical devices that generate electrical energy and heat from reactants or oxidants (e.g., pure oxygen or air) and fuels (e.g., hydrogen or hydrogen-containing mixtures, or hydrocarbons or hydrocarbon derivatives). Fuel cell technology is applied to stationary and mobile applications such as power plants, automobiles, and laptop computers.

[0003] Generally, a fuel cell has two electrodes, an anode and a cathode, separated by an electrolyte membrane through which ions (e.g., hydrogen ions) can pass but free electrons cannot. The catalyst on the electrodes promotes the reaction with the fuel at the anode, separating electrons and protons / cations, and promotes the reaction with the oxidant at the cathode, reducing it to water. Then, a circuit is formed between the anode and the cathode to generate an electric current and supply power to electrical equipment and the like. The reaction fluid (e.g., oxygen and reaction air) is supplied to the cathode, and the 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). A fuel cell MEA operating at a moderate load produces an output voltage of approximately 0.7V, which is often too low for many practical applications. To increase this voltage, MEAs are typically assembled in a stack as shown in Figure 1. Each MEA1 has a layer of electrolyte membrane 1a (such as a Nafion® membrane) containing an ion-permeable membrane sandwiched between two electrode layers, and anodes 2 and cathodes 3 on either side of the electrolyte membrane. Adjacent MEAs can be separated by conductive bipolar separator plates 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 plates. End plates 9 are connected to external circuits via electrical connectors 7, 8. The number of these MEAs in the fuel cell stack determines the total voltage, and the surface area of ​​each membrane electrode determines the total current. The catalyst layer adjacent to the electrode enhances the rate and efficiency of the reaction at the electrode.

[0005] Figure 2 shows an exemplary fuel cell of the prior art (see, for example, Patent Document 1), in which multiple fuel cell substrates 22 are stacked between two end plates 21 to increase voltage and power. Electrode pairs are arranged in series along both sides of a single layer of polymer electrolyte 10, such as a Nafion® membrane. Anodes 11 are located on one surface of these membranes, and cathodes 12, separated by a gap, are located on the other, opposite surface of these membranes. The anodes and cathodes of two adjacent electrode pairs may partially overlap. Through-film electrical connectors 13 connect the electrodes across the membrane in the overlapping region and can be manufactured by a homogeneous chemical vapor deposition process. A catalyst layer adjacent to the electrodes facilitates the reaction at the electrodes. Fuel 17, such as hydrogen gas, flows along the surface of the fuel cell substrate 22 supplying the anodes 11, and reactants or oxidizers 16, such as oxygen gas and air, flow along the surface of the fuel cell substrate 22 supplying the cathodes 12. One electrode at the upper edge of the fuel cell substrate and another electrode at the other edge of 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 substrate 22, while the voltage accumulates in proportion to the number of electrode pairs on the fuel cell substrate 22.

[0006] The electrically insulating spacer 20 can be incorporated into a stack between each fuel cell substrate, which has a spacer made of an electrically insulating material (such as plastic).

[0007] The size of each individual cell (surface area of ​​a pair of electrodes) determines the magnitude of the current in the fuel cell substrate. The total number of individual cells on the fuel cell substrate determines the generated voltage. The number of fuel cell substrates in the stack determines the magnitude of the total current in the fuel cell stack.

[0008] The cathodes and anodes 11 at the ends of each fuel cell substrate are connected to the respective first and second output lines via electrical connections 18 and 19. The connection between each fuel cell substrate in the stack and the second output line is controlled by a switching mechanism such as a field-effect transistor (FET) switch, which directly provides power processing and control in the cell. Each of these switches can be controlled by an individual control line.

[0009] Numerous factors determine the performance of a fuel cell. Maintaining the correct water content of the electrolyte membrane is essential for optimizing fuel cell performance. A certain level of moisture is necessary for the electrolyte membrane to function properly and efficiently conduct ionic current, preventing a decrease in fuel cell current. Moisture generated by the cell is removed or discharged by the fluid flow along the cathode. [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] International Publication No. 2012 / 117035 [Overview of the Initiative] [Problems that the invention aims to solve]

[0011] Overheating of the fuel cell stack can also cause problems and often requires cooling. This is generally achieved by supplying a cooling fluid (such as air and water) circulating within the stack. Furthermore, to maintain the reaction, a reaction fluid (such as oxygen and reaction air) must be supplied to the cathode. Fuel cells can also reach temperatures below their optimal temperature (i.e., too cold) under certain conditions, such as during startup and in low-temperature environments.

[0012] Therefore, temperature control of fuel cells and fuel cell stacks is crucial and can be a limiting or determining factor in fuel cell performance. For example, fuel cells may be below their optimal operating temperature during startup, or they may be above their optimal operating temperature during operation. Furthermore, the temperature of the fuel cell may not be constant throughout the fuel cell stack (temperature imbalance). Environmental factors may also play a role in controlling the thermal characteristics of fuel cells; for example, different thermal management is required in low-temperature and high-temperature environments.

[0013] The ability to manage or control the thermal properties of a fuel cell, such as heating or cooling, is a crucial part of its operation. Fuel cells sometimes require a rapid response to temperature changes, and improved efficiency through thermal management contributes to enhanced fuel cell performance.

[0014] Thermal control design must balance the potential for limited available space within the fuel cell with the potential for reduced efficiency and increased manufacturing costs due to complex thermal control systems such as cooling systems. The power of the fuel cell and the valuable space within the fuel cell box may be lost by utilizing heat pumps or other thermal management systems. Fuel cells often require a design that is as compact and space-efficient as possible, particularly in the stack of fuel cell substrates within the fuel cell. Reducing the size of the fuel cell and the fuel cell stack is especially advantageous.

[0015] Therefore, it is desirable to provide improved fuel cells, fuel cell stacks, fuel cell designs, fuel cell components, improved means of managing the thermal properties of fuel cells, and applications for these fuel cells, while achieving improved thermal management of fuel cells, and being cost-effective without negatively impacting fuel cell efficiency, affordability, or size. Components for other electrochemical devices also need to be improved in a similar manner. [Means for solving the problem]

[0016] overview One aspect of the present invention provides a fuel cell comprising at least one fuel cell substrate. Each fuel cell substrate or component for a fuel cell described herein may comprise a membrane electrode assembly (MEA). The MEA comprises at least one ion-permeable membrane, at least one anode, and at least one cathode. One or more anodes are located on a first surface of the ion-permeable membrane, and one or more cathodes are located on a second surface of the ion-permeable membrane, and the MEA has a first insulating layer including at least one first fluid path, and a second insulating layer including at least one second fluid path. All anodes may be located on one surface of the ion-permeable membrane, and all cathodes may be located on the other surface of the ion-permeable membrane. The MEA is located between the first and second insulating layers such that at least one first fluid path is arranged to allow an oxidizing fluid to flow to one or more cathodes of at least one fuel cell substrate, and at least one second fluid path is arranged to allow a reducing fluid to flow to one or more anodes of at least one fuel cell substrate. The fuel cell substrate further includes at least one further / third fluid path for a heat exchange fluid. The further / third fluid path for a heat exchange fluid or thermal management fluid is a path or channel located in either or both of the first and second insulating layers, or in an additional (e.g., third) insulating layer of the fuel cell substrate, capable of carrying a thermal management fluid or temperature control fluid, as described herein. This fluid path may be a “heat exchange fluid path”. This fluid can act to thermally manage or control the temperature or thermal properties of the fuel cell substrate, fuel cell, components for a fuel cell, or fuel cell stack as described herein. In this specification, “controlling” temperature means that the temperature can be increased or decreased by heat transfer in and out of the fluid / flow path.

[0017] The invention currently being described is a modular fuel cell system in which fuel cell substrates can be stacked. Because it is modular, the design of the fuel cell stack can be controlled more freely, and the size, shape, output, and voltage-current characteristics of the fuel cell can be easily customized. Each substrate can be individually switched or removed, and its capacity can be changed. Fuel cells of various designs can be easily manufactured from the same components.

[0018] The insulating layer described herein may be a printed circuit board (PCB) layer as described herein. PCB substrates containing insulating materials with copper plating on one or more of their outer surfaces, such as FR-4 epoxy resin boards, have the advantage of enabling the mass production of components at low cost. For example, multiple flow-field substrates can be manufactured simultaneously by laminating thin laminate substrates and performing routing or drilling at the same time. Individually routed substrates are then stacked. PCBs can be laminated together (as needed) or mechanically pressed or compressed to provide a robust structure that is lightweight yet has high mechanical strength and good contact between individual layers. The PCB insulating layer of the present invention may have multiple PCB layers called single insulating layers. Thus, a monolithic, lightweight, and completely sealed structure can be obtained. By using insulating materials to construct such fuel cells, it is also possible to construct fuel cells, fuel cell substrates, and components of the present invention without the mass or size penalties that may exist when using other materials such as metals. The insulating material plates described herein can be plated with a conductive material such as copper (e.g., PCB substrates), and / or conductive material can be plated or filled through holes to conduct current through or across the plate. This improves current control through the stack, as not all plates, spacers, etc., need to be conductive, as in the case where prior art bipolar plates or conductive metal components are used in prior art stacks. Conductive features, such as copper plating or conductive resin-filled through-holes, can be provided in specific areas to enable advanced control of current passing through or across the fuel cell substrate / fuel cell stack.

[0019] The designs described herein integrate the heat exchange, thermal management, or temperature-controlled fluid pathways with the fuel cell substrate itself, further improving upon similar designs previously described. Integrating the heat exchange fluid pathways into the same layer as the anode or cathode fluid pathways is a feature not previously described in the designs described herein. This reduces the number of layers in the fuel cell stack by eliminating the need for separate thermal management, heat exchange, or heat exchange plates, or cooling water spacers for cooling water, heat exchange, or thermal management airflows. Fewer layers (i.e., fewer insulating or PCB layers) reduce the overall size of the fuel cell substrate and / or the fuel cell stack without reducing the possible power output of the fuel cell stack. Fewer layers (i.e., fewer insulating or PCB layers) or thinner layers / substrates increase the power density of the fuel cell substrate and / or fuel cell stack. The designs described herein can also provide improved efficiency. The heat exchange fluid is separated from the oxidizing fluid, and these are different fluid flows.

[0020] The fuel cell of the present invention can also increase the packing density of the fuel cell substrate due to the properties of the fuel cell substrate currently described. Compressed and / or laminated fuel cell substrates as described herein form an inherent seal and do not require gaskets between different fuel cell substrates to seal the substrates together, as seen in conventional fuel cell stacks (which do not have laminated insulating material substrates). A seal is formed because heat exchange fluid channels are located on or through the body of the insulating layer used to form the fuel cell substrate, or because heat exchange plates are used between the substrates, sealing any otherwise potentially existing gaps between the fuel cell substrates. As a result, the substrates are electrically insulated in the appropriate places.

[0021] Reducing the stack size can potentially reduce the size and weight of the fuel cell, offering advantages for applications where smaller or lighter fuel cells are required.

[0022] Such flow path or fuel cell substrate designs are impossible, or far more difficult, to achieve when manufacturing fuel cell substrates from insulating materials other than PCBs, as described herein. Metal fuel cell substrates are typically stamped to create a flow field design, resulting in identical flow path designs on both sides of the metal substrate, but the flow paths on one side of the substrate are a negative image of the flow paths on the other side of the stamped metal substrate. Therefore, the design flexibility described herein, i.e., having different flow path shapes or designs on two different sides or surfaces of the same layer of material, is impossible. In particular, since the flow paths are stamped into the metal plate, it is not possible to have differences in the height of the flow paths on opposite sides of the same metal plate. Consequently, having heat exchange fluid paths as described herein (comb-shaped, or having different flow paths within the same anode or cathode substrate, or having paths formed between plates) is not possible with standard metal plate designs, and the paths must be mirrored, repeated, or complemented by each other during the stamping manufacturing process. In the designs described herein, the insulating material described herein, such as PCB material, can be routed or milled to create channels, so that channels on opposite sides of the same substrate may have different channels, for example, different channel heights. Channels on opposite sides of the same layer may be comb-like relative to each other. Channels on different sides of a layer described herein may have different depths or paths than channels on the other side of the same substrate. This is far easier and cheaper with insulating materials such as PCB described herein compared to fuel cell substrate manufacturing materials of metal or other such materials, which are not possible with such metal or other material fuel cell substrate materials.

[0023] The heat exchange fluid can flow near, adjacent to, or in contact with one or more portions of the fuel cell substrate, fuel cell, components for a fuel cell, or fuel cell stack described herein. For example, the systems and methods described herein can cause a heat exchange fluid or a thermal management fluid to flow through a flow path adjacent to or proximate to the anode of a fuel cell substrate, acting to cool those anodes. Also, the cathode can be heated or cooled. Also, it can act to manage the temperature of adjacent fuel cell substrates, for example, the anodes or cathodes of adjacent fuel cell substrates.

[0024] Thermal management, heat exchange, or temperature control acts to maintain the fuel cell substrate or stack at a constant operating temperature, operate the system in a more energy-efficient manner, extend the operating life of the system, and / or provide more efficient fuel cell operation (e.g., cause the fuel cell to operate within set parameters and not lead to overproduction or underproduction of power).

[0025] Preferably, any of the fluid channels described herein can be formed in or on an insulating layer such that the fluid channel passes through the body or a portion of the body of one or more faces of the layer. In other words, the fluid channel is formed without the routing or groove penetrating the layer. This may also involve penetrating one or more layers of insulating material that make up the insulating layer. This only penetrates the copper layer and other layers (e.g., passivation layers, e.g., passivation ink layers), but not the layers of the insulating material itself. Preferably, any of the fluid channels described herein are in or on the surface of the insulating layer. As can be seen through some of the figures herein, a fluid channel can provide a channel for fluid within a single layer, in contrast to requiring one layer to provide a channel and another layer to provide a sealing surface that seals the fluid channel. Depth-direction routing can be up to 1 mm deep. Depth-direction routing is 3 mm, 2 mm, or up to 1 mm deep. Routing with depths of approximately 3mm, 2mm, 1mm, 0.9mm, 0.8mm, 0.7mm, 0.6mm, 0.5mm, 0.4mm, 0.3mm, 0.2mm, and 0.1mm. Depth-direction routing can be between 3mm and 0.1mm, between 1mm and 0.3mm, between 0.9mm and 0.4mm, between 0.8mm and 0.4mm, etc. Depth-direction routing can be used because it can maintain the sealing of individual layers. The channels can be formed by any technique, routing, or any other technique that results in a layer having such channels, known in the art. Preferably, the depth-direction routing does not penetrate the entire layer (e.g., PCB substrate), i.e., only 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% of the layer's depth is routed through. Preferably, only 10% to 90% of the layer depth is routed through, preferably 20% to 80% of the layer depth is routed through, and preferably 50% to 75% of the layer depth is routed through. This is also called deep drilling or deep routing.Preferably, after drilling in the depth direction, at least a 0.1 mm layer remains under the routed or drilled area. Preferably, a layer between about 0.10 mm and 0.40 mm remains under the routed or drilled area after depth drilling.

[0026] Preferably, any of the fluid flow paths described herein can be formed within or on the insulating layer such that the fluid flow path is routed or grooved through the entire surface of one or more of the layers. In other words, the fluid flow path is formed by being routed over the entire length through the layer. Some flow paths have a depth greater than the insulating layer (i.e., the depth of the layer, plus additional components above or on both sides of the layer, such as copper layers or passivation layers). These can be represented as flow paths routed to the full depth. Or, those routed to 100% of the layer depth, or those drilled or routed to the full depth.

[0027] Preferably, one or more third / further heat exchange fluid paths exist only in the copper plating layer or copper layer and, if any, the passivation layer on the insulating layer. This can be one or more of the first, second, third or further / other insulating layers. Preferably, the depth routing is through other layers existing outside the insulating core material, such as the copper plating layer or copper layer and / or passivation layer, rather than through the insulating material of the insulating layer, i.e., not through a PCB core material such as FR-4.

[0028] Preferably, one or more of the flow paths described herein penetrate the entire body of the layer. Preferably, one or more of the reaction fluid paths (e.g., the first or second fluid path) are routed through the entire body of the layer.

[0029] Preferably, at least two layers of the fuel cell substrate are laminated. Preferably, when in a fuel cell stack, at least two layers of the fuel cell substrate are mechanically pressed or compressed together, preferably with a sealant.

[0030] Preferably, the second insulating layer has 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 substrate, preferably the thermal properties or temperature of at least one anode. Alternatively or additionally, the first insulating layer has at least one further or third fluid path for the heat exchange fluid, or at least one additional / fourth fluid path for the heat exchange fluid. This allows for control of the thermal properties or temperature of the fuel cell substrate, preferably the thermal properties or temperature of at least one anode of at least adjacent fuel cell substrates.

[0031] The heat exchange fluid is separated from the oxidizing fluid, and these are different fluid flows.

[0032] Preferably, the fuel cell has a plurality of fuel cell substrates. Preferably, each of the plurality of fuel cell substrates may be arranged such that the first insulating layer and one or more cathodes of each fuel cell substrate face the second insulating layer and one or more anodes of an adjacent fuel cell substrate. Each of the plurality of fuel cell substrates may be arranged such that the second insulating layer and one or more anodes of each fuel cell substrate face the first insulating layer and one or more cathodes of an adjacent fuel cell substrate.

[0033] Preferably, the first layer further comprises at least one additional fluid path or a third fluid path for the heat exchange fluid. The at least one additional fluid path / third fluid path is arranged so that the heat exchange fluid can control the thermal properties or temperature of the fuel cell substrate and / or control the thermal properties or temperature of at least one adjacent fuel cell substrate. Preferably, the heat exchange fluid can control the thermal properties or temperature of at least one anode of the adjacent fuel cell substrate.

[0034] Preferably, at least one additional / third fluid path is located on the opposite side of the insulating layer to at least one first fluid path or at least one second fluid path on the same insulating layer. Preferably, at least one additional / third fluid path is located on the opposite side of the insulating layer so that the fluid path of the at least one additional / third fluid path through the insulating layer does not overlap with the paths of other fluid paths on the same insulating layer (at least one first fluid path or at least one second fluid path, whichever is located on the layer having the third path, or both if both layers have heat exchange fluid paths). Because at least one additional / third fluid path is located on the opposite side of the insulating layer, the fluid path of the at least one additional / third fluid path through the insulating layer does not overlap with the paths of at least one first fluid path or at least one second fluid path on the same insulating layer.

[0035] Preferably, there is no overlap of fluid paths, and fluid paths do not cross each other. These fluid paths never come into contact with each other and never cross paths. Alternatively, each path may never cross a layer in the space above (vertically) of another flow path, or a path passing through a body in the insulating layer may never cross a body. The path of at least one further / third fluid path does not intersect with the path of any other fluid path on the same layer. The surface area of ​​the insulating layer covered by at least one further / third fluid path is different from the surface area of ​​the insulating layer covered by any other fluid path on the opposite side of the insulating layer (the path of the first or second fluid path).

[0036] Preferably, if there are further / third fluid paths on the first insulating layer, the sum of the depths of i) at least one first fluid path and ii) further / third fluid paths is greater than or equal to the thickness of the first insulating layer. Preferably, if there are further / third fluid paths on the second insulating layer, the sum of the depths of i) at least one second fluid path and ii) further / third fluid paths is greater than or equal to the thickness of the second insulating layer. Both of these can occur if both the first and second insulating layers have third / further fluid paths for the heat exchange fluid. This is sometimes referred to herein as a comb-like structure of flow channels. The flow channels run adjacent to each other but never touch or intersect. This is preferred when the flow channels are on opposite faces of the same insulating layer. The thickness of the layer is the distance between two faces of the layer having at least two channels.

[0037] If there are multiple fluid channels, preferably, the sum of the depths of i) at least one of the first fluid channels or at least one of the second fluid channels and ii) one of the further / third fluid channels is equal to or greater than the thickness of either the first or second insulating layer that constitutes the further / third fluid channel. Alternatively, it may be the average value of the fluid channel depths, not limited to either one.

[0038] Preferably, the fluid channels do not intersect or overlap with an axis (or one or more axes) defined by the top or bottom of another channel on / inside the same insulating substrate, located on the opposite side of the same insulating substrate, and this axis is parallel to the two surfaces of the insulating substrate where these two or more channels are found. These channels are considered to be integrated within the same substrate, but not comb-shaped relative to each other.

[0039] Preferably, the fluid channels are on the same insulating substrate but do not intersect or overlap with axes defined by the vertical edges of other channels on the opposite side of the same insulating substrate, and these axes are perpendicular to axes parallel to two faces of the insulating substrate where these two or more channels are found. These channels are considered to be integrated on the same substrate and may be comb-shaped relative to each other. If they are comb-shaped relative to each other, the fluid channels may intersect or overlap with a second axis defined by the upper or lower part of another channel on the same insulating substrate on the opposite side of the same insulating substrate, and this second axis is parallel to two faces of the insulating substrate where these two or more channels are found. These channels are considered to be integrated on the same substrate and are comb-shaped relative to each other.

[0040] If the sum of the depths of the flow channels is greater than the thickness of the layer, the bottom or depth of the first fluid path is lower or less than the height or top of the second fluid path (through the body of the insulating layer), or the height or top of the second fluid path is higher or greater than the bottom or depth of the first fluid path. If there are multiple flow channels, preferably the bottom or depth of one of the first flow channels is lower or less than the height or top of one of the second flow channels (through the body of the insulating layer), or the height or top of one of the second flow channels is higher or greater than the bottom or depth of one of the first flow channels. Alternatively, it may be the average value of the depths of the fluid flow channels.

[0041] Preferably, the depth of the (at least one) further / third fluid path is less than or equal to the thickness of either the first or second insulating layer containing the further / third fluid path. Preferably, if the first insulating layer contains at least one further / third fluid path, the depth of at least one first fluid path is also greater than the thickness of the first insulating layer. Furthermore, or alternatively, if the second insulating layer contains at least one further / third fluid path, the depth of at least one second fluid path may also be greater than or equal to the thickness of the first insulating layer. Here, one or more fluid paths penetrate the body of the insulating layer. This means that the fluid channels / flow paths / channels are open to both faces or surfaces of the insulating layer. As described herein, additional layers of insulating material or additional insulating layers can be added to seal or cap one or more of these flow paths.

[0042] Preferably, the first insulating layer includes a copper layer on the side opposite to the cathode-facing side of the first insulating layer. Preferably, the first insulating layer may also include a passivation layer on the copper layer. At least one third fluid path may be in the copper and / or in the passivation layer on the first insulating layer. Preferably, the second insulating layer has a copper layer on the side opposite to the anode-facing side of the second insulating layer. Preferably, the second insulating layer also has a passivation layer on the copper layer. At least one third fluid path may be in the copper and / or in the passivation layer on the second insulating layer. Preferably, the fuel cell substrate has a plurality of fuel cell substrates, and at least two of the plurality of fuel cell substrates are arranged such that at least one heat exchange fluid path is formed between the two fuel cell substrates when adjacent substrates are aligned with each other. At least one third fluid path in the copper and / or passivation layer on the insulating layer of one fuel cell substrate and at least one third fluid path in the copper and / or passivation layer on the insulating layer of another adjacent fuel cell substrate are aligned with each other to form at least one heat exchange fluid path between the two adjacent fuel cell substrates (a combined heat exchange fluid path between the two fuel cell substrates). Where observed in the copper / passivation layer, the flow path may be open when viewed separately as a single layer.

[0043] The fluid pathways formed between two fuel cell substrates are sometimes called negative space pathways, and the heat exchange pathways are formed in the negative space between two or more fuel cell substrates. Because the pathways are formed in the copper (and passivation layer, if any) layer between the two substrates rather than in the core layer itself, space can be saved compared to other arrangements. As a result, the overall layer of fuel cell substrates can be thinner. Adjacent fuel cell substrates can be aligned so that the heat exchange fluid pathways are aligned and form combined / joined heat exchange fluid pathways.

[0044] Preferably, the fuel cell substrate has at least one third / further insulating layer. If the first insulating layer has at least one third / further fluid path, the third / further insulating layer can be positioned on or adjacent to the surface of the first insulating layer having the third / further fluid path so as to seal at least one further / third fluid path. Preferably, the depth of the first fluid path is greater than or equal to the thickness of the first insulating layer, and the third insulating layer also seals the side of at least one of the first fluid paths that is not adjacent to the cathode. If the second insulating layer has a third / further fluid path, the third / further insulating layer can be positioned on or adjacent to the surface of the second insulating layer having the third / further fluid path so as to seal at least one further / third fluid path. Preferably, the depth of the second fluid path is greater than or equal to the thickness of the second insulating layer, and the third insulating layer can also seal the side of at least one of the second fluid paths that is not adjacent to the anode.

[0045] Preferably, when the depth of the first fluid path is greater than or equal to the thickness of the first insulating layer, or when the depth of the second fluid path is greater than or equal to the thickness of the second insulating layer, the third insulating layer seals the side of the first fluid path that does not face the cathode and / or the side of the second fluid path that does not face the anode.

[0046] Preferably, when the depth of the first fluid path is greater than or equal to the thickness of the first insulating layer, or when the depth of the second fluid path is greater than or equal to the thickness of the second insulating layer, the third insulating layer seals the side of the first fluid path not facing the cathode, or the side of the second fluid path not facing the anode, and a further / fourth insulating layer seals the side of the first fluid path not facing the cathode, or the side of the second fluid path not facing the anode. Here, there are two or more capping layers for each fuel cell substrate to seal both sides of the fuel cell substrate so that the first and second fluid paths are sealed or capped.

[0047] Preferably, if the third and / or fourth insulating layer seals the first and / or second fluid pathways, the third and / or fourth insulating layer may have a copper layer on the side opposite to the side of the third or fourth insulating layer that seals the first and / or second fluid pathways. Alternatively, the third and / or fourth insulating layer may have a passivation layer on the copper layer. Preferably, at least one third fluid pathway is located within this passivation layer on the copper and / or first insulating layer. Preferably, the fuel cell has a plurality of fuel cell substrates, and at least two of the plurality of fuel cell substrates are arranged such that at least one heat exchange fluid path is formed between two adjacent fuel cell substrates when aligned with each other, where at least one third fluid path formed in the copper and / or passivation layer of the third or fourth insulating layer of one fuel cell substrate and at least one third fluid path formed in the copper and / or passivation layer of the third or fourth insulating layer of another adjacent fuel cell substrate are aligned with each other so as to form a combined heat exchange fluid path between the two fuel cell substrates. Preferably, if the third insulating layer and / or further / fourth insulating layer has at least one third fluid path for the heat exchange fluid, the depth of the at least one third fluid path for the heat exchange fluid may be greater than or equal to the thickness of the third insulating layer and / or fourth insulating layer. Adjacent fuel cell substrates can be aligned so that the heat exchange fluid paths are aligned and form a coupled / jointed heat exchange fluid path.

[0048] Preferably, both the first and second insulating layers have further insulating layers (third and fourth insulating layers) that cap / seal the first and second fluid paths, and the first and second fluid paths are thicker than or equal to the thickness of the first and second insulating layers. Preferably, both the third and fourth insulating layers have heat exchange fluid paths (third and fourth fluid paths). Preferably, each heat exchange fluid path in the third and fourth insulating layers is thicker than or equal to the thickness of the respective insulating layer. Alternatively, preferably, the heat exchange fluid paths are formed in the copper layers (and optionally the passivation layer) of the third and fourth insulating layers. If these substrates are adjacent to other fuel cell substrates in which heat exchange fluid paths are formed in the copper / passivation layer, the adjacent substrates can be aligned with each other to form a combined heat exchange fluid path between the two fuel cell substrates.

[0049] The negative space fluid path is as described above. By combining this with first and / or second flow paths that penetrate the entire body of the first and / or second insulating layer, these embodiments offer further space-saving advantages. As a result, the first and second layers can be made thinner, the heat exchange path can be placed in the negative space between fuel cell substrates, and a more space-efficient fuel cell stack can be realized.

[0050] The third / further insulating layer can be thinner than the first / second insulating layer. This third / further insulating layer may be referred to as a capping layer. It functions to "cap" or seal adjacent fluid pathways. Here, it is adjacent to at least one further / third fluid pathway, or to the first or second fluid pathway, and acts to seal this pathway. Preferably, the third / further insulating layer is laminated onto the fuel cell substrate or mechanically compressed within the fuel cell stack. One or more fluid pathways sealed by this further / third insulating layer are sealed so that the fluid flowing through these pathways flows only along the intended pathway and not elsewhere. In any of the embodiments described herein, the third layer may be referred to as a capping layer.

[0051] Preferably, at least one third / further insulating layer is positioned on or over one or more third / further fluid paths to cover, cap, or seal one or more third / further fluid paths. Preferably, at least one third / further insulating layer is positioned on multiple third / further fluid paths to cover multiple third / further fluid paths.

[0052] Preferably, the fuel cell substrate may have multiple third / further insulating layers adjacent to and capping or sealing multiple fluid channels of the fuel cell substrate. These may preferably all be third / further fluid channels for heat exchange fluid, but may also cover other fluid channels.

[0053] Preferably, one or more third / further insulating layers are substantially the same size as or appropriately sized (i.e., width, dimensions) as the first or second insulating layer, so as to cover substantially all of the first or second insulating layer. Preferably, one or more third / further insulating layers are substantially the same size as the area of ​​the first or second insulating layer having one or more third / further fluid passages, so as to cover all of the third / further fluid passages.

[0054] Preferably, at least one of the first fluid channel, the second fluid channel, or the third / further fluid channel is substantially linear. Preferably, at least one of the first fluid channel, the second fluid channel, or the third / further fluid channel is meandering.

[0055] Preferably, the fuel cell substrate comprises 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 substrate comprises at least one of a plurality of substantially linear and substantially parallel first fluid paths, a plurality of substantially linear and substantially parallel second fluid paths, and / or a plurality of substantially linear and substantially parallel third / further fluid paths.

[0056] Preferably, one of the first, second, third, fourth, or further fluid paths may open to one or both sides of the insulating layer. Preferably, one of the first, second, third, fourth, or further fluid paths may be uncovered or an open channel.

[0057] Preferably, at least one further / third fluid path has a different flow path pattern or flow field 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.

[0058] Preferably, one of the multiple first fluid paths and / or multiple second fluid paths and / or multiple third / further fluid paths may be more numerous than the other fluid paths, for example, more third / further fluid paths than first fluid paths.

[0059] Preferably, one or more insulating layers have one or more PCB substrates. Preferably, one or more PCB substrates have an FR-4 layer, also known as FR-4 epoxy resin, polyimide, and / or other polymeric material. The PCB substrates contain an insulating material such as FR-4 epoxy resin and have one or more outer surfaces plated with copper or a conductive material. Preferably, one or more insulating layers have at least some conductive material (e.g., copper, at least partially coated with copper) on at least a portion of one face or surface of the insulating layer, i.e., on a layer of copper, or have at least some conductive material (coated, laminated, or plated) on at least a portion of both faces or surfaces of the insulating layer. Preferably, the faces or surfaces that are at least partially covered or plated with the conductive material are the same faces or surfaces of the insulating layer including the first, second, or third / further fluid channels described herein. Preferably, the surfaces or faces that are at least partially covered or plated with the conductive material are the same surfaces or faces of an insulating layer (one or more) adjacent to the anode or cathode, and the conductive material can act to conduct current to or from the anode and / or cathode. Preferably, the conductive material may also act to conduct or deduct current to conductive through-holes that may be formed through the body of the insulating layer (one or more), for example, through-holes plated with the conductive material or through-holes filled with the conductive material. At least some of the conductive material may also act to conduct or deduct current to adjacent fuel cell substrates or other components of the fuel cell. Preferably, there are multiple layers of insulating material, for example multiple PCB substrate layers, to form a single layer, and optionally, one or more of the outer layers of these multiple layers contain the conductive material.

[0060] Preferably, at least one of the first insulating layer, the second insulating layer, and / or the third / further insulating layer comprises one or more means for conducting current from one surface or face of the insulating layer to the opposite surface or face of the other (first, second, and / or third / further) insulating layer. Preferably, the means for conducting current is a plated through-hole. Preferably, the plated through-hole is a copper-plated through-hole. Preferably, the surfaces or faces of the insulating layers constituting these means also have the first, second, or third / further fluid passages described herein. Preferably, one or more means for conducting current from one surface or face of the insulating layer to the other surface or face of the (first, second, and / or third / further) insulating layer are on the same surface or face of an insulating material layer (one or more) adjacent to the anode or cathode, and the means (e.g., a copper-plated through-hole) can act to conduct current to or away from the anode and / or cathode. Preferably, the means can conduct current to and from the copper plating on the insulating layer, and this copper plating can also act to conduct current to and from the anode and / or cathode, or away from the anode and / or cathode. The current-conducting means described herein may also act to conduct current to or from adjacent fuel cell substrates or other components of the fuel cell.

[0061] Preferably, the heat exchange fluid contains water or a mixture of water and glycol, and preferably the water is deionized water. Depending on the application, the water may or may not be deionized water. Preferably, the heat exchange fluid is a fluid in which the ratio of (deionized) water to glycol (such as ethylene glycol or propylene glycol) is 1:1, or the ratio of deionized water to glycol is 2:1, or the ratio of deionized water to glycol is 3:1, or the ratio of deionized water to glycol is 4:1, or the ratio of deionized water to glycol is 5:1. The heat exchange fluid can contain up to 10% glycol in (deionized) water, or up to 1% glycol in deionized water, or up to 2% glycol in deionized water, or up to 5% glycol in deionized water, or up to 10% glycol in deionized water, or up to 20% glycol in deionized water, or up to 30% glycol in deionized water, or up to 40% glycol in deionized water, or up to 50% glycol in deionized water. The heat exchange fluid may be a mixture of deionized water and another type of alcohol (e.g., methanol, ethanol, isopropyl alcohol). The solution may contain up to 10% alcohol in deionized water, or up to 1% alcohol in deionized water, or up to 2% alcohol in deionized water, or up to 5% alcohol in deionized water, or up to 10% alcohol in deionized water, or up to 20% alcohol in deionized water, or up to 30% alcohol in deionized water, or up to 40% alcohol in deionized water, or up to 50% alcohol in deionized water. The coolant may also contain one or more perfluoroamines, such as Fluorinert. Throughout this text, water referred to as deionized water may also include non-deionized water, and vice versa.

[0062] Preferably, the fuel cell includes a heat exchange fluid in at least a third fluid path. The heat exchange fluid may be present in the fuel cell as described herein, and preferably in one or more third fluid paths for the heat exchange fluid.

[0063] Preferably, each fuel cell substrate comprises multiple anodes and multiple cathodes, the anodes and cathodes arranged opposite each other across an ion-permeable membrane. Preferably, in a single fuel cell substrate, all anodes are on the same side of the ion-permeable membrane and all cathodes are on the opposite side of the same ion-permeable membrane. Preferably, each fuel cell substrate includes only one anode and / or each fuel cell substrate includes only one cathode.

[0064] Preferably, the fuel cell further comprises means for controlling the temperature of at least one fuel cell substrate or adjacent fuel cell substrates. The means for controlling the temperature of at least one fuel cell substrate has at least one further insulating layer, which has at least one further / fourth fluid path for heat exchange fluid. This at least one further insulating layer is located between the first insulating layer of the fuel cell substrate and the second insulating layer of the adjacent fuel cell substrate. This at least one further insulating layer comprises means for conducting current from one side of the at least one further insulating layer to the other side of the at least one further insulating layer. This allows it to function as a bipolar plate. This allows electrical contact between the anode and cathode of adjacent fuel cell substrates, as described herein. The heat exchange insulating layer can be laminated on the first or second insulating layer of the fuel cell substrate. Preferably, this further means is laminated adjacent to the second insulating layer, i.e., on the anode side of the MEA. By laminating further means onto the fuel cell substrate, the energy density can be increased because, in contrast to the multilayer or thick means described earlier, only one additional layer may be present. Furthermore, by sealing the further means plate onto the fuel cell substrate, the assembly of the fuel cell stack is simplified because there are fewer components and fewer non-integrated seals into the stack. Preferably, this further / fourth fluid path carries a cooling fluid for cooling the fuel cell substrate or adjacent fuel cell substrates. Preferably, this heat exchange fluid is identical to the heat exchange fluid of the third / further fluid path located within / on the first insulating layer and / or within / on the second insulating layer. Preferably, this heat exchange fluid is different from the heat exchange fluid of the third / further fluid path located within / on the first insulating layer and / or within / on the second insulating layer. Further means for controlling the temperature of the at least one fuel cell substrate or adjacent fuel cell substrates may be present if neither the first insulating layer nor the second insulating layer has at least one further / third fluid path for the heat exchange fluid (i.e., there is no at least one further / third fluid path for the heat exchange fluid).Preferably, further means for controlling the temperature of at least one fuel cell substrate comprises a second further insulating layer, the second layer sealing or capping the flow paths of further / fourth fluid paths (acting as described in other embodiments herein). The first insulating layer constituting the further means for controlling the temperature of this at least one fuel cell substrate or adjacent fuel cell substrates may be thicker than the second further insulating layer, or the second further insulating layer may be thinner than the first insulating layer having the further means for controlling the temperature of this at least one fuel cell substrate or adjacent fuel cell substrates. The further means for controlling the temperature of this at least one fuel cell substrate or adjacent fuel cell substrates may have multiple fluid paths for heat exchange fluid of different sizes, shapes and / or dimensions, different fluid types, or fluids of different flow rates or different fluid temperatures. The fluid may be at different temperatures or different flow rates in different plates, or at different temperatures or different flow rates in different paths within the same plate. This can address the varying coolant needs throughout the fuel cell. Preferably, if a single fuel cell stack has multiple further means for controlling the temperature of at least one fuel cell substrate or adjacent fuel cell substrates, each further means for controlling the temperature of at least one fuel cell substrate or adjacent fuel cell substrates may have different fluid paths, fluid paths of different sizes, shapes, or dimensions, or be designed to carry different fluids, or fluids of different temperatures, or fluids of different flow rates. This can accommodate the changing coolant needs throughout the fuel cell. Further / fourth fluid paths can be routed or depth-routed into the insulating layer of this plate.

[0065] Fuel cell stacks having such additional heat exchange layers are advantageous because they do not need to be open to the input of cooling air, as described in prior art systems, and are completely sealed from the atmosphere. While integrating the heat exchange fluid path within the first or second insulating layer, as described herein, is more space-efficient, utilizing these additional heat exchange layers allows for increased power density compared to prior art stacks, and therefore increases power density and reactant distribution on the electrodes, because there are no non-functional spacer elements and the ability to supply reaction gases at higher pressures.

[0066] Preferably, the surface of the first insulating layer adjacent to the cathode of the fuel cell substrate is a surface having at least one first fluid flow path or channel, allowing the oxidizing fluid to flow or diffuse to one or more cathodes (all cathodes) of the MEA. This may be via a gas diffusion layer.

[0067] Preferably, the surface of the second insulating layer adjacent to the anode of the fuel cell substrate is a surface or surface having at least one second fluid channel or flow path, so that the reducing agent fluid can flow to or diffuse to one or more anodes (all anodes) of the MEA. This may be via a gas diffusion layer.

[0068] Preferably, the membrane electrode assembly (MEA) further comprises at least one gas diffusion layer. One or more gas diffusion layers are located between at least one cathode or all cathodes, a first insulating layer, and at least one or all of the first fluid paths. One or more gas diffusion layers are located between at least one anode or all anodes, a second insulating layer, and at least one or all of the second fluid paths. The MEA may have multiple gas diffusion layers as described herein.

[0069] Preferably, one or more layers described herein are laminated. Preferably, if one or more layers described herein are in a fuel cell stack, they may be mechanically pressed or compressed together. This lamination or compression may be achieved or assisted by chemical bonding by heating the prepreg layers between insulating layers under pressure and elevated temperature, as described herein, or by the use of a sealant.

[0070] The use of epoxy resin prepregs also maintains the compression of the gas diffusion layer in the MEA. This is a crucial factor in maintaining fuel cell performance, as it provides an electrical path with sufficiently low resistance without compromising the distribution of the reaction fluid.

[0071] Preferably, an oxidizing fluid, a reducing fluid, and / or one or more heat exchange fluids enter and exit the relevant fluid path described herein via inlets and outlets. These inlets and outlets can connect the fluid path to a manifold that supplies the relevant fluids to the fluid path. These manifolds are described herein, but may also be openings in an insulating layer.

[0072] Preferably, each fuel cell substrate described in any aspect of the present invention as described herein is connected to an electronic circuit that generates an electrical output, and the connection between each fuel cell substrate and the electronic circuit is individually switchable. Preferably, the connection between each fuel cell substrate and the output line of the fuel cell can be controlled by a switching mechanism such as a field-effect transistor (FET) switch, providing direct power processing and control at the cell. Each of these switches can be controlled by an individual control line. This is possible by providing a switch on each fuel cell substrate.

[0073] Preferably, the oxidizing fluid described in any embodiment of the present invention as described herein is air, and / or the reducing fluid is hydrogen gas.

[0074] Preferably, each fuel cell substrate may have a rated power of at least 10W. Preferably, each fuel cell substrate may have a rated power of up to 1000W. Preferably, each fuel cell substrate has a rated power of 10W to 1000W. Preferably, a fuel cell having multiple fuel cell substrates has a rated power of at least 10kW. Preferably, a fuel cell having multiple fuel cell substrates has a rated power of up to 1000kW. Preferably, each fuel cell in a fuel cell having multiple fuel cell substrates has a rated power of 10kW to 1000kW.

[0075] Preferably, at least one fuel cell substrate may include at least one electrical connector configured to connect at least one anode to at least one cathode via at least one ion-permeable membrane. By connecting the anode and cathode with the electrical connector via the ion-permeable membrane, current can be passed in a direction along the plane of the membrane. Preferably, at least one through-membrane electrical connector can connect electrodes across the membrane in a region where the anode and cathode overlap at least partially, and at least one through-membrane electrical connector can be manufactured, for example, by a homogeneous chemical vapor deposition process.

[0076] One aspect of the present invention is a component for an electrochemical device. This component may include any of the features described herein relating to an insulating layer for a fuel cell substrate, which are interchangeable. The insulating layer may have 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 referred to as the first insulating layer.

[0077] This is a component for electrochemical apparatuses where controlling the flow of fluid is crucial, and in such apparatuses, utilizing the flow of heat-exchange fluid is advantageous. For example, it is for fuel cells as described herein. Alternatively, electrolytic devices or other electrochemical apparatuses are also possible.

[0078] Preferably, the second fluid path is located on the opposite side of the insulating layer, such that at least one fluid path passing through the insulating layer of the second path does not overlap with the first fluid path. Because there is no overlap of fluid paths, the fluid paths do not cross each other. Fluid paths may never cross in the sense that they never come into contact. Alternatively, paths passing through the body of the insulating layer may never cross, such that each path does not traverse the layer in the space above (vertically) the other flow path. The path of at least one further / third fluid path does not intersect with the path of any other fluid path on the same insulating layer. The surface area of ​​the surface of the insulating layer covered by at least one further / third fluid path is different from the surface area of ​​the surface of the insulating layer covered by any other fluid path on the opposite side of the insulating layer (the path of the first or second fluid path).

[0079] Preferably, the sum of the depths of at least one first fluid path and a second fluid path may be greater than or equal to the thickness of the first insulating layer. This is sometimes called a comb-shaped flow path. The flow paths run adjacent to each other but never touch or intersect. The thickness of the layer is the distance between two faces of the layer in which at least two channels exist. If there are multiple flow paths, the thickness may be the average of the depths of the fluid flow paths, rather than just one of them.

[0080] Preferably, the insulating layer has a copper layer on the opposite side of the first fluid channel of the first insulating layer. The insulating layer may also have a passivation layer on the copper layer. The second fluid channel may be in the copper and / or in the passivation layer on the insulating layer. If it is in the copper / passivation layer, this heat exchange fluid channel may be open when viewed separately as a substrate.

[0081] Preferably, the component has a second insulating layer, which is positioned on or adjacent to the surface of the first initial insulating layer constituting the second fluid passage, so as to seal the second fluid passage. The second insulating layer may be thinner than the first insulating layer. This second insulating layer acts to "cap" or seal adjacent passages, here adjacent to at least one second fluid passage, and acting to seal this passage. Preferably, the second fluid passage is within the second insulating layer, rather than within the first insulating layer. Preferably, the depth of the second fluid passage is greater than or equal to the thickness of the second insulating layer. Preferably, the second insulating layer is laminated onto the fuel cell substrate. One or more fluid passages sealed by this further / third insulating layer are sealed so that the fluid flowing through these passages flows only along / through the intended path and not anywhere else.

[0082] Preferably, the depth of the first fluid path is greater than or equal to the thickness of the insulating layer, and the second insulating layer seals one side of the first fluid path. Preferably, the second insulating layer may have a passivation layer on the copper layer. The second fluid path is located within the copper and / or within the passivation layer on the second insulating layer, and not within or part of the first insulating layer / insulating core material.

[0083] Preferably, one or more insulating layers may have a PCB layer, as described in the first embodiment above.

[0084] Preferably, one or more fluid channels are formed in or on an insulating layer such that the fluid channels pass through the body or a portion of the body of one or more faces of the layer. In other words, the fluid channels are formed without routing or grooves penetrating the layer. As can be seen throughout the figures of this specification, the fluid channels or paths provide a channel for fluid within a single layer, in contrast to requiring one layer to provide a channel and another layer to provide a sealing surface to seal the fluid channel, as may be required in the arrangement of the art. Routing to depth is as described in the first embodiment of the present invention.

[0085] Preferably, one or more channels described herein are routed through the entire body of the layer.

[0086] Preferably, the layers are laminated together. Preferably, the layers are mechanically pressed or compressed together.

[0087] 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 or the second fluid path is meandering. Preferably, the fuel cell substrate comprises a plurality of first fluid paths and / or a plurality of second fluid paths. Preferably, the fuel cell substrate comprises at least one of a plurality of substantially linear and substantially parallel first fluid paths and / or a plurality of substantially linear and substantially parallel second fluid paths. Preferably, at least one second fluid path has a flow path different from at least one first fluid path. One of the paths may be substantially linear and the other may be meandering. Preferably, one of the plurality of first fluid paths and / or a plurality of second fluid paths may have more second fluid paths than the other fluid path, for example, more second fluid paths than first fluid paths.

[0088] Preferably, the fluid path is routed within the insulating layer. The fluid path can be routed within the insulating layer before copper plating is applied to at least one portion of the insulating layer.

[0089] Preferably, the heat exchange fluid has the composition described in the first embodiment.

[0090] One aspect of the present invention provides the use of any fuel cell described herein.

[0091] In aspects of the present invention, a method is provided for using any fuel cell, fuel cell component, or component for an electrochemical device as described herein.

[0092] In one aspect of the present invention, a method for thermally managing a fuel cell is provided. This method includes managing the thermal properties of a fuel cell or transferring heat to the vicinity of a fuel cell using components or fuel cell substrates described herein, in which a heat exchange fluid described herein is present. [Brief explanation of the drawing]

[0093] Next, embodiments of the present disclosure will be described with reference to the accompanying drawings. [Figure 1] Figure 1 is a schematic side view of a conventional stacked fuel cell. [Figure 2] Figure 2 shows a cross-section of a prior art fuel cell equipped with a stack of fuel cell substrates. [Figure 3A] Figure 3A shows an enlarged embodiment of the fuel cell substrate of the present invention. [Figure 3B] Figure 3B shows an alternative diagram of an enlarged embodiment of the same fuel cell substrate of the present invention. [Figure 4A] Figure 4A shows an enlarged embodiment of the fuel cell substrate of the present invention. [Figure 4B] Figure 4B shows an alternative diagram of an enlarged embodiment of the same fuel cell substrate of the present invention. [Figure 5A] Figure 5A shows one side of the cathode plate. [Figure 5B] Figure 5B shows the other side of the same cathode plate. [Figure 6A] Figure 6A shows one side of the anode plate. [Figure 6B] Figure 6B shows the other side of the same anode plate. [Figure 7] Figure 7 shows the cap layer. [Figure 8] Figure 8 shows the MEA layer. [Figure 9A] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 9B] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 9C] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 9D] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 10] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 11] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 12] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 13] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 14A] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 14B] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 15] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 16] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 17] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 18] This is a schematic diagram illustrating how fluid paths or channels may exist in the layers / plates described herein. [Figure 19A] Figure 19A shows one side of the heat exchange plate. [Figure 19B] Figure 19B shows one of the two layers that make up the heat exchange plate. [Figure 19C] Figure 19C shows the side profile of the heat exchange plate. [Figure 20] Figure 20 is a schematic diagram of a fuel cell stack according to one embodiment. [Figure 21] Figure 21 shows a simplified schematic diagram of a fuel cell substrate layer in one embodiment. [Figure 22] Figure 22 shows a fuel cell according to one embodiment. [Modes for carrying out the invention]

[0094] Detailed explanation The embodiments will be described in detail below with reference to the accompanying drawings. The same reference numerals indicate identical or similar features in different figures and embodiments of the present invention; however, these are for reference only and do not limit the invention. The following detailed description provides several specific details as examples to fully understand the relevant teachings. However, it will be apparent to those skilled in the art that these teachings can be carried out without these specific details.

[0095] Figure 3A is a schematic diagram showing an enlarged example of a fuel cell substrate 200 in one embodiment. The fuel cell substrate 200 is shown enlarged for the purposes of this figure to show a membrane electrode assembly (MEA) layer 103 having a MEA 113 separated from a cathode plate 101, an anode plate 102, and a cap layer 150. The cathode plate may be a first insulating layer as described herein. The anode plate may be a second insulating layer as described herein.

[0096] As will be described in more detail herein, here there is a single MEA 113. This MEA 113 has an ion-permeable membrane, an anode / anode layer, and a cathode / cathode layer. The cathode layer is on the side of the MEA layer 103 adjacent to the cathode plate 101, and the anode layer is on the side of the MEA layer 103 adjacent to the anode plate 102. Here there is only a single cathode and a single anode on both sides of the ion-permeable membrane. In this embodiment, the MEA 113 is laminated between the cathode plate 101 and the anode plate 102, but is shown separated / enlarged in this figure only to show its presence. The lamination process will be described later. The MEA layer 103 has a sealing / laminating material such as a prepreg that appears as part of the MEA layer 103 as a region that is not part of the MEA 113. 113 represents an MEA which may include a gas diffusion layer. The ion-permeable membrane extends a short distance beyond this region (approximately 0.2 mm to the edge of the module) to form a seal with the prepreg. The ion-permeable membrane is sandwiched between the prepreg in this portion.

[0097] This shows one embodiment of an MEA suitable for use in the embodiments described herein. Other MEA designs, shapes, and orientations are known to those skilled in the art and will be understood to be suitable for this embodiment.

[0098] 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 as described herein. In the fuel cell substrate 200, the cathode plate 101 and anode plate 102 are laminated with a cap layer 150 together with an MEA 113, which is an MEA between the cathode plate 101 and the anode plate 102, to form the fuel cell substrate 200. In Figure 3A, the inner surface 102a of the anode plate 102 is visible. Both inner surfaces (101a and 102a, respectively) of the cathode plate 101 and anode plate 102 are copper-plated and routed in the design of flow fields 111, 112, and passivation inkscreens are printed on the surfaces of the flow fields 111, 112 (inner surfaces 101a, 102a of both plates 101, 102) to prevent degradation. Flow fields 112 are visible on the inner surface 102a and the anode plate in Figure 3A (flow field 111 is visible on the inner surface 101a of the cathode plate 101 in Figure 3B, but is not visible in Figure 3A). In Figure 3A, two flow field paths 112 of several visible parallel flow channels are labeled. Multiple single flow fields 111, 112 constitute a “flow field” for each plate, and flow fields may be referred to singularly or plurally throughout. Flow fields 111, 112 are shown as parallel flow channels traversing each layer from one side of each layer to the other side of plates 101, 102. Flow field 111 on the cathode plate 101 may be a first fluid path as described herein, and flow field 112 on the anode plate 102 may be a second fluid path as described herein.

[0099] Figure 3A shows the cap layer 150. The inner surface 150a of the cap layer 150 is shown, which, when laminated with the other layers shown, is adjacent to the surface 102b of the anode substrate 102. The cap layer 150 has a labeled cathode manifold 105, a heat exchange fluid manifold 107, and an anode manifold 109. The cap layer 150 also shows a plurality of 18 rows of plated (unlabeled) through-holes. The cap layer 150 may be a third / further insulating layer as described herein.

[0100] In the specific embodiments shown in Figures 3A and 3B, and generally in all embodiments, flow fields are routed to the PCB to provide pathways for the reactants (e.g., air, hydrogen) to be supplied to the cathodes and anodes. The oxidizing fluid flows to all or only one or more cathodes of each fuel cell substrate, and the reducing fluid flows to all or only one or more anodes of each fuel cell substrate. In this specification, “oxidizing fluid” refers to the fluid that reacts at the cathode (e.g., an oxidizing agent such as air or oxygen). “Reducing fluid” refers to the fluid that reacts at the anode (e.g., a reducing agent such as hydrogen). The MEA113 is positioned between an anode plate (first insulating layer) 102 and a cathode plate (second insulating layer) 101, with at least one first fluid path 111 in the cathode plate 101 arranged so that an oxidizing fluid can flow to all cathodes of the MEA113, and the anode plate 102 arranged so that at least one second fluid path 112 can flow to all anodes of the MEA113.

[0101] The terms “fluid path,” “fluid channel,” “flow path,” “fluid flow path,” “fluid path,” “flow field,” and “channel” may all be used interchangeably and may be substituted for each other herein. All of these refer to means by which a fluid can flow or move along, under, or through. The fluid may be substantially guided along a fluid flow path, fluid channel, etc., with or without assistance.

[0102] The flow paths are channels routed in the PCB. In this embodiment, the fluid paths are shown not to be routed through the entire body or volume of the substrate, but in other embodiments, they may run through the entire layer. Here, there may be paths or holes penetrating the substrate at the inlet or outlet end to allow the flow. This arrangement allows for effective separation of reactants for the anode and cathode. When the substrates are stacked together or mechanically compressed, flow fields (anode flow field on the anode, cathode flow field on the cathode) are positioned over the relevant portions of the MEA 113 to supply the relevant reactants directly to the anode and cathode. The pressure of the supplied reactant fluid ensures the reaction at the anode and cathode. The reactants enter one side or corner of the plate and exit through the opposite side or corner of the plate. Face 101b of the cathode plate 101 shows the flow field that passes through the substrate body to the cathode manifold 105. The flow field 111 is connected to these paths and is also visible on the other (not shown) surface (101a) of the cathode plate 101. Eighteen rows of plated (unlabeled) through-holes are also visible on this surface 101b of the cathode plate 101.

[0103] Various channel / fluid path / flow field patterns on the plate and inlets and outlets to the plate will be known to those skilled in the art. For example, the channels (such as those shown parallel to each other in Figures 3 and 4, and in subsequent embodiments) may be meandering, circular, or linear and substantially straight across the plate. The flow field may enter and exit at the same edge of the plate, or at opposite sides or corners of the plate. The enter and exit of the reactant flow at opposite sides of the plate is advantageous for allowing the reactant manifold to be easily separated at opposing sides of the fuel cell. The channels may differ on different sides of the plate; for example, one side of the plate may have one or more meandering channels, while another side may have parallel channels.

[0104] The outer surfaces 101b and 102b of plates 101 and 102 are also partially copper-plated and routed according to the desired copper design.

[0105] The cathode manifold 105 supplies the compressed reaction fluid, and reaction air exits through the cathode manifold 105 from the cathode plate 101 and the entire fuel cell substrate 200. This air may come from the atmosphere (i.e., from outside the fuel cell) but enters the fuel cell system via an air compressor (rather than a fan, as may occur in later embodiments). This allows for higher pressure air, although it increases the parasitic energy cost of operating the compressor compared to a fan.

[0106] The heat exchange fluid manifold 107 and anode manifold 109 are also shown in Figure 3A, but can be perforated or routed into the plates after stacking, or possibly before stacking or compression. The holes in the manifolds are visible throughout all layers and individual layers of the fuel cell stack, but not all holes are labeled in all figures. Equivalent holes align with equivalent holes when the plates are stacked. In general, in all embodiments herein, manifolds of any suitable size, dimensions and shape are used to supply and collect reactants and heat exchange fluids, or other related materials, at the inlet and outlet of the fuel cell substrate. Vertical channels above and below the fuel cell stack are connected to manifolds along two opposing edges of the stack to supply reactants, heat exchange fluids (such as coolants), etc., to and collect from the substrate. These can be perforated or routed into individual substrates before or after stacking with other substrates.

[0107] Additionally, the plate may have holes drilled or routed for bolt holes, and / or alignment pins may be inserted into them.

[0108] Figure 3B is a schematic diagram of the same enlarged fuel cell substrate 200, opposite to that in Figure 3A. The fuel cell substrate 200 is shown enlarged for the purposes of this figure to show the membrane electrode assembly (MEA) 113 separated from the cathode plate 101, anode plate 102, and cap layer 150.

[0109] In Figure 3B, only the inner surface 101a of the cathode plate 101 and the outer surface 102b of the anode plate 102 are visible. The cathode flow field 111 is visible on the inner surface 101a of the cathode plate 101 (in Figure 3B, two flow fields 111 are labeled, but multiple flow field paths 111 are visible). The passivation ink is also screen printed on this flow field surface. In Figure 3B, the flow field 112 of the anode plate 102 is not visible, but it is located on the invisible inner surface 102a of the cathode plate 102.

[0110] The anode manifold 105, heat exchange fluid manifold 107, and cathode manifold 105 are also visible in Figure 3B.

[0111] The heat exchange fluid pathways 302 are visible on the surface 102b of the anode plate 102 in Figure 3B (not visible in Figure 3A). Two of the illustrated pathways 302 are labeled. These connect to the heat exchange fluid manifold 107. They supply the heat exchange fluid to the flow paths on the surface 102b of the anode plate 102. The cap layer 150 is also visible here, but surface 150b is visible from this angle. The heat exchange fluid pathways 302 may be third / further fluid pathways for the heat exchange fluid, as described herein.

[0112] The capping layer 150, as described here and herein, serves to “cap” or seal the adjacent channels. Here it is shown adjacent to the channel 302 on the anode substrate 102. When the layers of Figures 3A and 3B are laminated or compressed together, the capping layer 150 seals the channel 302 on the anode substrate 102 so that the heat exchange fluid flowing through these channels flows only along / through the intended channels and not elsewhere. The capping layer 150 is relatively unremarkable, showing only a row of plated through-holes for conducting current through the body of insulating material from which the capping layer 150 is made, away from the anode plate. This layer is described throughout as the third or fourth layer, in relation to the first and second layers, which are the cathode plate and anode plate.

[0113] If the heat exchange fluid path is located on the cathode plate, the cap layer may be located adjacent to the plate surface having the heat exchange path (for example, here the cathode plate surface 101b has the heat exchange fluid path 302, and the cap layer 150 may be adjacent to the cathode plate 101, on the opposite side of the illustrated fuel cell substrate 200).

[0114] Figure 4A is a schematic diagram of an enlarged fuel cell substrate 201 of one embodiment. The fuel cell substrate 201 is shown enlarged for the purposes of this figure to show a membrane electrode assembly (MEA) layer 103 having an MEA 113 separated from the cathode plate 101 and anode plate 102. Here, the cap layer is absent compared to the fuel cell substrate 200. All other features are identical and labeled accordingly.

[0115] Here, if there are multiple fuel cell substrates 102 in the fuel cell stack and they are stacked so that the anodes of the MEAs face the cathodes of the MEAs of adjacent fuel cell substrates, then the exposed heat exchange fluid path 302 on the surface 102b of the anode plate 102 will be adjacent to the surface 101b of the adjacent cathode plate 101. When the surfaces 101b of the adjacent cathode plates 101 are stacked or compressed, they act to cap or seal the path 302 so that the fluid can flow through the path but does not flow out in the intended direction. A capping layer 150 is not necessary in this design.

[0116] Figure 4B is a schematic view of the same enlarged fuel cell substrate 201, opposite to that in Figure 4A. The fuel cell substrate 201 is also shown enlarged for the purposes of this figure to show the membrane electrode assembly (MEA) 113 separated from the cathode plate 101 and anode plate 102. Here, the cap layer is absent compared to the fuel cell substrate 200. Here, the heat exchange fluid path 302 is visible on the surface 102b of the anode plate 102.

[0117] Similar to the embodiments shown in Figures 3A and 3B, the heat exchange fluid path 302 may be located on the surface 101b of the cathode plate 101.

[0118] Figure 5A shows the inner surface 101a of the cathode plate 101 in one embodiment. Parallel flow fields 111 are clearly visible, two of which are labeled, and the flow fields 111 are routed to the inner surface 101a of the cathode PCB plate 101. The cathode manifold 105, heat exchange fluid manifold 107, and anode manifold 109 are all visible. The flow fields 111 pass through the body of the substrate to the cathode manifold 109 on the opposite side of the plate, as seen in Figure 5B.

[0119] Figure 5B shows the outer surface 101b of the cathode plate 101 in one embodiment. The cathode manifold 105, coolant manifold 107, anode manifold 109, and plating through-holes 120 are all shown. Here, the flow field 111 is connected to the cathode manifold 105.

[0120] Figure 6A shows the inner surface 102a of the anode substrate 102 in one embodiment. Parallel flow fields 112 are clearly visible, two of which are labeled and routed to the inner surface 102a of the anode PCB plate 102. The cathode manifold 105, coolant manifold 107, and anode manifold 109 are all shown. Reaction hydrogen enters and exits through the anode flow fields 112 via the anode manifold 109.

[0121] Figure 6B shows the outer surface 102b of the anode plate 102 in one embodiment. The cathode manifold 105, heat exchange fluid manifold 107, and anode manifold 109 are labeled. Here, heat exchange fluid paths 302 are visible on the surface 102b of the anode plate 102. Two of the illustrated paths 302 are labeled. These are connected to the heat exchange fluid manifold 107. They supply heat exchange fluid to the flow paths on the surface 102b of the anode substrate 102.

[0122] Figure 7 shows the capping layer 150, or which may be referred to herein as “further layers” or third / fourth layers. The capping layer 150 is shown by a row of plated (two labeled) through-holes 120 for conducting electric current through the body of the insulating material from which it is made. The cathode manifold 105, heat exchange fluid manifold 107, and anode manifold 109 are also labeled.

[0123] Figure 8 shows an MEA layer 103 of one embodiment, separated from a cathode plate 101, an anode plate 102, and an optional cap layer 150. Here, a single rectangular MEA 113 is present. This MEA 113 has an ion-permeable membrane, an anode / anode layer, and a cathode / cathode layer. Such an MEA layer may have multiple membranes, anodes, or cathodes in various arrangements as described herein.

[0124] Figure 9A schematically illustrates how fluid paths or channels may exist in the layers / plates described herein. Here, an insulating core layer 160, corresponding to the “insulating layer” described herein, is shown. This is the core of the insulating material and may have a plating / passivation layer of conductive material, which may also be considered part of the insulating layer. The insulating core 160 shown here may be the cathode plate 101 or anode plate 102 as described above. Here, copper plating 903 is seen over at least a portion of both sides of the insulating core 160. This copper plating 903 penetrates the entire insulating core 160 and is plated through holes 120 that electrically connect the two layers of copper plating 903.

[0125] Figure 9A shows the heat exchange fluid pathway 302 within the layers of insulating material 101, 102, along with the reaction fluid pathways 111, 112 within the body of the insulating material layer. The reaction fluid pathways 111, 112 can carry oxidizing or reducing fluids to the cathode or anode, as described herein. Here, they are shown adjacent to the GDL layer 901, which allows the fluid to diffuse to the cathode or anode of the MEA. The GDL is a selective feature of all embodiments described herein and is located between the flow field and the anode / cathode of the MEA. Here, this is merely a cross-section of a typical insulating layer with the ends of the channel cut off. The plates and all plates shown in Figures 9A through 13 and other such figures are merely cross-sections of plates which may have multiple or each channel shown across the plate.

[0126] Here, only one heat exchange fluid path 302 and two reaction fluid paths 111, 112 are shown, but in embodiments herein, there may be multiple of each in each insulating substrate described herein, or there may be only one of each. These paths may have various designs, i.e., patterns, fields, geometric shapes or arrangements, as described herein.

[0127] Figure 9A shows that the heat exchange fluid path 302 may be integrated into the same insulating core material 160 as the fluid paths (channels) 111 and 112 for supplying fluid to the MEA. Here, the heat exchange fluid path 302 is located on the opposite side of the insulating layer from the two reaction fluid paths 111 and 112.

[0128] Figure 9A shows that the heat exchange fluid path 302 and the reaction fluid paths 111 and 112 may be comb-shaped. Here, the heat exchange fluid path 302 does not overlap with the reaction fluid paths 111 and 112 in its path or body as it passes through the insulating core material 160 of the heat exchange fluid path 302. That is, there is no overlap in the sense that the fluid paths never intersect or come into contact. In addition or alternatively, the paths passing through the body of the insulating layer do not intersect or overlap in such a way that each path does not (perpendicularly) cross the insulating core material 160 in the space above the other flow path. The surface area of ​​the insulating layer 101 / 102 covered by the heat exchange fluid path 302 is different from the surface area of ​​the insulating core material 160 covered by the reaction fluid paths 111 and 112.

[0129] The comb-like shape of the flow channels can be defined by their axes. Figure 9B shows a simplified version of Figure 9A with the addition of two labeled "y" axes, 903a and 903b. Axes 903a and 903b are parallel to the top and bottom / surface surfaces of the insulating core material 160. Axe 903a is defined as being parallel to the top surface of flow channel 302. Axe 903b is defined as being parallel to the bottom surface of flow channels 111 / 112. For a flow channel to be considered comb-like, at least a portion of flow channel 302 must intersect or overlap with axis 903b, and / or at least a portion of flow channels 111 / 112 must intersect or overlap with axis 903a. Here, such overlap exists because these are considered comb-like.

[0130] In embodiments of this specification, fluid channels may intersect or overlap axes defined by the upper or lower parts of other channels on / inside the same insulating substrate, located on opposite sides of the same insulating substrate, and these axes are parallel to the two surfaces of the insulating substrate where these two or more channels are located. These channels are considered to be integrated on the same substrate and to be comb-like.

[0131] In embodiments of this specification, the fluid channels do not need to intersect or overlap with an axis (or one or more axes) defined by the upper or lower part of another channel within the same insulating substrate, located on opposite sides of the same insulating substrate. This axis is parallel to the two surfaces of the insulating substrate where these two or more channels are located. These channels are considered to be integrated within the same substrate but not comb-shaped.

[0132] Another embodiment is shown in Figure 9C. Here, the channels are integrated on the same insulating layer, but are not comb-shaped. The channels can also be defined by axes. Figure 9C includes two additional labeled "y" axes, axis 903a and axis 903b. Axes 903a and 903b are parallel to the top and bottom / surface surfaces of the insulating core material 160. Axe 903a is defined as being parallel to the top surface of channel 302. Axe 903b is defined as being parallel to the bottom surface of channel 111 / 112. Here, neither channel overlaps with or intersects with an axis defined by the top or bottom of the channel as seen on the opposite side of the insulating core material 160. Because there is no overlap or intersection, these channels are not considered comb-shaped. These channels are considered to be integrated on the same plate.

[0133] In Figure 9C, the fluid path through the body of the insulating layer of channel 302 overlaps with channels 111 / 112 on the opposite face / surface of the insulating layer. This can also be defined by axes. The vertical "x" axes 905a, 905b, 905c, 905d, 905e are defined by the edges of the channels, but can also be defined by any point in these channels. Here, in the fluid channels, there is an intersection or overlap with some or all of the axes defined perpendicularly by the edges of the channels on the opposite face / surface of the insulating layer or by points within the channels. These axes (905a, 905b, 905c, 905d, 905e) are orthogonal to the top and bottom of the channels and the axes (903a and 903b) defined by the two surfaces of the insulating layer in which the channels are located.

[0134] This is in contrast to Figure 9D, where similar vertical "x" axes 905a, 905b, 905c, 905d, 905e are also defined by the edges of the flow channels. However, here, in the fluid flow channel, there is no intersection or overlap with any or all of the axes defined vertically by the edges of the flow channels on the opposite face / surface of the insulating layer or by points within the flow channels.

[0135] In the arrangements shown in Figures 9A and 9B, there is no such intersection or overlap in the fluid flow path with any or all of the axes defined by the vertical edges of the flow path on the opposite face / surface of the insulating layer or by points within the flow path. No point in flow path 302 or flow path 111 / 112 intersects with any of the axes (905a, 905b, 905c, 905d, 905e) defined by the vertical edges of the flow path on the opposite face / surface of the insulating layer or by points within the flow path.

[0136] In embodiments of this specification, fluid channels may be on the same insulating substrate but may not intersect or overlap with axes defined by the vertical edges of other channels on opposite faces of the same insulating substrate. These axes are perpendicular to axes parallel to the two faces of the insulating substrate containing these two or more channels. These channels are considered to be integrated on the same substrate and may be comb-shaped. If the fluid channels are comb-shaped, they may intersect or overlap with a second axis defined by the top or bottom of other channels on the same insulating substrate on opposite faces of the same insulating substrate. This second axis is parallel to the two faces of the insulating substrate containing these two or more channels. These channels are considered to be integrated on the same substrate and intersect with each other.

[0137] Furthermore, the comb-shaped channels can also be described as the sum of the depths of the channels. In embodiments, the sum of the channel depths may be greater than or equal to the thickness of the insulating substrate. In Figures 9A and 9B, the sum of the depths of channels 302 and 111 / 112 is greater than or equal to the thickness of the insulating layer. The channels run adjacent to each other but never touch or intersect. This is preferable when the channels are on opposite sides of the same insulating layer. The thickness of the layer is the distance between the two sides of the layer that have at least two channels. In Figures 9C and 9D, the sum of the depths of channels 111 / 112 and 302 is less than the thickness of the substrate.

[0138] Intersecting channels can also be described as the relative height or top / bottom of each channel. The bottom or depth of one channel is lower or smaller than the height or top of the other channel on the same insulating substrate. In Figures 9A and 9B, the top of channel 302 is higher than the bottom of channels 111 / 112. In Figures 9C and 9D, the height of channels 111 / 112 is higher than the height of channel 302, or the height of channel 302 is lower than the height of channel 111 / 112.

[0139] Using an insulating material layer such as a PCB substrate makes it possible to create a comb-like channel structure. This is not possible with prior art, particularly with metal fuel cell substrates. The comb-like structure reduces the thickness of the fuel cell substrate, resulting in space savings, weight reduction, and improved power density in the fuel cell stack.

[0140] In some embodiments of this specification, all flow paths or channels on both sides of the insulating layer are defined as crossing an axis that passes directly through the exact center of the insulating layer, parallel to the bottom / front surface of the insulating layer and / or parallel to the respective top or bottom surface of all flow paths on both sides / front surfaces of the insulating layer.

[0141] Figure 9A also includes a cap layer 150. This additional layer of insulating material or additional insulating layer seals or caps the flow path 302.

[0142] As described herein, an additional layer of insulating material or an additional insulating layer may be added to seal or cap one or more of these channels. This is adjacent to a layer having channels for heat exchange fluid. This serves to seal or cap these channels so that the fluid flowing through them flows along the channels, only along the intended channels. This layer may be laminated on insulating layers 101 / 102 or held in place by compression in a stack of such substrates or components. The copper plating 903 allows current to flow between these two insulating layers. Layer 150 is thinner than insulating layers 101 / 102. In the embodiments herein, this layer may be referred to as a further third or fourth insulating layer (relative to the first and second insulating layers forming the cathode and anode plates). These layers may have heat exchange fluid paths (negative space-type channels) in the core of the layers or in the copper / ink layers present on or as part of these layers.

[0143] These capping layers or further insulating layers may be of varying thicknesses. The capping layers or further insulating layers described herein may be rigid layers of insulating material, such as rigid PCBs, or thinner flexible layers of insulating material, such as flexible PCBs. They may be copper-plated and have a passivation layer, and they remain flexible.

[0144] Figure 9A shows various distances. These illustrate the relative distances between various components of this embodiment, although they represent only one exemplary embodiment of the present invention. These exemplary dimensions are listed in Table 1. [Table 1]

[0145] Furthermore, the insulating layer may include at least a partial layer or plating of a conductive material (e.g., copper), as described herein. This may have a thickness of 15 μm to 120 μm.

[0146] Furthermore, the insulating layer may include at least a partial passivation layer (e.g., passivation ink) as described herein. This may have a thickness of 3 μm to 100 μm, preferably 15 μm to 90 μm. For example, the passivation ink layer may be 15 μm to 90 μm thick, and the ENIG layer may be 3 μm to 10 μm, preferably 3 μm to 6 μm thick.

[0147] Flow channels and channels may exist only in these conductive material layers and passivation layers. Negative spaces, considered to be heat exchange channels, may have a depth between 180 and 500 microns and a width greater than 100 microns, with the upper limit depending on the shape of the selected flow channel / channel. These can be formed by etching a conductive material (e.g., copper) layer deposited on an insulating core material and coating a passivation layer deposited only on the remaining conductive material (e.g., copper).

[0148] The fuel cell substrate can be constructed to any suitable and desirable dimensions. In some embodiments, the thickness of the electrolyte membrane layer is 1 to 200 μm, preferably 5 to 100 μm. The electrode band may be up to 500 × 500 mm, preferably 300 × 100 mm, 300 × 200 mm, or 300 × 300 mm. The width of the electrode band may be 1 mm to 10 cm, preferably 2 mm to 5 cm. If present, the gap between the electrode band may be 0.1 mm to 1.5 cm wide, preferably 0.2 mm to 1 cm wide. The width of the through-film electrical connector may be 1 μm to 2 mm, preferably 10 μm to 1 mm.

[0149] These parameters and distances are applicable to the embodiments described herein. These embodiments and features may also be applicable to components for electrochemical devices described herein.

[0150] Figure 10 illustrates a further embodiment. Figure 10 schematically shows how fluid paths or fluid channels may exist in the layers / plates described herein. The insulating core material 160 shown herein may be located within the cathode plate 101 or the anode plate 102, as described above. Here, the copper plating 903 is present on at least a portion of both sides of the insulating core material 160. This copper plating 903 penetrates the entire insulating core material 160 and through through-holes 120 that electrically connect the two layers of copper plating 903. The copper plating through-holes 120 also penetrate the entire cap layer 150 and lead to a further copper plating layer of the cap layer 150.

[0151] In embodiments of this specification, the further insulating layer / capping layer may include means for conducting current from one side of the copper plating and / or capping layer to the other side (e.g., plated through-holes).

[0152] Figure 10 shows the heat exchange fluid pathway 302 in the layers of insulating materials 101 and 102, along with the reaction fluid pathways 111 and 112. These operate as described in Figure 9A. Here, two heat exchange fluid pathways 302 and two reaction fluid pathways 111 and 112 are shown. This is merely a typical cross-section of the insulating layer with the edges of the flow paths cut off.

[0153] Figure 10 shows that the heat exchange fluid path 302 may be integrated into the same insulating core material 160 as the fluid paths (channels) 111 and 112, and that path 302 is on the opposite side of the insulating layer from the two reaction fluid paths 111 and 112. Figure 10 shows a non-comb-shaped path. As described above in Figure 9C (Figure 10 has the same path arrangement as Figure 9C), these paths are not comb-shaped. Path 302 overlaps with the paths of the reaction fluid paths 111 and 112 in its path through the insulating core material 160 or in its body. Path 302 intersects or overlaps in its path through the body of the insulating layer such that each path traverses the insulating core material 160 in the space above (vertically) the other flow path.

[0154] Figure 11 shows a further embodiment. Figure 11 schematically illustrates how fluid paths or fluid channels may be in the layer / plate described herein. Figure 11 has the same path arrangement as Figure 9A, but here further components are shown as in Figure 9A and so on. Here, the plated copper also passes through the through-hole 120 and through the entire body of the cap layer 150 to further copper plating as part of / on the cap layer 150. The flow paths here are integrated and comb-shaped.

[0155] Figure 12 shows a further embodiment. Figure 12 schematically illustrates how fluid paths or fluid channels may be in the layer / plate described herein. Figure 12 has the same path arrangement as Figure 9D, but here further components are shown as in Figure 9A, etc. Here, the copper plated in the through-hole 120 passes through the entire body of the cap layer 150 to further copper plating as part of / on the cap layer 150. The flow paths here are integrated and comb-shaped.

[0156] Figure 13 illustrates a further embodiment. Figure 13 schematically shows how fluid paths or fluid channels may be in the layer / plate described herein. Here, reactant channels 111, 112 and coolant channel 302 are shown penetrating the entire body of the insulating core 160. Here, the depth of each or both of the reactant channels 111, 112 and coolant channel 302 is less than or equal to the thickness of the insulating layer. This means that the fluid channels / paths / channels are open to both faces or surfaces of the single insulating core 160 shown herein. Additional layers of insulating material or additional insulating layers or additional capping layers 150 are present to seal or cap both sides of the channel 302. These may be added individually or in a continuous layer to cap or cover one or more channels. However, no additional layers of insulating material or additional insulating layers are present to seal or cap at least one side of the reactant channels 111, 112, the side adjacent to the GDL901, so that the reactants can flow or diffuse to the anode or cathode. Appropriately designed cap layers may be added, or a single cap layer may be added / laminated to a layer of insulating material and perforated or routed to expose the associated fluid pathway (or both the cap layer and the layer of insulating material may be perforated or routed together to form a fluid pathway and be exposed to the fluid pathway through the cap layer). The sides of the reactant channels 111, 112 that are not adjacent to GDL901 are capped with additional insulating material, in this case cap layer 150.

[0157] This embodiment is considered advantageous over other described embodiments because, by having the reactant supply channel and the heat exchange fluid channel in the same plane, the insulating layer can be made thinner than in conventional designs. This reduces weight and manufacturing costs, and allows for a smaller stack size and increased power density.

[0158] Figure 14A illustrates a further embodiment. Figure 14A schematically shows how fluid paths or fluid channels may be in the layers / plates described herein. Here, the reactant channels 111,112 are of partial depth and therefore do not pass through the entire body of the insulating core material 160. The reactant channels 111,112 open only on one side / surface of the single insulating core material 160 shown here, on the GDL901 side. An additional layer of insulating material (cap layer) 150 is located between layers 101 / 102.

[0159] Here, the copper 903 layer and the passivation layer 904, as part of the cap layer 150, have gaps that can function as heat exchange fluid pathways 302. The copper 903 layer and the passivation layer 904 may be deposited / plated using techniques known in the art, or otherwise manufactured, or routed to have these gaps. These gaps, or negative spaces, may be used as heat exchange fluid pathways in these embodiments.

[0160] In the channel patterns in copper layers 903 and 904, identical or overlapping patterns are observed in adjacent substrates, so that when the substrates are stacked on top of each other, the paths can be aligned and joined to form channels. Here, the channels are formed from the negative space of the copper 903 layer and the passivation 904 layer of both cap layers 150. Since the paths are formed in the negative space between the two plates, they are sometimes called negative space channels or flow fields. The channel / flow field is the negative space between the substrates. This may be applied to other embodiments of this specification, where the substrates are aligned so that the channels in one layer form a joined channel. This is in contrast to the case where the channels are formed in the insulating core material itself.

[0161] In this configuration, there is no need to incorporate coolant pathways into the insulating material itself. Such pathways can be formed in layers already present on such a plate, saving space for other components such as coolant plates. The heat exchange fluid pathway 302 can function to control the temperature of the layers on either side of the heat exchange fluid pathway. Since these copper layers and passivation layers may already be present, forming pathways in them does not add any new layers to the substrate. These layers may be conductive materials or passivation layers as described herein.

[0162] Since the plated through-holes 120, the copper layer 903, and the passivation layer 904 are all conductive, current can pass through all of these plates.

[0163] The sealant 906 may also be present in any embodiment described herein. The sealant between / between the substrates can prevent leakage of the heat exchange fluid and can act to stabilize the stack against slippage of the modules in use due to vibration, for example. The sealant is representative here, and the substrate may have wider flow channels than shown.

[0164] In all figures herein, the size / thickness of the channels and substrates are not to scale but are adjusted only to show how they can be arranged, and the actual thickness, size, and number of channels may differ. As shown here, there may be multiple channels on a single substrate.

[0165] Figure 14B illustrates a further embodiment. Figure 14B schematically shows how fluid paths or fluid channels may be in the layers / plates described herein. Here, reactant channels 111, 112 are shown penetrating the entirety of one body of the insulating core 160, having the same effect as the arrangement shown and described in Figure 13. A capping layer 150 seals the channels 111 / 112 of each layer. The copper 903 layer and the passivation 904 layer are also present between the layers. The reactant fluid channels pass through the entire depth of the insulating core 160, but also through the copper 903 layer and the passivation layer 904 of this insulating layer. This is in contrast to Figure 14A, where the channels 111 / 112 do not penetrate the entire insulating core 160, nor do they penetrate the copper layer and the insulating layer.

[0166] Here, the copper 903 and passivation 904 layers of the cap layer 150 also have gaps that can function as heat exchange fluid pathways 302, as described in Figure 14A. These gaps, or negative spaces, can be used as heat exchange fluid pathways.

[0167] This embodiment is advantageous because having the reactant flow field 111 / 112 of full depth in combination with a cap layer 150 having a heat exchange fluid path 302 in the negative space created in the layer of the cap layer 150 between the insulating layers allows for thinner modules than in other embodiments. The insulating core material 160 may be thinner in these embodiments, and having the heat exchange fluid path 302 in the negative space means that the insulating core material 160 does not need to have a heat exchange fluid path. These are easier to manufacture and have improved power density. The reactant channel may be larger than, for example, that in Figure 14A, which is advantageous.

[0168] Figure 15 illustrates a further embodiment. Figure 15 schematically shows how fluid paths or fluid channels may be in the layers / plates described herein. Here, an asymmetrical arrangement is shown. The capping layer 150 seals the reactant channel 111 that penetrates the entire depth of the insulating core material 160a. In the core 160b, where the reactant channel 112 is at a partial depth rather than the entire layer, there is no capping layer in particular. Here, the capping layer 150 and the copper 903 layer and passivation 904 layer on the outer surface of the insulating core material 160b also have gaps that can function as heat exchange fluid paths 302, as described in Figures 14A and 14B. These gaps, or negative spaces, can be used as heat exchange fluid paths. Either side may have the arrangement of the capping layer; for example, the insulating core material 160b may seal the channel 112 instead of 111, which is just one representative embodiment.

[0169] Figure 16 shows a further embodiment. Figure 16 schematically illustrates how fluid paths or fluid channels may exist in the layer / plate described herein. Unlike the embodiments in Figures 14A, 14B and 15, there is no cap layer here. The reactant fluid channels 111 / 112 have a partial depth in each insulating core 160, i.e., they do not penetrate the entire body of the insulating layer. Here, the copper 903 and passivation 904 layers on the outer surface of the insulating core 160 have gaps that can function as heat exchange fluid paths 302, as described in Figures 14A, 14B and 15. These gaps, or negative spaces, can be used as heat exchange fluid paths.

[0170] These embodiments offer a space-saving advantage over other embodiments described herein by utilizing the negative space between fuel cell substrates for the heat exchange fluid.

[0171] Figure 17 illustrates a further embodiment. Figure 17 schematically shows how fluid paths or fluid channels may be in the layers / plates described herein. Here, 901 represents the GDL layer, and the structure of this +MEA is not shown as it is not necessary. Here, the reactant channels 111 / 112 can be considered to have a greater depth than the insulating core layers 101 / 102 in which they are located, and to exist through the copper 903 layer and the passivation 904 layer. The term “insulating layer” as used herein may refer to the insulating core 160 alone, or to the insulating core 160 together with the conductive material (e.g., copper 903) and the passivation 904 layer, as described earlier in other configurations. In this embodiment, the heat exchange channel 302 is located in the capping layer 150. These capping layers serve to cap or seal the reactant paths 111 / 112 in the insulating core 160, and at the same time, they also serve to have the heat exchange path 302 as part of themselves. The plated through-holes 120 are located throughout the layers and conduct current and heat through the layers. Here, the entire substrate or module is seen between two MEA / GDL layers 901, and half of another substrate or module is seen beneath the MEA / GDL layer 901.

[0172] Here, there is no bonding or gluing between the layers, and such an arrangement can be held together during operation by mechanical compression alone. The sealant 906 serves to seal, bond, or adhere the layers together, as shown. The sealant may be used throughout such a stack or layers, where appropriate, or mechanical compression may be used.

[0173] Figure 18 illustrates a further embodiment. Figure 18 schematically shows how fluid paths or fluid channels may be in the layer / plate described herein. Here, the reactant channels 111 / 112 have a greater depth than the insulating core material 160a / 160b in which they are placed. These are as previously described in other arrangements. Here, the entire substrate or module is seen between two MEA / GDL layers 901, and half of another substrate or module is seen beneath the second MEA / GDL layer 901.

[0174] Here, the cap layer 150 is a relatively thin flexible PCB layer. As described above, these cap layers are thinner than other potential cap layers and, when used, allow for a more compact arrangement which has the advantages described herein. A layer of prepreg 900 is also visible here, which functions as the prepreg described herein. The prepreg may be present between any and all layers described in all embodiments herein, but is not shown in all exemplary schematic diagrams.

[0175] In this embodiment, the heat exchange channel 302 is also located in the negative space formed in the copper 903 layer and the passivation 904 layer between the cap layers 105, as described in the previous embodiment.

[0176] Throughout the arrangements in Figures 17 and 18, there is a relatively close network of copper layers and passivation layers (which are both electrically and thermally conductive). This is effective for transferring heat throughout the layers shown here. In such an arrangement, both to and from the heat exchange channels 302, effective temperature control is possible. In such an arrangement, the thickness of the fuel cell substrate is reduced, space is saved, the fuel cell substrate is lighter, and the power density of the fuel cell stack is improved. Placing the heat exchange fluid pathways in the cap layer allows for alternative arrangements, such as those shown in Figures 10-13, where they are placed in the same insulating layer as the reaction fluid pathways.

[0177] These embodiments and features (e.g., flow path arrangement, relative depth, etc.) may also apply to components for electrochemical devices described herein.

[0178] Figure 19A shows one side of a further means 300 for controlling the temperature of the fuel cell substrate or a fuel cell substrate adjacent to this means. This may be a heat exchange plate or layer, a thermal management plate or layer, a coolant plate or liquid coolant plate. The cathode manifold 105, heat exchange fluid manifold 107, and anode manifold 109 are all labeled. These manifolds are aligned with equivalent manifolds on the fuel cell substrate (e.g., 200 or 201 seen earlier). The thermal management plate also has holes 115 for bolting or routing.

[0179] The heat exchange plate 300 is made of two PCB layers. Figure 19B shows one of these two PCB layers, 301, with its inner surface 301a shown. This is the thicker of the two PCB layers that together make up the heat exchange plate 300. This layer does not necessarily have to be thick, but it is thickened here. The heat exchange plate 300 is conductive because it is copper plated and has plated through-holes 120 that penetrate the plate body, and it functions as a bipolar plate between the adjacent cathode plate 101 and anode plate 102 of the adjacent fuel cell substrate 200. The plate through-holes 120 are drilled around the flow field 302 to provide a conductive path from one side of the plate 300 to the other. These allow for electrical connection between the anode and cathode of the adjacent fuel cell substrate. Four exemplary plated through-holes 120 are labeled, but ten rows of through-holes can be seen along the heat exchange plate 300. In the fuel cell stack of multiple fuel cell substrates according to this embodiment, the anode plate of one fuel cell substrate faces the cathode plate of an adjacent fuel cell substrate, and vice versa.

[0180] The flow field 302 is routed to the inner surface 301a of the PCB layer 301, and two of the five visible heat exchange flow fields of the plate 300 are labeled. Layer 301 is bonded to a featureless second layer (not visible separately in Figures 19A-19C) that seals the flow field 302 so that the heat exchange fluid can only enter and exit the flow field at the edge of the plate, as can be seen in Figure 19C.

[0181] Figure 19C shows a side profile of the substrate 301 of the heat exchange plate 300, showing only the PCB layer 301 with the flow field, where one of the heat exchange fluid flow fields 302 is visible with four visible labels. The inlet and outlet holes 304 of the flow field are visible, with three of the five holes labeled. Equivalent inlet and outlet holes 304 are also found at the opposite end of the flow field 302. The heat exchange fluid enters and exits the heat exchange fluid manifold 107 and the heat exchange fluid flow field 104 through these holes 304. During operation, the heat exchange fluid is fed into one side of the plate and flows out through the flow field from the other side of the plate.

[0182] The heat exchange plate is coupled with means for supplying heat exchange fluid to the plate. This may include, for example, a pump, a radiator, and heat exchange fluid circulating around a loop requiring a stack fluid circuit (similar to the engine cooling loop in a car where the stack replaces the engine). A small reservoir of fluid may also be provided to account for slight fluid loss over time. The fluid is stored in the reservoir and throughout the fluid circuit. The circuit can receive heat from the stack and dissipate it through a radiator (assisted by a fan that dissipates heat into the atmosphere), and the fluid can be continuously moved by a pump during operation. Alternatively, the circuit can add heat to the stack and remove heat from the warmer parts of the circuit.

[0183] The heat exchange plate 300 not only functions as a conductive plate between the adjacent cathode plate 101 and anode plate 102 of the adjacent fuel cell substrate 200, but also functions to control the temperature of the fuel cell substrate on both sides of the plate 300. The plate can extract heat from or add heat to other parts of the stack through the fluid flowing through the fluid pathways within the plate 300.

[0184] References herein to interchangeable “heat exchange fluid,” “thermal control fluid,” or “temperature control fluid” refer to fluids usable in a fuel cell or fuel cell component, or other such electrochemical device, which may flow in close proximity to, adjacent to, or in contact with one or more parts of a fuel cell substrate, fuel cell, fuel cell component, or fuel cell stack described herein. For example, the systems and methods described herein may cause the heat exchange fluid to flow in a channel adjacent to or near the anodes of a fuel cell substrate, and act to cool or heat these anodes. They can act to cool components, for example, by cooling the anodes of a fuel cell while the fuel cell is functioning. Alternatively, such heat exchange fluids can act to heat or warm components, for example, by heating the anode components of a fuel cell during startup, at the beginning of the fuel cell's operating time / program, or in a low-temperature environment. The heat exchange fluid may be a liquid, a gas, or any other suitable fluid as described herein. Heat or temperature can be added to or removed from various parts of a fuel cell substrate, fuel cell, fuel cell component, or fuel cell stack described herein.

[0185] The heat exchange fluid can come into contact with one or more parts of the fuel cell substrate, fuel cell, components for the fuel cell, or fuel cell stack described herein. For example, the systems and methods described herein can cause the heat exchange fluid to flow in a channel adjacent to or near the anodes of the fuel cell substrate, and act to cool these anodes.

[0186] Thermal management or heat exchange may be used to maintain the fuel cell substrate or stack at a specific operating temperature, to operate the system in a more energy-efficient manner, to extend the operating life of the system, and / or to provide more efficient fuel cell operation (for example, to operate the fuel cell within set parameters and to avoid over- or under-production of power).

[0187] 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 substrates, fuel cells, components for fuel cells, or fuel cell stacks described herein.

[0188] In particular, the heat exchange fluid can 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 with a ratio of deionized water to glycol (such as ethylene glycol or propylene glycol) of 1:1, or a fluid with a ratio of deionized water to glycol of 2:1, or a fluid with a ratio of deionized water to glycol of 3:1, or a fluid with a ratio of deionized water to glycol of 4:1, or a fluid with a ratio of deionized water to glycol of 5:1 can be used. The solution may be up to 10% glycol in deionized water, or up to 1% glycol in deionized water, or up to 2% glycol in deionized water, or up to 5% glycol in deionized water, or up to 10% glycol in deionized water, or up to 20% glycol in deionized water, or up to 30% glycol in deionized water, or up to 40% glycol in deionized water, or up to 50% glycol in deionized water. Alternatively, the heat exchange fluid may be a mixture of another type of alcohol (e.g., methanol, ethanol, isopropyl alcohol) and deionized water. The solution may contain up to 10% alcohol in deionized water, or up to 1% alcohol in deionized water, or up to 2% alcohol in deionized water, or up to 5% alcohol in deionized water, or up to 10% alcohol in deionized water, or up to 20% alcohol in deionized water, or up to 30% alcohol in deionized water, or up to 40% alcohol in deionized water, or up to 50% alcohol in deionized water. The coolant may contain one or more perfluoroamines such as Fluorinert.

[0189] An insulating layer may have multiple different fluid paths or channels of different sizes, shapes, and / or dimensions, or different flow velocities or different fluid temperatures within a single insulating layer. The fluid may have different temperatures or different flow rates in different plates, or different temperatures or different 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 be designed to carry different fluids. Depending on the changing needs of the thermal management fluid for the entire stack, different plates may carry fluids at different temperatures or fluids at different flow rates.

[0190] Overheating of a fuel cell stack can cause problems, and cooling of the stack is generally required. This is typically achieved by supplying a heat exchange fluid, such as a cooling fluid (e.g., air, water, or a mixture of water and glycol), circulating within the stack. The heat exchange fluid and the reaction fluid are usually supplied to the cathode in the same channel or flow. However, in all embodiments described herein, the heat exchange fluid is not part of the same flow as the “reactants” to the cathode (since the cathode reactants are usually air, the air is both the cathode reactants and the coolant). Separating the heat exchange fluid from the cathode reactants in this way is advantageous because it allows for greater control over the flow of reactants to the cathode, whose velocity is not determined by the velocity of the required cooling airflow. Anode cooling control is also improved.

[0191] Fuel cell stacks also encounter problems such as temperatures being too low for optimal operation, for example, during startup or in cold environments. Fluids intended to heat or raise the temperature of the fuel cell substrate, fuel cell, components for the fuel cell, or various components of the fuel cell stack described herein can be supplied in the same manner as coolants. These can be in a flow path in the fluid management plate, or the anode plate or cathode plate described herein.

[0192] In some embodiments, the same fluid used to cool various parts of the fuel cell substrate, fuel cell, components for the fuel cell, or fuel cell stack described herein can act to initially heat or raise the temperature of various parts of the fuel cell substrate, fuel cell, components for the fuel cell, or fuel cell stack described herein. This is for example, if the stack is cold at startup, the circulating fluid is at a higher temperature than the fuel cell substrate and therefore acts to warm the components it is supplied to or passes through. The same fluid then works to cool the supplied or passing components because it is at a lower temperature than the fuel cell substrate.

[0193] Using separate reactant sources for the heat exchange plates and cathodes—that is, reactants other than air supplied from the atmosphere—is particularly advantageous for fuel cell stacks operating at relatively high energy densities. Increased energy density leads to increased heat dissipation, allowing for the use of more efficient heat transfer means. For example, fluids with a greater heat capacity than air (i.e., water or a mixture of glycol and water) can be used because they have the ability to remove heat from the stack.

[0194] The heat exchange plate can be laminated with the fuel cell substrate or compressed and held on the anode side of the fuel cell substrate (i.e., the second PCB layer adjacent to the anode side of the MEA). This is the case for a heat exchange plate having only one PCB layer, i.e., a PCB layer 301 having a heat exchange fluid flow field 302. By laminating the heat exchange plate with the fuel cell substrate, it is possible to increase the energy density compared to a two-layer heat exchange plate because this coolant plate has only one PCB layer. Furthermore, sealing the coolant plate with the fuel cell substrate simplifies the assembly of the fuel cell stack by reducing the number of components and the amount of non-integrated sealing into the stack. This can be called a fluid plate module and may include all of the anode plate (first PCB layer), cathode plate (second PCB layer), MEA, and heat exchange plate in a single substrate, plate, module, or assembly. Multiple of these can form a fuel cell stack as described herein.

[0195] Figure 20 is a schematic diagram of the fuel cell stack of this embodiment. It shows four single-cell plates 200 / 201 and four fuel cell substrates 200 / 201 connected in series. The cathode plate 101 and anode plate 102 are not shown separately in Figure 20, but as described above, there is one of each on each fuel cell substrate 200 (there are four of each in a stack of this size). In Figure 20, three heat-non-heat-exchange plates are shown because the heat-exchange fluid path is present in either the cathode layer or both of the anode layers, as described herein.

[0196] Figure 20 shows anodes 2 and cathodes 3, with three of each labeled in Figure 20. Each fuel cell substrate 200 has 11 anodes 2 and 11 cathodes 3 arranged horizontally, with only anodes 2 and only cathodes 3 in each horizontal plane. Anodes 2 are positioned opposite cathodes 3, and a single electrolyte membrane 1a is positioned between anodes 2 and cathodes 3. The layout of anodes and cathodes in this embodiment is similar to that of conventional fuel cells, as there is a single electrode in the plane. In a typical bipolar fuel cell, the MEA is sandwiched between bipolar plates, forming a single cell in each layer. Bipolar plates are usually made of a conductive material such as graphite or metal. Here, conventional bipolar plates are not necessary because the anode and cathode plates are plated through-holes and copper plated. Not shown are plated through-holes that penetrate cathode substrate 101 and anode substrate 102, which electrically connect anodes 2 and cathodes 3 on adjacent substrates. In this embodiment, the electrolyte 1a does not have plated through-holes. Thanks to the copper plating and plated through-holes, the current does not need to cross the electrolyte layer and moves laterally from the anode to the cathode parallel to the horizontal plane of the electrode. As a result, through-film connections are not required to conduct the current.

[0197] Figure 21 is a simplified schematic diagram of the substrate structure of this embodiment. The fuel cell substrate is constructed by laminating MEA, an insulating layer, and an epoxy resin prepreg (here referred to as "prepreg"). In the structure of the fuel cell substrate 200 of this embodiment, MEA 113 is sandwiched between two layers of prepreg 900, and a cathode plate 101 and an anode plate 102 are laminated on both sides of the two layers of prepreg 900. All of these layers are laminated together. Then, plating through-holes 120 are drilled in the anode 102 and the cathode substrate 101. After this is completed, final drilling and routing can be performed to expose the anode flow field and cathode flow field, as well as to create holes for the gas manifold, bolt holes, and alignment pins.

[0198] By using encapsulating materials such as prepregs and insulating boards such as PCBs, the MEA is reliably sealed from substances that are not intentionally guided to the MEA components by the flow paths of substrates directly adjacent to the MEA (such as the anode and cathode substrates). This is an advantage of the technology described herein, as such structures can be constructed quickly, simply, and inexpensively. Furthermore, by using lamination with epoxy resin prepregs, for example, it is possible to maintain the compression of the gas diffusion layer of the MEA, which is an important element in maintaining the performance of the fuel cell, and to provide an electrical path with sufficiently low resistance without impairing the distribution of the reaction fluid.

[0199] Substrates laminated in a specific lamination process include careful pre-cutting and alignment of materials, and custom heating, cooling, pressurizing, and cleaning cycles.

[0200] The substrate or layers of the substrate can also be mechanically compressed or crimped by appropriate means. The entire fuel cell stack may be compressed together. In other words, lamination is not required in all embodiments. Layers of prepreg or other encapsulant-type materials can be used.

[0201] Once the fuel cell substrate 200 of this embodiment is constructed, it can be made into a fuel cell stack. These are modular and consist of two parts: the fuel cell substrate 200 and the thermal management plate 300. The stack begins and ends with end plates that provide compression through the stack, as well as sealing ports for connecting the fuel, oxidizer, and thermal management fluid. Means for removing excess current can also be used at both ends of the stack to remove significantly high currents when needed. The stack can be constructed in a repeating sequence of fuel cell substrates 200, with the addition of the thermal exchange plate 300 also possible. The stack shown throughout can be held together with bolts or compression bands that also provide compression for sealing between modules, but any means for holding the compressed stack together, or any means for sealing the fuel cell substrate, possible thermal exchange plate, or modules together, and types of end plates known in the art are available. Gaskets for sealing the manifold or other parts of the fuel cell stack together can be used as needed, but may not be necessary in such a stack.

[0202] Figure 22 shows a fuel cell stack 30-1 of one embodiment. The fuel cell stack 30-1 is enclosed in a fuel cell casing in which the end plate 31 is visible. In this embodiment, there are 12 fuel cell substrates 200. As shown in Figure 22, the fuel cell has two cathode inlets and outlets 32, two heat exchange fluid inlets and outlets 33, and two anode inlets and outlets 34.

[0203] The cathode inlet 32 ​​is connected to a compressed air canister or air compressor and supplies compressed air that acts as an oxidizer reacting at the cathode during the operation of the fuel cell. The cathode outlet 32 ​​is connected to the exhaust to the atmosphere. The cathode outlet 32 ​​may also be connected to the exhaust via a humidifier so that the water produced in the fuel cell can be used to humidify the air entering the stack. This is achieved by passing the inflow and outflow fluids through a water permeable membrane.

[0204] The anode inlet 34 is connected to a hydrogen canister and supplies hydrogen reactants to the anode, which act as reducing gases to fuel the operation of the fuel cell. The anode outlet 34 is either exhausted to the atmosphere or connected to an anode recirculation system.

[0205] The anode recirculation system may include a water trap (to remove accumulated water) and a hydrogen pump or orifice to increase the pressure so that unused hydrogen can be returned to the stack.

[0206] 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.

[0207] In this specification, the structure of fuel cell substrates 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 only and do not limit the scope of the invention. It will be apparent to the reader that fuel cell substrates can be positioned in any plane, not just the horizontal plane. Furthermore, the term "opposite" is not limited to the electrodes being aligned. The anode is on one side of the polymer electrolyte and faces the cathode, which is on the opposite side of the same electrolyte membrane layer.

[0208] In this specification, “fuel cell substrate” refers to a membrane electrode assembly (MEA) 113 sandwiched between a cathode plate 101 and an anode plate 102. In this embodiment, the three layers may be laminated together or compressed together. Depending on the fuel cell substrate, a cap layer 150 may also be included as part of the structure. The fuel cell substrate may also be referred to as a fuel cell module in this specification. The use of “fuel cell substrate” is not intended to limit the size, shape, or arrangement of the MEA or other components of the substrate. The term “fuel cell substrate” is not intended to limit the size, shape, or dimensions of the substrate, but is merely a term in the art to refer to the MEA and plates described herein.

[0209] Fuel cells, fuel cell substrates, and components can be constructed from insulating layers, such as printed circuit boards (PCBs). Individual layers can be bonded to a solid structure using epoxy-containing glass fiber composites ("prepregs"). Fuel cell substrates can also be created by laser bonding MEAs onto insulating layers and laminating multiple substrates. Gaps between electrodes and sealing these gaps with epoxy resin prevent mixing of separate flows, i.e., air cooling, reactant, and fuel flows. Simple PCBs can also be used as end substrates or plates in the stacks described herein.

[0210] As used herein, the term “insulating layer” may refer to the insulating core material alone, or the insulating core material together with a conductive material and a passivation layer. The insulating layer in the embodiments herein may be a printed circuit board (PCB). A PCB according to an embodiment may be manufactured by known methods. In this specification, “printed circuit board” or “PCB” refers to a layer of one or more insulating materials including a dielectric substrate such as epoxy resin, e.g., 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, preferably the insulating layer including FR-4. Multiple layers or substrates may be bonded together, for example, with an epoxy resin prepreg. A plate or substrate may include one or more layers of these insulating materials, and one or more PCB substrates may include a single “insulating layer” as defined herein. The PCB substrate includes a plated area of ​​the conductive material. To obtain a conductive region, a thin layer of conductive material (e.g., metal, e.g., copper) can be deposited, plated, or applied to the entire insulating substrate and etched off (e.g., using a mask) to give the desired conductive pattern. The conductive material may be applied by electroplating. The PCB described throughout may or may not have copper plating on various parts of the entire PCB substrate. The insulating layer, e.g., the PCB, may be a flexible PCB, e.g., the thinner end of the thickness range listed in Table 1 above.

[0211] A means is needed to pass an electric current from one side of the plate or substrate to the other, such as plated through holes (PTHs) or conductive material-filled through holes. This is because, since the plates and substrates described herein have an electrically insulating material, such means must be introduced so that the copper surfaces on both sides of the insulating layer become conductive, allowing current to flow from the MEA to other electrical connections in the fuel cell and generate power from the fuel cell.

[0212] As used herein, “means of conducting electricity” may be plated through-holes or through-holes filled with conductive material. A “plated through-hole” (PTH) is a hole that forms a conduit that penetrates one or more layers of insulating material, the conduit running substantially perpendicular to the plane of the fuel cell substrate. These holes are plated with a conductive material, such as copper, and function as electrical conduits. Insulating materials (e.g., FR-4) require the introduction of PTHs because their core is electrically insulating. PTHs can be formed by drilling holes in a layer of insulating material (such as a PCB plate) and lining them with a conductive material. For example, the conductive material may be lined with copper along the edges of each hole by an electroplating dipping process. i) The rest of the holes can be filled with resin, which is achieved by pressing resin onto the PCB layer and allowing it to flow through all the holes present; ii) the resin-filled holes are electroplated again so that they are capped with copper on both sides; iii) there may be a light milling process after this to ensure the PCB surface is flat. A PTH, which penetrates a PCB layer and can create conductivity between two copper-plated layers on either side of the PCB, may penetrate only specific layers of the insulating material described herein, or only some layers of the fuel cell substrate described herein (for example, penetrating only the anode and cathode plates to allow current to flow from the anode / cathode to the outer surface of the insulating material layer). The PTH may also be formed to penetrate the entire fuel cell substrate (for example, penetrating both the anode and cathode plates with the same hole to allow current to flow from one surface of the fuel cell substrate to the other). Instead of, or in addition to, a hole filled with a conductive material such as resin or copper may be used. The insulating layer may not have means of conducting material through the layer body.

[0213] In some embodiments, a metal or other conductive material is chemically deposited within the film to deposit a through-film electrical connector. This material is preferably chemically stable within the film under the operating conditions of the fuel cell and may typically be a noble metal (e.g., Pt, Au, Ru, Ir, Rh, Pd) or an oxide of a noble metal. Various approaches for depositing conductive bands in the film are described in WO2012 / 117035, which is incorporated herein by reference.

[0214] The fuel cell substrate may have a single layer of anode and cathode, or the MEA layer ( / fuel cell substrate) may have multiple anode-cathode pairs. This technology can be applied to fuel cells having one or more fuel cell substrates, each having a single anode-cathode pair, or to fuel cells having one or more fuel cell substrates, each having multiple anode-cathode pairs on each substrate.

[0215] The anode can be designed to facilitate hydrogen oxidation reactions (HOR), be resistant to degradation (thermal cycling, voltage, acidic environments), and have a high electrochemically active surface area (ECSA). The cathode is similar, but is used for oxygen reduction reactions (ORR).

[0216] The anode and cathode may contain platinum supported on carbon. Other platinum group metals (Pt, Ir, Os, Pa, Rh, Ru, Pd) or non-precious metals (NPMs) with much lower electrochemical activity, such as Ni, Fe, Co, and Sn, can also be used.

[0217] These values ​​vary depending on the ionomer content, PTFE content, catalyst content, electrode composition, and coating on the electrode.

[0218] The material of the anode and / or cathode itself can also be varied. This is possible by changing the material of the electrodes. For example, the electrodes may be made of graphite, platinum, Ir, a mixture thereof, or a different mixture or material across the entire surface of the fuel cell substrate. For example, the platinum ratio of the graphite electrode may vary across the fuel cell substrate to account for variations in the overall state of the fuel cell substrate.

[0219] The additives added to the anode and / or cathode also vary. This can be achieved by adding IrOx, PTFE, and Ru at varying concentrations throughout the fuel cell substrate.

[0220] In some embodiments, a catalyst layer on the electrodes facilitates the reaction between the fuel (on the anode electrode) and the oxidizer (on the cathode electrode), generating or consuming ions and electrons. This layer can be made of a catalyst material suitable for the reaction of interest, as is generally understood by those skilled in the art of fuel cell manufacturing. For example, the catalyst layer can consist of platinum nanoparticles deposited on carbon and bonded to a proton-conducting polymer (such as Nafion®).

[0221] The MEA may also have one or more gas diffusion layers (GDLs). These may be porous carbon papers such as Siguraset® (SGL Carbon), Abukab, or Toray®. These may also be metal foams or porous metallic materials (such as foams or felt). These may include aluminum, titanium, or stainless steel.

[0222] The electrolyte membrane may be a proton exchange membrane (PEMFC), also known as a polymer electrolyte membrane (PEM). This may be a fluorinated membrane (e.g., a sulfonated tetrafluoroethylene-based fluoropolymer, 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, a Gore-Select® membrane, or a Fumatec Fumapem membrane. Alternatively, the electrolyte membrane may be an anion exchange membrane (e.g., a Fumatec Fumasep FAA-3 membrane). Other suitable membranes known in the art may be used in conjunction with the embodiments herein.

[0223] The reaction fluid may be oxygen gas, air or pressurized air, or other suitable fluid to be oxidized at the cathode. As described above, the reaction fluid for the cathode may be air drawn in from the atmosphere outside the fuel cell by a fan or air compressor.

[0224] The structure and advantages of fuel cells made from PCBs are further described in WO2012 / 117035 and WO2013 / 164639, which are incorporated herein by reference.

[0225] In this specification, passivation layer means an additional layer deposited on a copper or other conductive metal layer. The passivation layer may also be a passivation ink, which may refer to a conductive ink, in particular, which may have a carbon-based functional conductive element. The ink serves to provide a low in-plane 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 the mobile copper, which otherwise could cause irreversible damage to the electrolyte / membrane. Furthermore, inks such as carbon inks, silver pastes, and inks based on polyurethane with conductive elements such as carbon nanotubes or gold / silver nanoparticles dispersed in them are known to those skilled in the art. The passivation layer may contain gold, silver, or nickel, and / or may be an electroless nickel immersion gold (ENIG) layer, an organic solderability preservation layer, or an electroless silver plating layer, or other passivation treatments known in the art. When forming channels in copper on an insulating layer, the manufacturing process may consist of first etching away the conductive material (e.g., copper), and then depositing a passivation layer that is deposited only on the conductive material (e.g., copper).

[0226] During operation, the fuel cell is housed in a housing and sealed from the atmosphere. Reactants are supplied to the fuel cell's flow path through sealed connections. The seal is made of, for example, PDMS. In particular, the fuel (e.g., H2) and oxidizer (e.g., O2) are supplied to the appropriate channels in the fuel cell stack, with the fuel supplied to the anode and the oxidizer to the cathode. The resulting current can be taken directly, or the output of the fuel cell boards can be adjusted using the aforementioned switches. There are various ways to keep the stack output constant. For example, all fuel cell boards can be constantly loaded. Alternatively, the fuel cell boards can be divided into groups, and these groups can be "switched on" sequentially in a synchronous manner (i.e., switching all fuel cell boards at predetermined times). That is, each fuel cell board is connected to or disconnected from the load for a defined period and frequency individually specified for each fuel cell board. The output power of the stack can be continuously changed by switching the fuel cell boards to be connected to the load for a proportion of the time corresponding to the duty cycle. For example, if only 50% of the fuel cell boards are connected to the load during a certain sampling period, the output power of the fuel cell stack will similarly decrease. For example, half of the fuel cell substrate could be disconnected from the load, while the other half remained connected for the entire duration. Alternatively, half of the fuel cell substrate could be connected to the load for one-quarter of the sampling period, and the remaining half for three-quarters. The choice of specific schemes and duty cycles may depend on the performance of individual fuel cell substrates, the need to avoid localized heating or "hot spots," the need to avoid flooding by generated water at the cathode site, the need to prevent membrane dehydration, or the need to prevent electrode poisoning. The duty cycle may be predetermined or controlled in real time based on monitored fuel cell performance. Part-time use of fuel cell substrates can also improve efficiency because it allows for optimal load conditions and power conversion for individual fuel cell substrates rather than the fuel cell stack, which is a limitation of current designs.By adding switching and filtering components to the fuel cell substrate, it is possible to obtain not only simple "switching" or stepping from one potential to another, but also smoothly changing outputs, such as a sine wave.

[0227] For example, if an electrode's performance deteriorates or a defect occurs, it is possible to use individual electronic devices to switch the affected substrate, and also to stop the supply of fuel or oxidizer to a specific electrode.

[0228] It will be understood that the aspects of the present invention can be rearranged or juxtaposed as appropriate. The fuel used is not limited to hydrogen, but any suitable fuel can be used. For example, the new fuel cell stack configuration described herein is also applicable to methanol used in direct methanol fuel cells.

[0229] In the illustrated invention, hydrogen is used as the reaction fuel (i.e., the reducing agent gas for the anode), but the fuel cell can be used with any suitable pressurized fluid. As used herein, “fluid” means a substance that does not have a fixed shape and readily yields 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 hydrogen-containing mixtures, or hydrocarbons or hydrocarbon derivatives. The fuel may be other gaseous fuels such as methane or propane. The fuel may be other gaseous fuels such as methane or propane, and the fluid may include air and an oxidizing agent such as oxygen.

[0230] The fuel cells and fuel cell substrates described herein are capable of any output expected for a fuel cell stack. Each fuel cell substrate may have a rated power of at least 100 W. The rated power of each fuel cell substrate is up to 1000 W. The rated power of each fuel cell substrate is between 10 W and 1000 W. A fuel cell having multiple fuel cell substrates has a rated power of at least 10 kW. Preferably, each fuel cell having multiple fuel cell substrates may have a rated power of up to 1000 kW. Preferably, each fuel cell having multiple fuel cell substrates may have a rated power between 10 kW and 1000 kW. However, any power ratings are representative of the current embodiments, and ratings may differ from those described here as examples only.

[0231] The system and method can be used with pressurized fuel storage units or containers, as is well known in the art. The fuel can be stored in pressurized storage units, such as bottles or canisters. These can be pressurized to, for example, 700-300 bar.

[0232] One aspect of the present invention is a component for an electrochemical device. This component may include any of the features described herein relating to an insulating layer for a fuel cell substrate. This may have 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 side of the insulating layer.

[0233] This may be a component for any type of electrochemical device where control of fluid flow is important, and it would be advantageous to utilize the flow of heat exchange fluid in such devices. For example, for fuel cells as described herein. Alternatively, electrolytic devices or other electrochemical devices are also conceivable.

[0234] It will be apparent to those skilled in the art that many improvements and modifications can be made to the exemplary embodiments described above without departing from the scope of this disclosure.

Claims

1. Equipped with at least one fuel cell substrate, The aforementioned fuel cell substrate is i) A membrane electrode assembly (MEA) comprising at least one ion-permeable membrane, at least one anode, and at least one cathode, wherein the one or more anodes are located on a first surface of the ion-permeable membrane, and the one or more cathodes are located on a second surface of the ion-permeable membrane, ii) A first insulating layer comprising at least one first fluid path, iii) A second insulating layer comprising at least one second fluid path, The MEA is located between the first insulating layer and the second insulating layer such that the at least one first fluid path is arranged so that an oxidizing fluid can flow to one or more cathodes of the at least one fuel cell substrate, and the at least one second fluid path is arranged so that a reducing fluid can flow to one or more anodes of the at least one fuel cell substrate. The fuel cell substrate has at least one third fluid path for heat exchange fluid. fuel cell.

2. The second insulating layer includes the at least one third fluid path for the heat exchange fluid, the at least one third fluid path is arranged so that the heat exchange fluid can control the temperature of the fuel cell substrate, preferably the temperature of the at least one anode, and / or The first insulating layer includes the at least one third fluid path or further / fourth fluid path for the heat exchange fluid and is arranged to control the temperature of the fuel cell substrate, preferably the temperature of at least one anode of at least adjacent fuel cell substrates. The fuel cell according to claim 1.

3. The fuel cell comprises a plurality of the at least one fuel cell substrates, Each of the plurality of fuel cell substrates is arranged such that the first insulating layer and one or more cathodes of each fuel cell substrate face the second insulating layer and one or more anodes of an adjacent fuel cell substrate, and / or Each of the plurality of fuel cell substrates is arranged such that the second insulating layer and one or more anodes of each fuel cell substrate face the first insulating layer and one or more cathodes of an adjacent fuel cell substrate. The fuel cell according to claim 1.

4. The first layer further includes the at least one third fluid path for a heat exchange fluid, wherein the at least one third fluid path is arranged such that the heat exchange fluid can control the temperature of the fuel cell substrate and / or the temperature of at least one adjacent fuel cell substrate, preferably such that the heat exchange fluid can control the temperature of the at least one anode of the adjacent fuel cell substrate. The fuel cell according to claim 3.

5. Preferably, the at least one third fluid path is located on the opposite side of the insulating layer from the at least one first fluid path or the at least one second fluid path on the same insulating layer, such that the fluid path of the at least one third fluid path passing through the insulating layer does not overlap with the path of the at least one first fluid path or the at least one second fluid path on the same insulating layer. A fuel cell according to any one of claims 1 to 4.

6. If the first insulating layer includes the at least one third fluid path for the heat exchange fluid, i) the at least one first fluid path, and ii) The fluid path of the third fluid path The sum of the depths is greater than or equal to the thickness of the first insulating layer, and / or If the second insulating layer includes the at least one third fluid path for the heat exchange fluid, i) the at least one second fluid path, and ii) The fluid path of the third fluid path The sum of the depths is greater than or equal to the thickness of the second insulating layer. The fuel cell according to claim 2 or claim 5.

7. If the first insulating layer includes the at least one third fluid path, the depth of the at least one third fluid path is greater than or equal to the thickness of the first insulating layer, and / or If the second insulating layer includes the at least one third fluid path, the depth of the at least one third fluid path is equal to the thickness of the second insulating layer. A fuel cell according to any one of claims 1 to 6.

8. If the first insulating layer further includes the at least one third fluid path, the depth of the at least one first fluid path is also greater than or equal to the thickness of the first insulating layer, and / or If the second insulating layer further includes the at least one third fluid path, or also includes the at least one heat exchange fluid path, the depth of the at least one second fluid path is also greater than or equal to the thickness of the second insulating layer. The fuel cell according to claim 7.

9. The first insulating layer has a copper layer on the side of the first insulating layer opposite to the side facing the cathode, and optionally the first insulating layer also has a passivation layer on the copper layer, and the at least one third fluid path is located within the copper layer and / or within the passivation layer on the first insulating layer, and / or The second insulating layer has a copper layer on the side of the second insulating layer opposite to the side facing the anode, and optionally the second insulating layer also has a passivation layer on the copper layer, and the at least one third fluid path is within the copper layer and / or the passivation layer on the second insulating layer. A fuel cell according to any one of claims 1 to 5.

10. The fuel cell comprises a plurality of at least one fuel cell substrates, and at least two of the plurality of fuel cell substrates are arranged such that, when aligned with each other, at least one heat exchange fluid path lies between the two adjacent fuel cell substrates. The at least one third fluid path within the copper layer and / or the passivation layer on the insulating layer of one fuel cell substrate and the at least one third fluid path within the copper layer and / or the passivation layer on the insulating layer of another adjacent fuel cell substrate are aligned with each other so as to form at least one heat exchange fluid path between the two adjacent fuel cell substrates. The fuel cell according to claim 9.

11. The fuel cell substrate has at least one third insulating layer, i) The first insulating layer includes the third fluid path, the third insulating layer is located on or adjacent to the surface of the first insulating layer including the third fluid path so as to seal the at least one third fluid path, optionally the depth of the first fluid path is greater than or equal to the thickness of the first insulating layer, and the third insulating layer also seals the side of the at least one first fluid path that is not adjacent to the cathode, and / or ii) The second insulating layer includes the third fluid path, the third insulating layer is located on or adjacent to the surface of the second insulating layer including the third fluid path, to seal the at least one third fluid path, optionally the depth of the second fluid path is greater than or equal to the thickness of the second insulating layer, and the third insulating layer also seals the side of the at least one second fluid path that is not adjacent to the anode, and / or iii) The depth of the first fluid path is greater than or equal to the thickness of the first insulating layer, or the depth of the second fluid path is greater than or equal to the thickness of the second insulating layer, and the third insulating layer seals the side of the first fluid path that does not face the cathode, and / or the side of the second fluid path that does not face the anode, and / or iv) The depth of the first fluid path is greater than or equal to the thickness of the first insulating layer, the depth of the second fluid path is greater than or equal to the thickness of the second insulating layer, the third insulating layer seals the side of the first fluid path not facing the cathode, or the side of the second fluid path not facing the anode, and a further / fourth insulating layer seals the side of the first fluid path not facing the cathode, or the side of the second fluid path not facing the anode, and optionally, at least one of the third insulating layers or the fourth insulating layer is thinner than the first insulating layer or the second insulating layer. A fuel cell according to any one of claims 1 to 10.

12. iii) and / or iv) further comprises a third insulating layer and / or a fourth insulating layer, the third insulating layer and / or the fourth insulating layer having a copper layer on the side opposite to the side of the third insulating layer or the fourth insulating layer that seals the first fluid path and / or the second fluid path, and optionally the first insulating layer also includes a passivation layer on the copper layer. The at least one third fluid path is located within the copper layer and / or the passivation layer on the third insulating layer. The fuel cell according to claim 11.

13. The fuel cell comprises a plurality of at least one fuel cell substrates, and at least two of the plurality of fuel cell substrates are arranged such that, when aligned with each other, at least one heat exchange fluid path is formed between the two adjacent fuel cell substrates. The at least one third fluid path within the copper layer and / or passivation layer on the third or fourth insulating layer of one fuel cell substrate and the at least one third fluid path within the copper layer and / or passivation layer on the third or fourth insulating layer of another adjacent fuel cell substrate are aligned with each other to form a combined heat exchange fluid path between the two fuel cell substrates. The fuel cell according to claim 12.

14. In iii) or iv), the third insulating layer and / or further / fourth insulating layer includes the at least one third fluid path for the heat exchange fluid, and optionally, the depth of the at least one third fluid path for the heat exchange fluid is greater than or equal to the thickness of the third insulating layer and / or fourth insulating layer. The fuel cell according to claim 11.

15. The fuel cell substrate has a plurality of first fluid paths and / or a plurality of second fluid paths and / or a plurality of third fluid paths. A fuel cell according to any one of claims 1 to 14.

16. The at least one third fluid path has a different flow path pattern or flow field than the at least one first fluid path or the at least one second fluid path. A fuel cell according to any one of claims 1 to 15.

17. One or more of the insulating layers have one or more PCB layers. A fuel cell according to any one of claims 1 to 16.

18. At least one of the first insulating layer, the second insulating layer, and / or the third insulating layer has one or more means for conducting current from one side of the insulating layer to the other side of the insulating layer, preferably the means for conducting current is a plated through-hole, preferably a copper plated through-hole. A fuel cell according to any one of claims 1 to 17.

19. The heat exchange fluid includes water or a mixture of water and glycol. A fuel cell according to any one of claims 1 to 18.

20. One or more of the insulating layers are stacked together, mechanically pressed together, or compressed together within the fuel cell. A fuel cell according to any one of claims 1 to 19.

21. The oxidizing fluid is air, and / or the reducing fluid is hydrogen gas. A fuel cell according to any one of claims 1 to 20.

22. The fuel cell substrate has a rated power of 10W to 1000W, and / or the fuel cell has a rated power of 10kW to 1000kW. A fuel cell according to any one of claims 1 to 21.

23. Use of a fuel cell according to any one of claims 1 to 22.

24. A component for electrochemical devices, The aforementioned component includes an insulating layer, The insulating layer includes at least one first fluid path on one side of the insulating layer and a second fluid path for heat exchange fluid on the opposite side of the insulating layer. parts.

25. The second fluid path is located on the opposite side of the insulating layer, and the fluid path of at least one of the second paths passing through the insulating layer does not overlap with the first fluid path. The part according to claim 24.

26. i) The sum of the depths of the at least one first fluid path and ii) the depths of the second fluid path is equal to or greater than the thickness of the insulating layer. The component according to claim 24 or claim 25.

27. The component comprises a second insulating layer, the second insulating layer being located on or adjacent to the surface of the insulating layer containing the second fluid path, so as to seal the second fluid path, and optionally the second insulating layer being thinner than the insulating layer. The component according to any one of claims 24 to 26

28. The insulating layer has a copper layer on the opposite side of the first fluid path of the first insulating layer, and optionally the first insulating layer also includes a passivation layer on the copper layer, and the second fluid path is within the copper layer and / or within the passivation layer. The component according to any one of claims 24 to 27.

29. One or more of the insulating layers have one or more PCB layers. The component according to any one of claims 24 to 28.

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