Integrated counter flow heat and mass exchangers within fuel cells

Abstract

Integration of heat and mass exchangers within planar array fuel cells, using paired parallel counter flow channels to mass exchange and heat exchange via concentration and heat gradients through a gas permeable dielectric diffusion layer for spatially uniform delivery of heat and molecules. Provide the spatially uniform temperature and humidity environment and membrane control needed by fuel cells for optimum performance, fuel efficiency, and delivery of useful heat and desalinated water to the environment. Reduce interface connections and enable printing of the system, greater precision, and reliability. Enable faster adaptation to dynamic loads and the environment, enlarge the operating environment range, provide greater efficiency and performance. Applications to provide power to mobile and stationary systems that are exposed to a wide range of environmental conditions and performance demands for heating, electric power, fuel production, cooling, cleaning air, water purification, and humidification.

Description

[0001] Integrated Counter Flow Heat and Mass Exchangers Within Fuel Cells

[0002] BACKGROUND

[0003] There is a current and sustained demand to convert renewable energy to hydrogen to be used in fuel cells to fuel vehicles, to power utilities, and to reduce anthropological greenhouse gas emissions. To meet the mass market demand for fuel cell powered vehicles and fuel cell powered utilities, electrolysis cells need to operate reliably and be low cost to manufacture.

[0004] While most of the description herein relates to fuel cells, the teachings herein can also be applied to electrolysis cells that are essentially fuel cells with the current flow reversed, and with reactants that are produced rather than consumed. The innovations described herein are applicable to both fuel cells and electrolysis cells. I will use the term “electrochemical cells” to identify both systems. These fuel cells for vehicles need to be mass producible and be able to deliver sensible heat for batteries and passengers in the vehicles.

[0005] The devices described herein addresses multiple desired system goals with synergistic physical mechanisms put uniquely within the fuel cells and electrolysis cells to optimize performance. There is a need to remove inert cross-over gas impurities through the electrolyte in fuel cells and provide uniform temperature with heat flow removal or addition to the fuel cell electrodes. For optimum performance, there is a need to maintain a uniform concentration of reactants over the surface of the fuel cell electrodes, uniform concentration of inert gases, and uniform temperature and humidity. A homeostasis water balance of the fuel cell needs to be achieved over a range of ambient temperatures and humidity. This is necessary to obtain optimum performance. The water balance necessary in operating a fuel cell is similar to the water needed in an animal cell to maintain cell function. Without this water balance, the fuel cell can flood or dehydrate, reducing the performance of the fuel cell.

[0006] As an example, within the fuel cell electrodes of fuel cells fueled by hydrogen and oxygen from the air, there is a triple interface zone where electrolyte, catalytic electrodes and reactant fluids are in diffusive contact with each other. This is typically an intersection of solid, liquid and gas. In this triple interface the reactants diffuse through the electrolyte, and catalytically on the electrode exchange electrons with the electrode. The reactant atoms form ions in the electrolyte and move through the electrolyte while the electrons move through the electrodes from the negatively charged electrode to the positively charged electrode. The electrons go through the electrical load and the ions travel through the electrolyte that separates the reactants and the electrodes of the fuel cell. The ions and the electrons are re-united on the oxidizer electrode. The product of uniting the ions with electrons on the electrode forms water on an electrode.

[0007] When operating, the fuel cell must balance the water content of the electrolyte so that it completely covers the electrodes or it will evaporate and dry out and lose contact with the electrodes. When an ion travels through the electrolyte it will drag water molecules through the electrolyte flooding one electrode and drying the other, so a recirculation, diffusion, or pressure push back of the water is needed to provide the water to maintain liquid contact on the electrodes. Hydrophobic and hydrophilic surfaces and porosity are typically used to position the water on the electrodes. Wicking materials and channels have been used to remove and add water to the two sides of the fuel cells. As fuel cells operate, this water balance of the fuel cell is crucial to maintain performance. During operation this dynamic water content equilibrium of the fuel cell can be maintained by removing water at the same rate that it is created. This can be done by removing liquid water or water vapor from the cells.

[0008] The fuel cells also create and remove heat from the enthalpy change from the reactants to products, from the reaction inefficiencies, and ion and electrical flows. In most cases the fuel cell needs to remove heat. Removing product water and heat can be done by circulating the electrolyte with a dehydration mechanism or evaporating the water from the electrolyte within the fuel cell or both mechanisms simultaneously. Thermal contact with conductors, liquid circulation and radiant cooling have been done. To evaporate water from the fuel cell, excess unsaturated air or fuel flow can flow across the fuel cell electrode with the water diffusing from the electrode to the air. The water carried in the gas can be condensed if the temperature of the gas is lowered and the heat of condensation is released. If the temperature of the fuel cell, flow of reactants, heat flows, and water content of the reactants is controlled and can be adjusted, the water balance of the fuel cell can be maintained. A typical polymer electrolyte fuel cell has a dynamic equilibrium operating temperature of 80°C. In applications such as in automobiles, the power output can be very dynamic and the humidity, temperature, and pressure environment can change. For the automotive environment, fuel cells are expected to operate in an external environmental extreme ranging from -40°C to 50°C, 0% to 100% relative humidity and air pressure of 1 bar to Vi bar. Therefore, to maintain a typical optimum condition in the fuel cell, the system that is in earth’s climate needs to be able to start at low temperatures from -40°C to 40°C and rise to 80°C.

[0009] A critical problem is to not allow liquid water, such as condensate inside tubes and channels and fuel cell electrodes, to freeze and expand and be damaged by excess tension stress. Concentrated electrolytes freeze at lower temperatures. Two problems occur with cold start-ups. The electrolytes are cold and can even be frozen, so they have very low ionic conductivity, and the fuel cell has insufficient power output to heat itself. Once the fuel cell is started, the product water will condense within the fuel cell flooding the catalytic electrodes. Typical solutions are to externally heat the fuel cell or catalytically bum fuel within the fuel cell by mixing air and fuel on the fuel cell electrodes. The external heat source, such as a warmed building or electrical source with a resistance heater, may not be available. The internal catalytic combustion on the fuel cell electrode can lead to internal fires, explosions, hots spots or degradation of the electrodes, electrolytes, and hydrophobic surfaces.

[0010] Catalytic combustion on the fuel cell electrodes can also lead to water condensation on the electrodes and flooding, particularly if there is a need for substantial heating. Surrounding electronics and batteries, particularly semiconductor electronics, liquid crystal displays and lithium-ion batteries, may have difficulty operating in the range of -40°C to 40°C. The human beings and cargo inside the cabins of the vehicles also may be damaged over these temperature extremes. The ideal operating temperature range for lithium-ion batteries that may be in the vehicle for propulsion power and general electrical power is 15°C to 35°C. Heating, cooling, and humidity control is needed to bring the vehicle interior to human comfort temperature and humidity ranges of roughly 22°C to 27°C and a 40% to 60% relative humidity.

[0011] Most of the current fuel cell and electrolysis systems have separate heating and cooling systems, heat exchangers, and air humidifiers. Reactant flow and product flow to and from each fuel cell or electrolysis cell must flow laterally through the bipolar plate networks and electrical current must flow perpendicularly through the bipolar plates. By eliminating the bi-polar mechanical stack of the fuel cell with the accompanying gasket seals and compression, catalytic heaters and heat exchangers can more easily be placed in intimate thermal contact with the fuel cell or electrolysis cell. By changing the fuel cell stacking to a planar fuel cell array there is the need to electrically separate adjacent cells with dielectric breaks and prevent electrolytes and liquid water from bridging these dielectric breaks.

[0012] Also described herein are devices that eliminate condensed water and electrolytes from bridging the gaps and prevent water freeze expansion damage and dehydration in the fuel cell system. Ionic drag in solid electrolytes that can move water to one electrode and dehydrate the other can be re-balanced.

[0013] I have estimated that in just the fuel cell or electrolysis cell that a 35% to 90% cost reduction could be realized by switching to a planar current collection scheme rather than a bi-polar stack, and thereby eliminate competition for space and volume with the collection of electrical power from the fuel cells. Mechanical gas seals of bi-polar stacks are eliminated by using welded seals. Heat exchangers and gas manifolds to the fuel cell or electrolysis cells do not have to have electrical conductivity to conduct electrical current between fuel cells. And they can be made at a lower cost with dielectrics such as polymers or ceramics that can obtain lower weight and higher heat exchanger efficiencies with gases and can withstand oxidizing and reducing environments. Water, fuel, and air are safer to use by electrically separating the high voltage electrical current collection system from the heat exchange system. This leads to the ability to rapidly heat or cool the fuel cell system. New advances in 3D printing capabilities have opened the opportunity to print optimized geometries of heat exchangers with materials such as metals, polymers, biological active materials, and ceramics. Enclosed channel spaces can be created for optimum mass transfer and heat transfer surfaces. Printing technologies allow the structure and composition of materials in the completed device to be varied within the structure. Catalytic, hydrophilic, hydrophobic, elastic, rigid, porous, selectively permeable, and impermeable deposits can be created in different zones all within the same printed component. 3D printing of most or all the system is possible. Rolled packed systems are possible with the planar array of fuel cell or electrolysis cells, gas manifolds, heat exchangers, catalytic heaters and humidity control membranes that can be printed and rolled. Folded packed systems are possible. Elimination of connectors can be done. The challenge is to engineer fuel cells to be dependable, robust, able to start at low temperatures, maintain operation conditions while having dynamic electrical loads, heat and cool, and be economical for product applications.

[0014] A particular need of planar array fuel cells over bipolar fuel cell arrays is that they need to supply fuel and oxidizer uniformly to all cells that arc in an electrical scries. The bipolar cell stack typically can tolerate a lack of uniform fuel on oxidizer distribution on an electrode simply because it is all at the same electrical potential and some portions would produce less current. But in an array of cells with a common fueling and oxidizer manifold the lack of ability to produce current in a cell would result in high voltage across that cell and could act as an electrolysis cell. In the most severe situation, we could dehydrate the fuel cell electrolyte creating a high resistance to the current output of the array and possibly melt and breach that fuel cell.

[0015] Reasons to Switch from Bipolar to Planar Electrical System in Electrolysis Cells and Fuel Cells

[0016] Intrinsic Conventional Bipolar Electrolysis and Fuel Cell System Faults

[0017] 1. The bipolar plates in electrolysis cells and fuel cells are done to increase output voltage of these devices to consume or deliver power to cells that have voltages between 0.5 and 1.8 volts and with electrical conductors to and from electronics and motors that are manageable in size and mass. The mass and cost of the electrical conductors is proportional to the square of the distance traveled between cells. What this means for system design is keep the distances short and the cost and mass of conductors will go down dramatically.

[0018] 2. Conventional bipolar plate systems try to minimize the distance through the plates to the next cell. But these plates also provide the reactant flows and heating and cooling flows. Thus, there is an intrinsic compromise between minimizing the plate thickness for reducing the cost of the plates and gas flows with larger reactant flow channels for lower drag.

[0019] 3. The conventional bipolar plate system is a mechanical assembly of a sandwich of electrolyte, two electrodes, two gas diffusion layers, and bipolar metal plates. This sandwich requires 6 seals on the perimeter edge and mechanical compression to make mechanical electrical contact and gasket compression. When the cells pressurize, the internal pressure pushes on the end plates and the gaskets. The end plates are typically made to be as rigid as possible to minimize the bending of the plates and thereby reduces the electrical contact pressure between the cell electrodes, diffusion layer and the bipolar plates. This leads to the conventional bipolar stack end plates to be as rigid as possible, heavy, and expensive. The typical electrolytes can expand or contract when hydrated or heated so the assembled stack is held together with spring loaded bolts that can make electrical contact across the stack. The gas diffusion layer on either side of the cells is typically an elastic electrically conductive felt that maintains electrical contact even while the end plates bend and the stack expands. If the desire is to go to high operating pressures, the bipolar system has to increase its strength and rigidity, driving up cost and mass.

[0020] 4. The mechanical electrical contacts in a wet electrolyte environment of electrolysis cells or fuel cells are a challenging corrosion situation for the metals or semi-metals on the electrodes, gas diffusion layers and bipolar plates.

[0021] 5. A system safety maxim is to minimize the metal to dielectric contact of an electrochemical system to be a fuse rather than a short. If there is an electrical short, such as through a cell, it is desirable to locally fuse that region to seal and open the electrical short. This allows the system to keep running and prevents a catastrophic melt expansion and breach between fuel and oxidizer. A cell system that shorts can divert all the electrical and chemical energy into the short and is a burning or explosion failure.

[0022] 6. Some fuel cell and electrolysis systems will be in high acceleration and vibration environments. Inertial mismatch between metal electrical plates and elastic gas diffusion layers and thin electrolyte separators could be a recipe for impact breaching and friction wearing.

[0023] 7. The optimization of a bipolar stack is to minimize the resistance though the electrolyte by making it thinner and increasing the electrical conductivity of the bipolar plates with more metal mass. This is pushing the system toward a greater chance of catastrophic failure. There is a way to escape this trap.

[0024] Intrinsic Planar Electrolysis and Fuel Cell Array System Benefits

[0025] 1. With the planar system, the parallel series array of cells can be printed to have small high voltage series cells and all arrays deliver the same output voltage. A far less fraction of the total mass of the system is devoted to current conductors.

[0026] 2. With the planar system, the current is collected laterally to the plane of the cells in the space above the cells. It can be enlarged to accommodate larger reactant flow channels and lower drag on reactant flow. Plus, the flow channels can be made of dielectrics instead of metal. This eliminates electrochemical corrosion of mechanical contacts in bi-polar stacked fuel cells. It also allows tubular membrane electrolytes to enter and exit in close proximity through porous dielectrics to the fuel cell electrodes to flow electrolytes and exchange water vapor and not make electrical contact and carry electrical currents. Dielectrics such as ceramics, plastics, and rubbers are less expensive and lighter in weight. Many of these dielectrics can also be 3D printed. Each planar cell array can be made to have one seal on a common reactant manifold over many cells with all the anodes in one manifold and all the cathodes in separate manifolds. One arrangement is to have two planar arrays back-to-back with the anodes hydrogen facing each other with a common hydrogen manifold and oxygen manifolds. These can have welded perimeter seals. The cell array and manifolds can be placed within an outer pressure vessel to operate at high pressures. If the difference in pressure across cells is kept equalized there is no significant pressure across the electrolytes and the entire system pressure can be raised to the limit of the outer pressure vessel shell rather than that of the gaskets. The cell electrical contact does not need mechanical compression to make electrode-electrolyte contact. The planar cells should be designed to hold the electrode and electrolyte together without mechanical pressure. To do this the electrolyte or porous substrate that holds the electrolyte needs to be able to withstand internal tension holding bonded electrodes onto the electrolyte. This is analogous to a printed circuit board. No more wet electrical contacts! The series array of cells makes continuous metallic deposits contact through the dielectric substrate or the electrolytes. Electrical contact to the outside of the fuel cells can be through continuous printed circuits and pass through dielectric seals. The metal to dielectric ratio by volume can be very small with the electrical circuitry being thin film deposits. The dielectric reactant manifolds, such as plastics or ceramics, can be robust for strength without compromising conductivity and efficiency of the system. By increasing the dielectric mass, safety increases with the fusing effect of opening circuits and melting seal breaches. This anticipates making the fuel cell self-healing to small leaks or shorts and to fail safe in the event of mechanical trauma such as crashes, impalements, or bullets. Fuel cells can excel in vibration and acceleration environments. They could increase longevity in these environments by removing the large dense metal objects bipolar plates and their end plates from next to low density elastic and low strength materials gas diffusion layers, electrodes, and electrolyte that make up the cells. A rough analogy is like shipping a brick with wine glasses in a package. The planar fuel solution is to eliminate the high-density inertial masses and match all the materials to have similar low inertia, elasticity, and high strength. Elimination of the bipolar plates’ cost and the mass of these plates is driving the optimization to maximize the power per square centimeter of fuel cell electrodes to amortize the cost of the bipolar plates. The electrolytes arc thinned to increase conductivity pushing toward more fragile fuel cells. Without the bipolar plates the optimization can reduce the power density per unit area and increase the thickness of the electrolytes, thus increasing the mechanical strength of the cells and increasing surface area to meet power requirements with more efficient reactant flows and cooling. The power per unit mass can be increased several times over the bipolar cells because of the lower system mass without the bi-polar plates, all while the mass density goes down.

[0027] The unique problems of planar electrolysis cells and fuel cells:

[0028] 1. The cells need to be printed on a stable and strong substrate.

[0029] 2. The print needs to hold firmly to the substrate under tension and compression.

[0030] 3. The substrate needs to not deform or creep.

[0031] 4. Condensed water and electrolyte should not bridge the electrical gaps between the cells. Bipolar plate systems will not short if the cells are flooded. They may not allow any reactants to the electrodes but they will not short the system and can be partially flooded and still operate. This one difference is due to the way the electrode geometries are arranged. The bipolar arrangement has a similar shorting weakness if water or electrolyte is outside the cell and current can flow between electrodes. The imperative for the planar electrolysis cells and fuel cells is to keep the electrolyte and condensed water from forming sufficient size to become a continuous layer over the cell gaps. Water control and position in the planar electrolysis cells are vitally important to function. The devices described herein address exact water control with devices in electrolysis and fuel cells to function and perform well in a wide variety of situations. These include start-ups, shutdowns, cold and hot operating environments, high and low pressures operation, low and high humidity. They also include salt spray, snow, hail, rain, dust, viruses, fungi, and airborne contamination, plus the need for desalinated water or increased heat output, dehydration and / or cooling of air. They can also perform well with water sources that are contaminated with salts, hydrocarbons, metals, biological life, biological effluents, and catalytic poisons. The adaptive mechanisms are expected to be unique to electrolysis cells and fuel cells because they have unique electrochemical mechanisms not obviously found in nature. By embodying unique adaptations, environmental conditions can be adapted to. This will push the design of the electrolysis and fuel cells to be more functional and mass producible. SUMMARY

[0032] System Design

[0033] Engineer fuel cells combined with catalytic heater systems that would be robust and fail safe in the automotive and aircraft environments. We expect the following component innovation can be made stemming from eliminating the bi-polar stacking of conventional fuel cells and incorporating catalytic heaters with heat exchangers into a single module. Some of these innovations are done to enable the system to be adapted to the environment or work in the operational range of vehicular heating and electrical power needs. Other innovations are unique to enabling the planar array to have an efficient and robust performance. New material discoveries can be advantageously utilized to enable this new system because of changed physical property constraints of the system.

[0034] Fundamental System Design Objectives

[0035] 1. Increase the environmental temperature range in which fuel cell systems can start and operate.

[0036] 2. Make the system more robust to shorting failure by raising the insulator to metal ratio of system.

[0037] 3. Make more mass producible by eliminating the bi-polar plates, seals, and mechanical stacking.

[0038] 4. Use planar electrical collection geometry, printed electrodes, and catalysts.

[0039] 5. Integrate the fuel cell, heating and cooling system with the vehicles or structures.

[0040] 6. Filter and disinfect air into both fuel cells and vehicle.

[0041] 7. Maintain electrolyte hydration and desalinate water from both the ionic drag effect and multiple effect distillation.

[0042] 8. Provide air dehydration for cooling.

[0043] 9. Improve temperature uniformity of heat delivered by incorporating evaporation, boiling, condensation, and heat pipes.

[0044] 10. Increase system efficiency by using counter flow heat and counter flow molecular exchange. 11 . Increase uniformity of molecular diffusion delivery by counter flow exchange to a target manifold that flows back on its own flow or uses two counter flows in molecular exchange to target manifold.

[0045] 12. Increase manufacturability and reduce system weight by spiral packing the fuel cell components.

[0046] 13. Increase system reliability and responsiveness by using electronic feedback and control.

[0047] 14. Tighten the temperature and humidity control.

[0048] 15. Lower the system start-up temperature and time by using catalytic heating for startup heat and gas purging.

[0049] 16. Enable the fuel cell and water desalination to adapt to a range of power output conditions and environmental conditions, inside and outside the fuel cell, and optimize its performance and efficiency.

[0050] 17. Enable the fuel cell system to safely adapt to a range of failure conditions, electrical shorts, flooding, dehydration, breaches, overheating, fire, explosions, flow blockage, and catalyst poisoning.

[0051] 18. Take advantage of new electrolytes, substrates, and graphene.

[0052] 19. Design the system to use deposition and printing technologies for mass production.

[0053] 20. Design the system components such that they can be 3D printed to enable higher performance, lower product costs, and repair costs.

[0054] 21. Increase the system mechanical elasticity by increasing the use of plastics and composites instead of metals and semi-metals.

[0055] Matrix of System Objectives

[0056] Increase the environmental temperature range in which fuel cell systems can start and operate.

[0057] Fuel cells have an optimum operating range of temperature in which they perform well. This range is typically set by the electrolytes’ conductivity and the reactivity of the reactants with the catalysts. The electrolyte conductivity requires that the ions be mobile in the electrolyte; too cold and the ions are immobilized, too hot and the solute vaporizes, and the ions do not exist. The catalytic reactivity typically follows the Arrhenius relationship with temperature that roughly doubles the reactivity for each rise of approximately 8 degrees Kelvin at about 300°K. If we provide a means to heat, humidify and hold the fuel cell in optimum environmental conditions, the fuel cell performance can be optimized. When fuel cells arc in a lower power mode the conduction heat losses to the environment are a higher proportion of the systems fuel cells’ heat production. Fuel cells can condense product water internally and flood the electrolytes and gas flow channels. Thus, the higher the heat exchangers’ efficiency, to bring in dry oxygen or air and remove product water then the lower the idle power and heat that are needed to keep the fuel cell operational. At maximum power, the fuel cell will need to remove heat to the environment and can distill water, barring the electrochemical limits of ionic conduction and electrical conduction. The more effective the heat removal at the set temperature - without dehydrating the electrolyte - the higher the operational environmental temperature that the fuel cell can operate in.

[0058] Make the system more robust to shorting failure by raising the insulator to metal ratio of the system.

[0059] Conventional low temperature fuel cell stacks have large metal plates separated by thin electrodes and membrane electrolytes. This design is focused on minimizing the electrolyte resistance and collecting low voltage current from discrete layers of the fuel cell electrodes and porous conductors by mechanically making compression electrical contact in a wet environment. Gas seals are made at the perimeter of each cell and electrical separation is made by the electrolyte or dielectric framing each electrolyte. The weakness of this design is that the seals and electrical separators are the pressure housing of the fuel cell or electrolysis cell. If there is an electrical short through the electrolyte, the high proportion of metal content leads to a melting of metal and vaporizing of the electrolyte or dielectric separator. The system will be fused closed instead of fused open. By having the ability to rapidly and precisely print onto porous dielectric membrane substrates, the situation is changed to a mass-produced system to be a high voltage low current collector scheme with a low metal content fraction. This low metal content ratio with meltable dielectrics results in electrical shorts that open their circuits and weld the dielectric to seal the breach. Make more mass producible by eliminating the bi-polar plates, seals, and mechanical stacking.

[0060] Conventional low temperature fuel cells and electrolysis stacks have large metal plates separated by thin electrodes and membrane electrolytes. This stacking with spring-loaded bolts does not lend itself easily to rapid precision production. The alternative is to print the components on a tough dielectric substrate and sealed packages as a mass production unit. In the event of a substantial internal failure the unit is replaced and recycled.

[0061] Use planar electrical collection geometry, printed electrodes, and catalysts.

[0062] By using a planar electrical collection geometry away from a bipolar electrical collection geometry, the amount of metal content of the fuel cell system is reduced dramatically because the electrical high voltage and lower currents can be carried by metal films. The competition for space in a bipolar stack system between electrical collection and reactant flows is eliminated. The reactant flows can flow through light weight dielectric flow channels rather than metal plates. The density of plastics are typically several times lower than metals. Plastics and rubbers are more flexible and will allow the possibility of curving the fuel cell arrays to enable cylindrically wound fuel cell membrane arrays.

[0063] Heat pipe or fluid cooling in a non-current carrying component.

[0064] A secondary but vital task of fuel cells and electrolysis cells is to maintain operating temperature and be a source of heat. Therefore, they need the capability to exchange heat. Ideally, they should be able internally to collect or receive heat at constant temperature to maintain a uniform performance within the fuel cell and avoid water condensation buildup or depletion. Heat of evaporation and condensation can be utilized. Heat delivered from a fuel cell or electrolysis cell can be delivered to batteries or humans. They need heat delivered in a narrow range of temperature and to be uniformly distributed. Therefore, heat pipes that can remove and deliver heat at a temperature uniformly over an area can be integrated into the fuel cell or electrolysis system. Conventional bi-polar stacked fuel cells are not amenable to sealed metal heat pipes inserted into the bipolar cell separators because of the need to maintain electrical conductivity, which means the heat pipe would be at the voltage of the cell stack where it is inserted. If multiple heat pipes are inserted into the fuel cell they would be at multiple voltages. This is a hazard with an electrified heat transfer system. A dielectric separation with planar array fuel cells is more compatible with heat pipes. Prior art bipolar fuel cells often use circulated liquid water in the bipolar plate to cool and remove heat from fuel cells and electrolysis cells. Typically, the water is deionized to avoid the liquid water being electrically conductive and providing electrical shorting paths within and outside the fuel cell and being an electrical hazard.

[0065] Use planar electrical collection geometry, printed electrodes, and catalysts.

[0066] The concept of printing a fuel cell electrode in planar geometry has been implemented with micro-fuel cells and solid oxide fuel cells. It is enabled by a suitable porous dielectric substrate. That enables a high dielectric system ratio. That ultimately will make the fuel cell and electrolysis systems robust and fail safe. The planar current collection increases the degree of system configuration freedom to use more space above the electrodes to move reactants, heat, and products. Printing the fuel cell electrical circuits on the electrolyte holding substrate also allows for semiconductors and sensors to be printed as well, which can enable diagnostics, electrical switches, and micro valve control inside the fuel cell.

[0067] Counter flow heat and molecular exchange.

[0068] Counter flow heat exchange is the most efficient heat exchange mode for heat exchangers by maintaining a constant thermal gradient between the exchanging fluids. There are parallels in molecular exchange as well. Heat transfer uses thermal gradients to move heat, while molecular exchange uses concentration gradients. Counter flow heat transfer and a molecular exchanger can be used to heat incoming air or fuel and exchange water into the fuel or air. Counter flow molecular' diffusion exchanger through membranes can be done to deliver hydrogen to the fuel cell electrodes and water to the fuel electrode with concentration gradient, while removing impurity gases by molecular diffusion through the same membranes with concentration gradients. Many fuel cells without humidification will have poor performance if the electrolyte is dehydrated. Inert gasses diffuse through the electrolyte into the fuel gas manifold and inhibit the flow of hydrogen delivery to the fuel electrodes. A typical solution has been to periodically purge the fuel gas to remove the inert gas concentration build up. This is wasteful and potentially explosive. Liquid electrolytes can be diluted with product water and flood the fuel cell electrodes. One solution is to extract excess water, as liquid or vapor, from the electrolyte with an osmotic membrane retaining a separate circulated vapor pressure reducing electrolyte and without removing the ions of the fuel cell electrolyte. The walls between gas flows can be selectively permeable to transfer hydrogen and water but not inert gasses such as nitrogen and argon. Two flows that are counter flowed can achieve the same result as a double backed flow on a single flow with a third component, such as the fuel cell electrodes, in diffusion communication. This maintains an optimum temperature, reactant, and humidity environment in the fuel cell.

[0069] Counter flow heat and molecular exchange.

[0070] The objective in the reactant gas manifolds of the fuel cell is to deliver a more uniform intensity of reactants such as hydrogen molecules per unit area and oxygen molecules per unit area to the electrodes of the fuel cell. Another objective is to remove product water as vapor from the electrodes and add water to the electrolyte of the fuel cell, as well as heating or cooling the fuel cell electrodes. For the fuel cell or electrolysis cell to achieve and maintain optimum performance, balanced amounts of reactants and products in the electrodes are needed. The counter flow heat and / or mass transfer with a double back flow or paired counter flow channels can be created such that a molecular component can be consumed with a more uniform distribution of reactants, even though the concentrations and temperatures in the individual flows are declining as they pass over the fuel cell. This result comes from a more uniform distribution of reactants by physically pairing counter flows that can transfer heat and mass between the flows to the fuel cell such that a more constant average concentration gradient, and thermal gradient, occurs in the flows to the fuel cell. This arrangement is also effective for heat transfer from a hot fluid to heat a surface uniformly with a heat conductive layer in thermal communication with both flows and the heat consuming target surface. This heat transfer system can be used to remove heat uniformly from the fuel cell electrodes and deliver it uniformly to a target system such as a battery bank with fluid heat transfer.

[0071] Tubular membrane reactant and water diffusion circulation delivery.

[0072] Insertion and even distribution of fuel and water vapor can be accomplished by a fuel or water held within a membrane. This could be single or multiple selectively permeable membranes such as micro-porous Teflon, urethane, or silicone rubber. Single or multiple tubes can loop in and out of the manifolds to the fuel cells or electrolysis cells. The membrane reservoir can have a vapor pressure reducing additive such as a salt electrolyte, acid, or base that can reduce the vapor pressure of water so that the membrane delivery system will not deliver saturated water vapor gases, effectively creating an equilibrium vapor pressure control of the water content of the fuel cell electrolyte. Therefore, when the fuel cell electrolyte is dehydrating from ionic drag, water vapor from the tubular membrane will be delivered to maintain hydration and when an electrode is over hydrated from ionic drag, water vapor will be removed to the tubular membrane. The tubular membrane can also be 3D printed into and onto the fuel cell membrane electrode assemblies and / or the reactant flow manifolds and heat exchangers. By incorporating the circulation of an electrolyte liquid in the fuel cell gas heat and mass heat manifolds and heat exchangers, the heat carrying capacity and temperature stability from both the evaporation and heat capacity of the fluids flowing though the manifolds are higher than gas flows and have a higher specific heat transfer per unit mass than liquid circulation heat transfer systems.

[0073] Use spiral packing.

[0074] Bipolar stacking of fuel cells and electrolysis cells series connections have mechanical fluid seals of typically six per cell. It is not amenable to placing non-electrically conductive reactant manifolds between the cells because of the requirement that electrical current flows through these manifolds. As an example, successful lithium-ion battery designs have spiral stacking and are successful in providing high surface areas with thin electrolytes, minimizing the exterior surface area, and have light weight welded seals. They also have spiral winding about a cylinder with multiple flow channels within the cylinder with open ports printed, flow channels on the planar fuel cell arrays, reactant heat exchange channels and manifolds. The electrical contact is also a wrapped contact on the cylinder that has at least a portion of the tube being electrically conductive. High voltage electrical contact can be made on the outside of the spiral and secure the tension and expansion of the spiral wind with an exterior cylindrical pressure wall that is at least partially electrically conductive. Micro valves for local thermal, pressure, and humidity control.

[0075] Wc have explored local climate control with self-actuating micro valves to control diffusion and heat transfer. The example in nature is the stomata of plants that respond to temperature and humidity. The fuel cells are dynamic and need to accommodate local excess temperature or humidity such as heat loss from the perimeter of the fuel cell assembly. Self-actuating micro valves allow increased evaporation to cool or shed condensed water, or close and thermally insulate. The diffusion gas layer can change its diffusion properties to regulate moisture transpiration rates and heat loss rates. The fuel cell electrode and electrolyte system can have a local positive feedback loop effect. For example, if a region heats up faster than a neighboring region the electrolyte can cause the performance to increase, heating and drying the electrolyte, while the neighboring region is cooler and flooded with condensation, reducing performance. A micro valve system can provide a negative feedback loop that reduces diffusion of reactants slowing performance and moisture loss, while the neighboring region increases performance with increased reactant flow and increased removal of water product. Micro valves also can be used as pressure vent valves that avoid excessive pressure across membranes. Micro valves can be used as auto sealing valves to cutoff reactants if temperatures are excessive in a region of a fuel cell manifold. Micro valves can be used to limit or block flow if excessive flow occurs, such as a breach to prevent excessive reactant losses and fires. By using the print format on a planar substrate, 3D printing of the small micro valves can be formed directly within the fuel cells that would otherwise be difficult or impractical. Due to their small scale, micro valves can regulate flows and can mix and disperse flows on small areas to collectively affect a more uniform flow and diffusion over the fuel cell electrodes and moisture and heat transfer areas. Larger scale valving would have more concentrated flows and require larger mixing and diffusion manifolds. Within the multiple effect distillation in heat exchangers to transfer water vapor from an electrolyte retained by a selectively permeable membrane or small pore hydrophobic barrier, a temperature difference between the electrolyte surface and the condensing surface must be above the point that the condensing surface has a lower vapor pressure than the electrolyte surface to transfer water. The micro valves can be placed inside the heat exchangers such that they can react to relative humidity, temperature, or temperature gradients to adjust fluid flows or diffusion flux to maintain the distillation effect. This control is particularly useful to adjust water retention or removal from the electrolytes when the fuel cell electrical power output is dynamically changing or changes in the outside environment occur.

[0076] Electronic feedback and control.

[0077] Fuel cells and electrolysis systems are complex. They will need sophisticated feedback loops to control their internal housekeeping and respond to the surrounding environment.

[0078] Tighten temperature and humidity control.

[0079] Fuel cells and electrolysis cells are dramatically affected by the range of climates on earth. They produce products that can build up and need to be removed to continue operating or need a minimum temperature and humidity for the electrolytes to function. Catalytic heaters inserted into the fuel cells can function over wider ranges than the fuel cells. The catalytic heater can be used to moderate the environment for the fuel cell or electrolysis cells.

[0080] Catalytic heater for startup, shut down, pressure balance, and purging gas.

[0081] Fuel cells and electrolysis cells usually have an optimum operating range in which they can perform well and continuously. Upon shut down, humidity needs to be sufficient to keep the electrolytes conductive or dehydrated and the fuel is removed. To start back up, the temperature can be increased to the operating range, the electrolytes humidified, and fuel and oxidizer flowed through the system. The purge of inert gases also results in puffs of fuel or small leaks, such a loss of fuel and possible safety hazard. The use of a catalytic heater can provide the heating and humidification, and catalytically combust purge gas. When operating, the fuel cells can create pressure differences between the fuel and oxidizer manifolds from molecular diffusion through the electrolyte, ion drag, water vaporization, leakage, reactant flow mismatching and pressure regulation. This can cause pressure differences across the electrolyte, that can lead to electrolyte membrane bursting, wear on the electrolyte membrane and changes in electrolyte positioning and water mass flow. A solution is to provide a pressure relief route between the fuel and oxidizer through a catalytic heater that will combust excess fuel with the oxidizer. By maintaining low pressure across the electrolyte, liquid electrolytes positioning with capillary effects is also feasible. Mitigation of leaks is also a feature of keeping an equal pressure across the electrolyte membrane. Designed Electrolyte / Substrate to take advantage of new electrolytes and substrates, including graphene as a possible component.

[0082] There are a host of new materials that have been discovered recently discovered that have possibly useful properties such as graphene having the unusual property of exclusive proton transport through perpendicular to the graphene plane. This could be used to reduce the molecular diffusion cross over of fuel and oxidizer and inert gases from air such as nitrogen, and argon through the electrolyte. It can also be used to stabilize liquid electrolytes in the fiber or porous substrate of the printed fuel cell arrays. Graphene is a good electrical conductor in the planar direction. It can be incorporated as planar electrical conductors between the fuel cells.

[0083] 3D printing for heat exchange and possibly most of the system.

[0084] Metal deposition methods, inkjet printing and 3-D printing techniques can be used to print tubular channels and different layered materials. In forming this system, the fuel cell / electrolysis cell arrays are printed on a porous dielectric substrate with conductive metal electrodes, catalytic inks, and electrolytes. Then porous hydrophilic and hydrophobic layers are printed to create wetted electrode areas over the fuel cell electrodes and non-wetted areas in the cell vias and gaps. Gas Diffusion Layers that are hydrophobic, and possible wicking channels, are printed over the fuel cell electrodes. Fuel and air gas distribution tube manifolds are printed over the gas distribution manifolds. Heat exchangers and catalytic heaters are printed onto this assembly.

[0085] Design in mechanical elasticity.

[0086] A concept is to create Elastic Polymorphic Surfaces to enable the product to have the ability to be tough and elastic. Ceramic materials are compatible over a wide range of temperatures and chemical environments that the fuel cells and electrolysis cells experience. Catalytic heaters work very well with ceramic substrates, but these materials are typically very brittle. To ameliorate the brittle property, the structures of the system can be made so that they can bend and flex. There is also the possibility of blending materials to give them hybrid properties. By incorporating these design forms into the product, a higher toughness could be achieved. With the shaping and three-dimensional printing of elastic polymorphic surfaces of the materials in the fuel cells we can add both elasticity and better fluid heat transfer and molecular transfer performance into the fuel cells.

[0087] Use semipermeable membrane tubes or membranes in gas manifolds and heat exchangers. Semipermeable membranes can be used to filter molecules from fluids. Salts and electrolytes can be contained by the semipermeable membrane. The relative humidity in a fuel cell needs to be regulated to maintain electrolyte conductivity and the ideal position of the triple interface is between the catalyst, gas, and electrolyte - the electrochemical active sites. If electrolyte fluid is circulated through a semipermeable membrane tube through the heat exchangers and into the fuel and / or the oxidizer manifolds, a delivery of water vapor at a set relative humidity can be achieved. The vapor pressure of the electrolyte within the semipermeable membrane reservoir can be set to the relative humidity at the exterior surface of the membrane. When the relative humidity goes below the vapor pressure of the contained electrolyte, water vapor diffuses into the manifold and fuel cell electrolyte. When the relative humidity goes above the vapor pressure of the electrolyte, water will condense into the contained electrolyte behind the semi-permeable membrane. Electrolytes that could be used are salts such as NaOH, KOH. Acids such as H2SO4 ,or H3PO4 can have an acidic vapor pressure that can be helpful to maintain the acid content of the solid polymer electrolytes of the fuel cell. The circulated, heated, and cooled membrane tubes that go through the heat exchangers can be used to capture or neutralize poisons to the fuel cell such as CO2 for alkaline electrolyte fuel cells and limestone dust for acidic fuel cells. After it has delivered water vapor or acquired water vapor, the electrolyte can be cooled, exposed to condensed water in the heat exchangers and returned through the heat exchangers to humidify the fuel cell electrodes. De-humidifying air entering cabins can be done with a circulated membrane containing electrolyte and an additional source of water to humidity the fuel cells.

[0088] Use of semipermeable membrane between double backed in fuel manifold to concentrate inert gasses.

[0089] If the mass and heat exchangers’ manifolds to the fuel cell electrodes have semipermeable walls and / or the gas diffusion layer to the fuel cell, they can exchange molecules with the fuel cell. Typically, the fuel flow, such as pure hydrogen gas, flows to the fuel cell manifold and it is diffused to the fuel cell electrodes to be at a partial pressure on the consuming electrode. Simultaneously, inert gases such as nitrogen and argon diffuse from the air through the electrolyte into the hydrogen gas on the electrode and into the flowing manifold gas. Typically, the hydrogen gas concentration declines as the gas flows along the fuel cell electrodes. At the end of the fuel flow in the fuel cell the gas is depleted of hydrogen and the remaining gas is nitrogen and argon. It can be purged by venting through the fuel cell (dead ended) or out to the atmosphere (purged). Both these techniques represent a loss in performance because the concentration of hydrogen is not uniform across the fuel cell electrodes and purging released hydrogen. We demonstrate herein that the hydrogen concentration across the fuel cell electrodes can be optimized and more uniform. Reduced purging through a catalytic heater can be safer and can also convert purged fuel to useful heat and water.

[0090] Use of evaporative cooling and to remove heat and transfer heat from the fuel cell to external loads.

[0091] Hydrogen / air fuel cells produce water when they are running. They produce an imbalance of water across the electrolytes and circulate water due to ion drag in the electrolytes. The water can evaporate into the air flow from the surface of the fuel cell and cool the fuel cell. Using heat exchangers, the water can be condensed and recirculated through the membrane tubular system. Or it can be vaporized into the entering fuel stream as water vapor and vaporized from the circulated electrolyte inside the fuel manifold contained in a selectively permeable membrane. The heat of evaporation will be transferred where the evaporation is occurring.

[0092] Exchange water from exhaust flow to fuel flow.

[0093] Internal circulation of condensed water through the fuel cells can be done to maintain water balance on the fuel cells. A portion of the condensed water can be transferred into the membrane containing electrolyte through the membrane or directly injected into the electrolyte.

[0094] Wicking within semipermeable membranes to make water delivery uniform.

[0095] Water wicking, inside and outside of the semipermeable membrane tubes, is an important feature to distribute liquid water more uniformly over surfaces of the membranes and make them gravitationally less sensitive, particularly if the fluid in the semipermeable membranes is fluid and gas. If electrolytes such as sea water arc used as the source of water in the semi- permeable membranes inside the fuel cell or electrolysis cell, the temperature should be limited by when precipitates “scale” forms. Calcium sulfate precipitates in sea water from above 70°C to 75°C.

[0096] Pressurized air operation and heating and cooling capability.

[0097] The fuel cells can be pressurized above atmospheric pressure and operate for maximum power capacity. A compressor and decompressor on the air inlet and outlet can be employed to do this. The heat exchangers of the fuel cell can humidify the compressed air, and raise or lower its temperature, before it reaches the fuel cell. The exhaust air flows through the heat exchange and can be dehumidified with the membrane contained concentrated electrolyte, cooling the exhaust air. An extended heat exchanger cools the pressurized exhaust with atmospheric pressure air flow through the heat exchangers. Then this pressurized exhaust air, cooled to ambient temperatures, can be expanded and cooled below ambient temperature in the decompressor. This cool exhaust air can then be used to provide chilled air to structures or human occupied spaces.

[0098] Brief Summary of the System

[0099] A fuel cell system that:

[0100] 1. Uses planar electrical conductors and fuel cell arrays.

[0101] 2. Uses a hydrophobic dielectric porous cover layer covering the fuel cell electrode surfaces that allows gases to pass through while preventing liquid water and / or electrolyte coverage of fuel cell surfaces.

[0102] 3. Uses diffusion barriers, membranes, and flow patterns to control molecular concentrations and flow.

[0103] 4. Uses paired counter flow patterns for more uniform heat and molecular flux delivery of reactants and removal of impurities.

[0104] 5. Incorporates catalytic heaters into the fuel cell system that can also purge fuel and give differential pressure relief.

[0105] 6. Incorporates catalytic heaters and temperature and humidity sensors inside the fuel cells.

[0106] 7. Integrates the heating and cooling system of the fuel cell and vehicle. 8. Incorporates heat pipes into fuel cells.

[0107] 9. Utilizes evaporative cooling in the heat exchangers to cool fluids.

[0108] 10. Uses auto actuating micro valves and / or micro-pumps for local thermal, reactant, and humidity control.

[0109] 11. Incorporates semipermeable membrane tubing or channels and circulation of fluid with electrolyte within heat exchangers’, fuel cells’, or electrolysis cells’ fuel and oxidizer manifolds to maintain water homeostasis.

[0110] 12. Incorporates liquid wicking within and / or over semipermeable tubing surfaces.

[0111] 13. Incorporates the heat and mass exchangers with selectively permeable membranes, exchange, condensation with three or more interacting fluid flows.

[0112] 14. Incorporates fuel cells, catalytic heaters, and / or electrolysis cells, counter flow heat and mass exchangers, and compression and decompression of fluid flows to provide heat and / or cooling and / or purification of water.

[0113] 15. Incorporates both membrane electrolyte ion drag and multiple effect thermal distillation in a fuel cell system to de-ionize water.

[0114] 16. Incorporates micro-valves into fluid flow channels of manifolds of fuel cells.

[0115] 17. Incorporates electrical switches and / or semiconductor devices into the electrical collection circuits of the fuel cell electrodes.

[0116] 18. Incorporates electrostatic filtration and / or biocides surfaces into heat exchangers in fuel cells.

[0117] 19. Utilizes planar electrical conductor series connected fuel cells and heat and mass flow channels printed onto dielectric sheet substrates that are wound onto a tube with multiple gas and apertures to fluid manifolds connected to pumps. 0. Encloses printed planar fuel cell arrays with welded seals between fuel and oxidizer manifolds with low differential pressure across electrolyte due to catalytic heater allowing low differential pressure venting between fuel and oxidizer in the pressure vessel.

[0118] BRIEF DESCRIPTION OF DRAWINGS

[0119] Fig. 1 Cross-sectional view of the Integrated Fuel Cell catalytic heat exchanger unit cell.

[0120] Fig. 2A Cross-sectional view of the Fuel Cell with diffusion layers and gas manifolds. Fig. 2B Cross-sectional view of the Fuel Cell with diffusion layers and gas manifolds showing symbolic representation of molecules and concentrations. Fig. 3 Straight double back counter flow gas manifold heat and molecular exchanger view into flow channels.

[0121] Fig. 4A Single double back counter flow serpentine heat and molecular exchanger manifold.

[0122] Fig. 4B Two pair counter flow serpentine heat and molecular exchanger manifold.

[0123] Fig. 5 Single double back counter flow spiral heat and molecular exchanger manifold.

[0124] Fig. 6 Cross-Sectional View of Laminate Actuator.

[0125] Fig 7 View of laminate actuator perpendicular to the plane of the actuator substrate matrix.

[0126] Fig 8A Integrated planar fuel cell, reactant manifolds, heat exchanger and catalytic heater in sheet print showing air side that will be facing electrical contact to central manifold cylinder.

[0127] Fig 8B Integrated planar- fuel cell, fuel reactant manifold channels, heat exchanger and catalytic heater in sheet print showing fuel side closest to the electrical contact to central manifold cylinder.

[0128] Fig. 8C Integrated planar fuel cell, fuel reactant manifold channels, heat exchanger and catalytic heater in sheet print showing fuel side furthest from to the electrical contact to central manifold cylinder.

[0129] Fig 8D Integrated planar fuel cell, reactant manifolds, heat exchanger and catalytic heater in sheet print showing air side facing away from the electrical contact to central manifold cylinder.

[0130] Fig 9A Cylindrical tube manifold for wound planar fuel cell arrays.

[0131] Fig 9B Cylindrical tube manifold for wound planar fuel cell arrays rotated 180 degrees.

[0132] Fig 10 Cross-sectional view of wound planar array fuel cells on cylindrical tube manifold.

[0133] Fig 11A Cross-Sectional view of planar fuel cell system with electrical contacts, air compressor, decompressor, blower, connectors to fuel line, electrolyte, heat load, cooling load, and water outlet.

[0134] Fig 11B Enlarged view of cross-sectional view of the rolled planer fuel cell and catalytic heaters sheet arrays.

[0135] Fig 1 Counter flow heat and mass exchanger fuel cell and catalytic heater system.

[0136] 101. Oxygen electrode

[0137] 102. Water electrolyte flow route to humidify fuel cell 103. Hydrogen inflow

[0138] 104. Hydrogen manifold and heat exchanger

[0139] 105. Fresh air inflow

[0140] 106. Semi -permeable membrane

[0141] 107. Condensed water on semipermeable membrane

[0142] 108. Condensed water

[0143] 109. Exhaust air

[0144] 110. Exhaust pipe of heat exchanger

[0145] 111. Liquid water electrolyte in pipe to humidifier membrane

[0146] 112. Condensed water

[0147] 113. Condensed water wicked on outer surface of semipermeable membrane

[0148] 114. Oxygen electrode current collector

[0149] 115. Fuel cell electrolyte and dielectric substrate

[0150] 116. Fuel cell electrode

[0151] 117. Oxygen fuel cell electrode

[0152] 118. Hydrogen electrode current collector

[0153] 119. Double back flow manifolds: double serpentine or double spiral oxygen manifold

[0154] 120. Catalytic heater bed

[0155] 121. Inlet to exhaust tube to heat exchanger

[0156] 122. Heated air in and out of cabin

[0157] 123. Jet cavity heater

[0158] 124. Hydrogen gas channel to catalytic heater

[0159] 125. Double serpentine or spiral hydrogen manifold

[0160] 126. Humidification membrane tube fuel and gas diffusion layer

[0161] 127. Hydrogen electrode current collector

[0162] 128. Electrolyte

[0163] 129. Oxygen fuel electrode collector

[0164] 130. Heat exchanger section for inlet air

[0165] 131. Heat pipe with wicking and condensed working fluid

[0166] 132. Electrolyte wicking inside semipermeable membrane tube

[0167] 133. Laminate actuating micro valve 134. Electrical via

[0168] 135. Electrolyte

[0169] 137. Condensed working fluid

[0170] 138. High surface area wicking material inside heat pipe tube

[0171] 139. Air flow into air manifold

[0172] 140. Pressure relief micro valve

[0173] 141. Semi-permeable membrane to vaporize water from electrolyte and gas diffusion layer

[0174] 142. Wicking material to wet the semi-permeable membrane

[0175] 143. Liquid electrolyte inside semipermeable membrane

[0176] 144. Heat pipe to deliver heat

[0177] 145. Condensed water

[0178] 146. Tube connection for outlet of water depleted electrolyte

[0179] 147. Water depleted electrolyte

[0180] 148. Adjustable recirculation electrolyte flow constrictor

[0181] 149. Fresh electrolyte inflow

[0182] 150. Tube connection for fresh electrolyte inflow

[0183] 151. Tube connection for fresh electrolyte inflow

[0184] 152. Fresh electrolyte inflow

[0185] 153. Adjustable recirculation electrolyte flow constrictor

[0186] 154. W ater depleted electrolyte

[0187] 155. Tube connection for outlet of water depleted electrolyte

[0188] 156. Exhaust air

[0189] 157. Air inflow

[0190] 158. Semipermeable membrane

[0191] 159. Circulated electrolyte

[0192] 160. Pipe containing hydrogen

[0193] 161. Bi-material laminate actuator on humidity and temperature over aperture in barrier

[0194] 162. Air flow

[0195] 163. Pressure release valve 164. Vented hydrogen and impurity gases

[0196] 165. Wicking channel material within heat pipe

[0197] 166. Porous catalytic bed

[0198] 167. Semipermeable membrane

[0199] 168. Semipermeable membrane

[0200] 169. Bi-material laminate actuator on humidity and temperature over aperture in barrier

[0201] 170. Bi-material laminate actuator on humidity and temperature over aperture in barrier

[0202] 171. Condensed working fluid in heat pipe

[0203] Fig. 2A Cross-sectional view of the membrane electrode assembly of the planar fuel cell with dielectric substrate, gas diffusion layer, semipermeable membrane water control tubes, laminate actuators, and counter flow heat and mass heat exchangers.

[0204] 201. Flow channel wall

[0205] 202. Hydrogen gas inflow channel

[0206] 203. Semi-permeable channel wall

[0207] 204. Paired outflow channel with hydrogen

[0208] 205. Semi-permeable electrolyte circulation tube wall

[0209] 206. Liquid electrolyte

[0210] 207. Wicking thread inside the semi-permeable membrane tube

[0211] 208. Semi-permeable electrolyte circulation tube wall

[0212] 209. Gas penetration to form triple interface of gas, electrolyte, and catalyst

[0213] 210. Catalytic layer and conductive layer of anode of the fuel cell

[0214] 211. Electrolyte of the fuel cell

[0215] 212. Dielectric porous substrate of the fuel cell

[0216] 213. Semi-permeable layer that preferentially allows ions through

[0217] 214. Electrolyte

[0218] 215. Dielectric porous substrate of the fuel cell

[0219] 216. Catalytic layer and conductive layer of cathode of the fuel cell

[0220] 217. Gas penetration to form triple interface of gas, electrolyte, and catalyst 218. Condensed water on wicking surface

[0221] 219. Wicking thread

[0222] 220. Gas flow manifold and heat exchanger

[0223] 221. High expansion layer of laminate actuator membrane

[0224] 222. Low expansion layer of laminate actuator membrane

[0225] 223. Aperture through the gas flow manifold channels

[0226] 224. Semi-permeable gas flow channel wall

[0227] 225. Wicking fiber on surface of semi-permeable membrane tube

[0228] 226. Wall of flow channel

[0229] 227. Condensed water on the inner wall surface of the flow channel manifold

[0230] 228. Condensed liquid water wetting of the semi-permeable membrane

[0231] 229. Wicking fiber on inner surface of semi-permeable membrane tube

[0232] 230. Electrolyte in the semi-permeable membrane tube

[0233] 231. Wall of semi-permeable membrane tube

[0234] 232. Out flowing exhaust air

[0235] 233. Wicking fiber inside the semi-permeable tube

[0236] 234. Electrolyte inside the semi-permeable tube

[0237] 235. Wall of semi-permeable membrane tube

[0238] 236. Gas within semi-permeable membrane tube

[0239] 237. Inflowing air inside flow channel of heat and mass counter flow exchanger

[0240] Fig 2B Fig. 2A Cross-sectional view of the membrane electrode assembly of the planar fuel cell with dielectric substrate, gas diffusion layer, semi-permeable membrane water control tubes, laminate actuators, and counter flow heat and mass heat exchangers with molecular species.

[0241] 201. Flow channel wall

[0242] 202. Hydrogen gas inflow channel

[0243] 203. Scmi-pcrmcablc channel wall

[0244] 204. Paired outflow channel with hydrogen

[0245] 205. Semi -permeable electrolyte circulation tube wall

[0246] 206. Liquid electrolyte 207. Wicking thread inside the semi-permeahle membrane tube

[0247] 208. Scmi-pcrmcablc electrolyte circulation tube wall

[0248] 209. Gas penetration to form triple interface of gas, electrolyte, and catalyst

[0249] 210. Catalytic layer and conductive layer of anode of the fuel cell

[0250] 211. Electrolyte of the fuel cell

[0251] 212. Dielectric porous substrate of the fuel cell

[0252] 213. Semi-permeable layer that preferentially allows ions through

[0253] 214. Electrolyte

[0254] 215. Dielectric porous substrate of the fuel cell

[0255] 216. Catalytic layer and conductive layer of cathode of the fuel cell

[0256] 217. Gas penetration to form triple interface of gas, electrolyte, and catalyst

[0257] 218. Condensed water on wicking surface

[0258] 219. Wicking thread

[0259] 220. Gas flow manifold and heat exchanger

[0260] 221. High expansion layer of laminate actuator membrane

[0261] 222. Low expansion layer of laminate actuator membrane

[0262] 223. Aperture through the gas flow manifold channels

[0263] 224. Semi-permeable gas flow channel wall

[0264] 225. Wicking fiber on surface of semi-permeable membrane tube

[0265] 226. Wall of flow channel

[0266] 227. Condensed water on the inner wall surface of the flow channel manifold

[0267] 228. Condensed liquid water wetting of the semi-permeable membrane

[0268] 229. Wicking fiber on inner surface of semi-permeable membrane tube

[0269] 230. Electrolyte in the semi-permeable membrane tube

[0270] 231. Wall of semi-permeable membrane tube

[0271] 232. Out flowing exhaust air

[0272] 233. Wicking fiber inside the semi-permeable tube

[0273] 234. Electrolyte inside the semi-permeable tube

[0274] 235. Wall of semi-permeable membrane tube

[0275] 236. Gas within semi-permeable membrane tube

[0276] 237. Inflowing air inside flow channel of heat and mass counter flow exchanger 238. Heat flux into hydrogen inlet gas channel

[0277] 239. Heat flux out of hydrogen outlet channel

[0278] 240. Heat flux out of air flow outlet channel

[0279] 241. Heat flux out of air inlet channel

[0280] 242. Hydrogen molecules

[0281] 243. Nitrogen molecules

[0282] 244. Hydrogen molecules diffusing through flow manifold and heat exchanger

[0283] 245. Nitrogen molecules diffusing through selectively permeable membrane

[0284] 246. Water molecule

[0285] 247. Water molecule

[0286] 248. Hydrogen molecule diffusing through semipermeable membrane

[0287] 249. Hydrogen molecule diffusing inside gas channel pore

[0288] 250. Hydrogen ion created on surface of hydrogen anode

[0289] 251. Hydrogen proton traveling through the proton conductive membrane

[0290] 252. Hydrogen proton emerging from the proton conductive membrane

[0291] 253. Two hydrogen ions and oxygen atom catalytically uniting on the cathode electrode

[0292] 254. Oxygen catalytically reacted on oxygen cathode

[0293] 255. Oxygen gas molecule diffusing over the cathode electrodes and within the diffusion layer.

[0294] 256. Water molecules diffusing from the surface of the cathode.

[0295] 257. Water molecules diffusing withing the air flow channels

[0296] Fig 3 Cross sectional view of single double back straight parallel flow heat exchanger

[0297] 300. Side wall

[0298] 301. Inlet cold hydrogen gas flow

[0299] 302. Outlet gas flow depleted of hydrogen and enriched with inert gases

[0300] 303. Heat transfer through permeable wall or through gas diffusion layer of fuel cell

[0301] 304. Separator wall with semi-permeable membrane

[0302] 305. Hydrogen molecule

[0303] 306. Nitrogen molecules diffusion through the fuel cell electrolyte Fig 4A Cross sectional view of a single double-backed serpentine flow heat and mass exchanger with molecules and heat flow direction

[0304] 401. Exhaust gas flow

[0305] 402. Inlet gas flow

[0306] 403. Perimeter walls

[0307] 404. Inner walls that have semi-permeability

[0308] 405. Diffusion and heat transfer through the inner walls

[0309] 406. Hydrogen fuel molecules high concentration

[0310] 407. Hydrogen fuel molecules low concentration

[0311] 408. Hydrogen molecules diffusing through barrier

[0312] 409. Low concentration of impurity molecules such as nitrogen gas molecules

[0313] 410. High concentration of impurity molecules in exhaust

[0314] 411. Exhaust flow channel and fuel cell membrane electrode assembly

[0315] 412. Inlet flow channel and fuel cell membrane electrode assembly

[0316] Fig 4B Cross sectional view of matched pair double-backed serpentine flow heat and mass exchanger with molecules and heat flow direction

[0317] 451. Exhaust gas flow

[0318] 452. Inlet flow

[0319] 453. Perimeter walls

[0320] 454. Semi-permeable channel walls

[0321] 455. Diffusion and heat transfer through inner walls

[0322] 456. Hydrogen fuel molecules high concentration

[0323] 457. Hydrogen fuel molecules low concentration

[0324] 458. Hydrogen molecules diffusing through barrier

[0325] 459. Low concentration of impurity molecules such as nitrogen gas molecules

[0326] 460. High concentration of impurity molecules in exhaust

[0327] 461. Exhaust flow channel and fuel cell membrane electrode assembly

[0328] 462. Inlet flow channel and fuel cell membrane electrode assembly

[0329] 463. Low concentration of impurity molecules such as nitrogen gas molecules

[0330] 464. High concentration of impurity molecules in exhaust 465. Hydrogen fuel molecules high concentration

[0331] 466. Diffusion molecules through scmi-pcrmcablc membrane walls

[0332] 467. Hydrogen fuel molecules low concentration

[0333] 468. Hydrogen molecules low concentration

[0334] 469. Diffusion of heat and molecules through flow channel walls

[0335] 470. Perimeter seal and channel wall

[0336] 471. Outlet flow depleted of hydrogen and concentrated impurity gases

[0337] 472. Inlet flow of hydrogen

[0338] Fig 5 Cross sectional view of a single double-backed spiral flow heat and mass exchanger with molecules and heat flow direction Outlet flow

[0339] 501. Inlet flow

[0340] 502. Perimeter seal and channel wall

[0341] 503. Diffusion of heat and molecules through membranes

[0342] 504. Semi-permeable membrane flow channel wall

[0343] 505. Low concentration of hydrogen molecules

[0344] 506. Hydrogen molecule inside semi-permeable membrane

[0345] 507. Hydrogen molecule in high concentration

[0346] 508. Nitrogen impurity gas in higher concentration

[0347] 509. Nitrogen impurity gas in low concentration

[0348] 510. Nitrogen molecule inside semi-permeable membrane

[0349] Fig. 6 Cross-Sectional View of Laminate Actuator

[0350] 601. Low expansion coefficient material

[0351] 602. Humidity expansion coefficient material

[0352] 603. Low expansion coefficient material

[0353] 604. Substrate material membrane

[0354] 605. Aperture substrate material

[0355] 606. Substrate material membrane

[0356] 607. Humidity expansion material

[0357] 608. Cut through the laminate material to form a free actuation of the micro-valve

[0358] 609. Anti fouling coating 610. Anti fouling coating

[0359] Fig 7 View of laminate actuator perpendicular to the plane of the actuator substrate matrix

[0360] 701. Substrate material membrane

[0361] 702. Laminate sheet low coefficient of expansion material

[0362] 703. Edge of low coefficient of expansion material

[0363] 704. Edge of high expansion coefficient material

[0364] 705. High expansion coefficient material sheet

[0365] 706. Aperture in substrate material

[0366] Fig 8A Integrated planar fuel cell, reactant manifolds, heat exchanger and catalytic heater in sheet print fuel side.

[0367] 801. Perimeter membrane welded seal

[0368] 802. Electrically conductive contact

[0369] 803. Inlet electrolyte flow aperture

[0370] 804. Outlet electrolyte flow aperture

[0371] 805. Air exhaust aperture

[0372] 806. Air flow aperture from 2ndarray to 1starray to counter flow return channel

[0373] 807. Air inlet aperture

[0374] 808. Unused

[0375] 809. Hydrogen inlet aperture

[0376] 810. Air exhaust region of gas flow channel

[0377] 811. Dielectric flow manifold wall and membrane enclosed electrolyte channel

[0378] 812. Porous bed of catalytic burner air side view

[0379] 813. Aperture through planar array for electrolyte to flow between air side and fuel side of array

[0380] 814. Non-porous dielectric sheet substrate material

[0381] 815. Electrical via through dielectric substrate in planar fuel cell array

[0382] 816. Electrical insulator gap on planar fuel cell array 817. Catalytic fuel cell membrane electrode assembly air cathode side

[0383] 818. Electrical via through dielectric substrate in planar fuel cell array

[0384] 819. Electrical insulator gap on planar fuel cell array

[0385] 820. Catalytic fuel cell membrane electrode assembly air cathode side

[0386] 821. Electrical contact layer

[0387] 822. Air flow aperture to flow air from 1starray to second array

[0388] 823. Electrical attachment aperture and planar array clamp attachment point for pins, bolts, adhesives, or rivets

[0389] Fig 8B Integrated planar fuel cell, reactant manifolds, heat exchanger and catalytic heater in sheet print fuel side.

[0390] 824. Perimeter membrane welded seal

[0391] 825. Dielectric membrane substrate non-porous area

[0392] 826. Aperture for cross through membrane electrolyte flow

[0393] 827. Dielectric membrane containing electrolyte and gas flow channel wall

[0394] 828. Hydrogen fuel inlet aperture

[0395] 829. Electrolyte outlet flow though with gasket seal

[0396] 830. Electrolyte inlet fluid flow aperture and channel

[0397] 831. Bed of catalytic heater viewing fuel side

[0398] 832. Membrane and flow channel wall containing flowing electrolyte

[0399] 833. Electrical insulator gap on planar fuel cell array

[0400] 834. Electrical via through dielectric substrate in planar fuel cell array

[0401] 835. Anode side of fuel cell membrane electrode assembly

[0402] 836. Electrical contact coating on membrane dielectric substrate

[0403] 837. Air flow through aperture to 2ndarray

[0404] 838. Electrical attachment aperture and planar array clamp attachment point for pins, bolts, adhesives, or rivets

[0405] 839. Hydrogen flow turn around at end of membrane flow channel

[0406] 840. Laminate actuator valve high expansion coefficient material

[0407] 841. Laminate actuator valve low expansion coefficient material

[0408] 842. Aperture substrate for the micro valve into the catalytic hydrogen burner 843. Hydrogen gas manifold block

[0409] Fig 8C Integrated planar fuel cell, reactant manifolds, heat exchanger and catalytic heater in sheet print fuel side

[0410] 850. Electrical attachment aperture and planar array clamp attachment point for pins, bolts, adhesives, or rivets

[0411] 851. Air flow aperture to flow air from 1starray to 2ndarray.

[0412] 852. Electrical contact layer

[0413] 853. Catalytic fuel cell membrane electrode assembly hydrogen cathode side

[0414] 854. Electrical via through dielectric substrate in planar fuel cell array

[0415] 855. Electrical insulator gap on planar fuel cell array

[0416] 856. Hydrogen flow channel

[0417] 857. Electrical insulator gap on planar fuel cell array and micro valve apertures

[0418] 858. Electrolyte flow channel and flow walls of hydrogen gas channel

[0419] 859. Catalytic heater bed

[0420] 860. Electrolyte flow channel and flow walls of hydrogen gas channel

[0421] 863. Entrance region of the hydrogen gas in the hydrogen manifold channel

[0422] 864. Electrolyte flow through apertures to oxygen side

[0423] 865. Electrolyte flow inlet channel from the inlet of electrolyte inlet aperture

[0424] 866. Perimeter seal

[0425] 867. Electrolyte exit aperture and perimeter

[0426] Fig 8D Integrated planar fuel cell, reactant manifolds, heat exchanger and catalytic heater in sheet print on air side.

[0427] 870. Electrical attachment aperture and planar array clamp attachment point for pins, bolts, adhesives, or rivets

[0428] 871. Air flow aperture to flow air from 1starray to 2ndarray.

[0429] 872. Electrical contact layer

[0430] 873. Catalytic fuel cell membrane electrode assembly hydrogen cathode side

[0431] 874. Electrical insulator gap on planar fuel cell array 875. Electrical via through dielectric substrate in planar fuel cell array

[0432] 876. Electrolyte flow channel and flow walls of air flow gas channel

[0433] 877. Dielectric substrate material non-porous

[0434] 878. Catalytic heater bed

[0435] 879. Constriction of air flow in air channel to move air flow over catalytic bed

[0436] 880. Aperture though membrane substrate return air flow

[0437] 881. Aperture in manifold wall to counter air flow return

[0438] 882. Electrolyte flow channel and outlet aperture

[0439] 883. Electrical contact coating

[0440] 884. Perimeter seal

[0441] 885. Flow aperture of electrolyte from hydrogen side of fuel cell arrays

[0442] Fig 9A Cylindrical tube manifold for wound planar fuel cell arrays with hydrogen fluid connection aperture shown to planar fuel cell arrays

[0443] 901. Flange and gasket.

[0444] 902. Threaded bolt hole

[0445] 903. Exhaust air flow channel

[0446] 904. Webbing defining flow channels within manifold tube

[0447] 905. Seal on electrolyte connection

[0448] 906. Electrolyte flow channel inlet

[0449] 907. Electrolyte flow channel

[0450] 908. Seal on electrolyte connection

[0451] 909. Air inlet flow channel

[0452] 910. Air flow aperture

[0453] 911. Hydrogen inlet flow channel

[0454] 912. Hydrogen outlet flow aperture to fuel cell array with air inter-connect pipe visible

[0455] 913. Electrically conductive wall to cylindrical pipe

[0456] 914. Flange

[0457] 915. Threaded bolt hole Fig 9B Cylindrical tube manifold for wound planar fuel cell arrays with fluid connection apertures to planar fuel cell arrays

[0458] 950. Flange

[0459] 951. Threaded bolt hole

[0460] 952. Air inflow

[0461] 953. Webbing defining flow channels within manifold tube

[0462] 954. Hydrogen flow channel

[0463] 955. Exhaust air flow channel

[0464] 956. Outlet Electrolyte tube seal

[0465] 957. Outlet Electrolyte flow channel

[0466] 958. Inlet Electrolyte flow channel

[0467] 959. Inlet Electrolyte tube seal

[0468] 960. Inlet Electrolyte Aperture

[0469] 961. Exhaust outlet flow aperture

[0470] 962. Air inlet aperture

[0471] 963. Flange

[0472] 964. Threaded bolt hole

[0473] 965. Electrically conductive wall cylindrical pipe

[0474] Fig 10 Cross-sectional view of wound planar array fuel cells on cylindrical tube manifold.

[0475] 1001. Aperture in dielectric membrane

[0476] 1002. Fuel aperture in electrically conductive distribution tube

[0477] 1003. Incoming flow air channel and heat exchanger in manifold

[0478] 1004. Channel webs within electrically conductive distribution tube.

[0479] 1005. Seal between air channel and fuel pass-through

[0480] 1006. Aperture in electrically conductive distribution tube for incoming fuel

[0481] 1007. Fuel pass-through aperture in membrane electrode assembly and leader length of metal coated dielectric membrane

[0482] 1008. Fuel gas within cylindrical tube gas manifold

[0483] 1009. Seal between air channel and fuel pass-through on printed array

[0484] 1010. Electrical contact through dielectric substrate interconnecting cells 1011. Dielectric filled gap between cells

[0485] 1012. Dielectric membranes substrate

[0486] 1013. Air electrode that can include channels for flow patterns and planar catalytic burners

[0487] 1014. Electrolyte membrane between fuel and air electrode

[0488] 1015. Fuel electrode

[0489] 1016. Fuel electrode

[0490] 1017. Electrolyte membrane

[0491] 1018. Air electrode that can include flow patterns and planar catalytic burners

[0492] 1019. Fuel manifold channels and heat and mass exchangers

[0493] 1020. Seal between air flow manifold and the pass-through exhaust flow

[0494] 1021. Seal between fuel flow manifold and pass-through exhaust flow

[0495] 1022. Aperture in electrically conductive tube manifold to return exhaust flow

[0496] 1023. Exhaust air flow in tube manifold

[0497] 1024. Aperture in membrane fuel cell assembly planar array

[0498] 1025. Seal between air flow manifold and exhaust flow through membrane electrode planar fuel cell array

[0499] 1026. Seal between fuel flow manifold and flow though exhaust

[0500] 1027. Dielectric leader of dielectric substrate membrane

[0501] 1028. Dielectric seals on back-to-back fuel cell planar arrays

[0502] 1029. Catalytic bed on the fuel cell planar array

[0503] 1030. Electrically conductive contact layer on the fuel cell array or the electrical leader

[0504] 1031. Electrically conductive coating on dielectric substrate

[0505] 1032. Electrically conductive tubular gas manifold

[0506] 1033. Dielectric conductive membrane

[0507] 1034. Air flow manifold

[0508] 1035. Bi-material pressure relief valve that opens when temperatures are low

[0509] 1036. Porous catalytic bed

[0510] 1037. Porous metal layer

[0511] 1038. Exhaust fuel, impurities, and water mass transfer manifold

[0512] 1039. Porous metal layer 1040. Porous catalytic bed

[0513] 10 1. Air and water vapor manifold

[0514] 1042. Fuel and circulated electrolyte containing membrane tube manifold

[0515] 1043. Air electrode and air manifold channels

[0516] 1050. Input air channel in tubular manifold

[0517] 1051. Metal contact layer on dielectric substrate

[0518] 1052. Hole in metal and dielectric membrane for mechanical clamping and electrical contact

[0519] 1053. Air cross over apertures in membrane to return air flow to route back through manifolds and heat exchangers to exhaust manifold on central tubular manifold

[0520] 1054. Electrical joining of two planar electrical arrays

[0521] 1055. Water depleted electrolyte in membrane tube in hydrogen manifold

[0522] 1056. Semi-permeable membrane tube wall

[0523] 1057. Dielectric seal about electrolyte membrane tube

[0524] 1058. Water depleted electrolyte in membrane tube in air manifold and heat exchanger returning to central tubular manifold

[0525] 1060. Electrolyte flow entrance through aperture in dielectric substrate and circular tube manifold

[0526] 1061. Membrane tube wall containing electrolyte outlet

[0527] 1062. Dielectric seals about electrolyte flow channel apertures on dielectric substrate

[0528] 1063. Electrolyte inlet through dielectric membrane to circular tube manifold

[0529] 1064. Semi-permeable membrane

[0530] 1070. Electrolyte return tube connection

[0531] 1072. Air flow channel

[0532] 1073. Air flow channel

[0533] 1074. Air flow channel end wall

[0534] 1075. Air flow channels end wall

[0535] 1076. Wicked working fluid within heat pipe

[0536] 1077. Wall of heat pipe

[0537] 1078. Wicking fiber or mesh

[0538] 1079. Condensed working fluid 1080. Hydrogen gas return

[0539] 1081. Hydrogen return aperture

[0540] 1082. Gas barrier in manifold

[0541] Fig 11A Wound planar fuel cell system with electrical contacts, air compressor, decompressor, blower, connectors to fuel line, electrolyte, heat load, cooling load, and water outlet.

[0542] 1100. Heat pipe wall material

[0543] 1101. Outflow of air-cooling fuel cell

[0544] 1102. Exit of concentrated liquid electrolyte

[0545] 1103. Entrance of liquid electrolyte

[0546] 1104. Hydrogen gas entrance

[0547] 1105. Entering liquid electrolyte channel in the central manifold cylinder

[0548] 1106. Hydrogen gas flow aperture to printed fuel cell channels

[0549] 1107. Flange of the central manifold cylinder

[0550] 1108. Metal pressure end plate of the cylindrical pressure vessel

[0551] 1109. The fuel cell arrays leader going to the wall of the pressure vessel

[0552] 1110. Dielectric flange in contact with the metal end plate

[0553] 1111. Dielectric cylinder wall

[0554] 1112. Rivet fastener to secure the electrical contact of the membrane

[0555] 1113. Metal coating inside dielectric cylinder wall

[0556] 1114. Metal coating on membrane

[0557] 1115. Threaded electrical contact

[0558] 1116. Dielectric membrane substrate

[0559] 1117. Dielectric flange of the pressure wall cylinder

[0560] 1118. Electrically conductive end plate of cylinder

[0561] 1119. Decompressed cool air exhaust pipe

[0562] 1120. Counter flow fresh air inlet

[0563] 1121. Decompressed exhaust air out flow

[0564] 1122. Heat exchange wall

[0565] 1123. Exterior heat exchange pipe 1124. Outlet of cool fresh air

[0566] 1125. Rotor blades of expander

[0567] 1126. Stator blades of expander

[0568] 1127. Shaft of compressor and expander

[0569] 1128. Shaft between decompressor and compressor

[0570] 1129. Compressed cooled air exhaust

[0571] 1130. Low pressurization bypass air flow inside inner pipe to cylindrical manifold

[0572] 1131. Compressed air

[0573] 1132. Bypass air outlet on compressor

[0574] 1133. Rotor blades on compressor

[0575] 1134. Stator blades on compressor

[0576] 1135. Inlet air to compressor

[0577] 1136. Inlet air manifold and pressure wall of compressor

[0578] 1137. Electric motor

[0579] 1138. Electrically conductive cylinder wall of manifold

[0580] 1139. Metal coating of fuel cell array membrane

[0581] 1140. Dielectric membrane substrate of the fuel cell membrane

[0582] 1141. Electrolyte circulation semi-permeable membrane tube

[0583] 1142. Air channel wall and heat exchange wall of reactant flow channel network

[0584] 1143. Air flow channel in heat exchanger and manifold

[0585] 1144. Porous catalytic membrane layer

[0586] 1145. Evaporating heat pipe working fluid wicked to fiber and wall of pipe

[0587] 1146. Working fluid vapor of heat pipe

[0588] 1147. Aperture metal coating layer

[0589] 1148. Electrolyte circulation semi-permeable membrane tube

[0590] 1149. Hydrogen gas manifold channel

[0591] 1150. Wall of the hydrogen manifold channel and heat transfer surface

[0592] 1151. Metal coating on porous dielectric catalytic bed

[0593] 1152. Pore in metal coating

[0594] 1153. Porous catalytic membrane layer

[0595] 1154. Electrolyte circulation semi-permeable membrane tube 1155. Air channel

[0596] 1156. Air channel w all

[0597] 1157. Air electrode c athode

[0598] 1158. Porous dielectric and solid electrolyte

[0599] 1159. Hydrogen electrode anode

[0600] 1160. Electrolyte circulation semi-permeable membrane tube

[0601] 1161. Hydrogen gas in channel

[0602] 1162. Hydrogen channel wall heat and molecular’ exchanger

[0603] 1163. Hydrogen electrode anode

[0604] 1164. Porous dielectric and solid electrolyte

[0605] 1165. Air electrode cathode

[0606] 1166. Air in gas channel

[0607] 1167. Dielectric outer membrane

[0608] 1168. Perimeter welded seal between fuel cell membrane arrays

[0609] 1169. Metal flange of cylindrical manifold

[0610] 1170. Air inlet aperture to fuel cell membrane gas channels and heat exchangers

[0611] 1171. Air outlet aperture from fuel cell membrane gas channels and heat exchangers

[0612] 1172. Cooling air flow heat transfer pipe

[0613] 1173. Exit electrolyte collection flow tube in manifold

[0614] 1174. Condensed liquid working fluid in heat pipe

[0615] 1175. Wicking fiber or mesh in heat pipe

[0616] 1176. Condensed and wicked liquid working fluid in heat pipe

[0617] 1177. Perimeter welded seal between fuel cell membrane arrays

[0618] Fig. 11B Enlarged view of a portion of the cross-sectional view of heat exchangers, catalytic layers, fuel cells and electrolyte membrane tubes of planar array as wound on the cylindrical manifold. All object numbers use the same as in Fig. 11A

[0619] 1117. Dielectric flange of the pressure wall cylinder

[0620] 1118. Electrically conductive end plate of cylinder

[0621] 1138. Electrically conductive cylinder wall of manifold

[0622] 1139. Metal coating of fuel cell array membrane 1140. Dielectric membrane substrate of the fuel cell membrane

[0623] 1141. Electrolyte circulation scmi-pcrmcablc membrane tube

[0624] 1142. Air channel wall and heat exchange wall of reactant flow channel network

[0625] 1143. Air flow channel in heat exchanger and manifold

[0626] 1144. Porous catalytic membrane layer

[0627] 1145. Evaporating heat pipe working fluid wicked to fiber and wall of pipe

[0628] 1146. Working fluid vapor of heat pipe

[0629] 1147. Aperture metal coating layer

[0630] 1148. Electrolyte circulation semi-permeable membrane tube

[0631] 1149. Hydrogen gas manifold channel

[0632] 1150. Wall of the hydrogen manifold channel and heat transfer surface

[0633] 1151. Metal coating on porous dielectric catalytic bed

[0634] 1152. Pore in metal coating

[0635] 1153. Porous catalytic membrane layer

[0636] 1154. Electrolyte circulation semi-permeable membrane tube

[0637] 1155. Air channel

[0638] 1156. Air channel w all

[0639] 1157. Air electrode c athode

[0640] 1158. Porous dielectric and solid electrolyte

[0641] 1159. Hydrogen electrode anode

[0642] 1160. Electrolyte circulation semi-permeable membrane tube

[0643] 1161. Hydrogen gas in channel

[0644] 1162. Hydrogen channel wall heat and molecular exchanger

[0645] 1163. Hydrogen electrode anode

[0646] 1164. Porous dielectric and solid electrolyte

[0647] 1165. Air electrode cathode

[0648] 1166. Air in gas channel

[0649] 1167. Dielectric outer membrane

[0650] 1168. Perimeter welded seal between fuel cell membrane arrays

[0651] 1169. Metal flange of cylindrical manifold

[0652] 1170. Air inlet aperture to fuel cell membrane gas channels and heat exchangers 1171. Air outlet aperture from fuel cell membrane gas channels and heat exchangers

[0653] DETAILED DECRIPTION

[0654] There are many possible choices of materials, temperatures, pressures, chemical environments, and configurations to meet the needs and physical environment in which the systems described herein will be used. I will describe as an embodiment a fuel cell system that uses hydrogen and air as the fuel and oxidizer gases, a solid polymer electrolyte with proton conductivity operating at about 80°C and 2 bar internal pressure and 1 bar exterior atmospheric pressure. This system consists of synergistic features which improve fuel cells and invented components that can be used with other systems including: electrolysis cells, water desalinization, water purification, machinery heating, machinery cooling, cooling, space heating, and space cooling, with improved performance and economics.

[0655] In Fig 1 a cross-sectional view of the integrated fuel cell arrays 114, 117, 134, 116, 118, 101,

[0656] 127, 128, 129 with reactant manifolds 125, 119, 162, heat exchangers 105, 106, 162, 166, 167, 102, 104, 168, 111, 158, 159, 157, 139, catalytic heater 120, 166, water circulation system 102, 158, and heat pipe 144, 131 are shown. A hydrogen reservoir, air blowers and electrically powered vehicle or structure are not shown. The cross-sectional cut is shown perpendicular to the major plane of each component.

[0657] Planar Fuel Cells or Electrolysis Cells

[0658] Shown In Fig 1. To construct this fuel cell system a pair of planar array of fuel cells 114, 117, 134, 116, 118, 127, 128, 129, 101 is started with a dielectric porous membrane substrate 159,

[0659] 128, such as a polyester plastic 115, 128 that is bombarded with charged particles and etched with a strong alkaline electrolyte and reinforced with polyester fibers (RoTrac® made by Oxyphen Switzerland). The membrane 115, 128 is ion milled and has vacuum deposited patterns of metal such as palladium, gold, silver, nickel and molybdenum di- silicide 117, 118, 128, 129. The metal coatings in the pattern form vias 134 in the dielectric substrate 115, 128, and have vias going through the dielectric substrate 115, 128 to an adjacent cell with insulator gaps 134 separating the cells on the dielectric substrate. Deposited catalyst films 117, 128, 129 can coat inside pores of the dielectric substrate 115, 128. Polymer electrolytes, such as Nafion®, impregnate the porous dielectric substrate 115, 128 such as fibrous PBI, polyester, or charged particle track etched polyester membranes RoTrac®. Powder catalysts 116, 117, 127, 129 can also be delivered into the metal coated pores with binding electrolyte such that a triple interface of reactant gas, catalyst and electrolyte is formed with electrical contact to the deposited metal film pattern. The metal film pattern forms electrically connected series cells 116, 117, 118 between the cells printed on the dielectric membrane substrate 115, with an interconnection 134 between the cells. A porous hydrophilic and hydrophobic 116, 117 surface allows gas reactants to reach the triple interface surface. A porous membrane or selectively permeable 141 surface can draw liquid water to the hydrophilic side facing away from the fuel cell anode when there is an excess of liquid water to prevent flooding blocking the gas reactants from reaching the triple interface surfaces 116. This surface is typically called the Gas Diffusion Layer 125, 141, 142. This membrane 141 can have both hydrophilic capillary channels and hydrophobic gas channels such that they can hold a dynamically balanced amount of liquid water in the assembly to humidify the fuel cell electrolyte but prevent flooding. Examples of this material are a porous material such as expanded PTFE that has filamentary structure that is impregnated with a solid polymer electrolyte coating that does not fill the pores and has been ion milled and heat annealed to provide a hydrophobic surface on the facing of the fuel cell surface. Another example is to deposit titanium dioxide Rutile that is very hydrophilic onto a porous polyester membrane with a striped pattern smaller than water droplets. Then on the opposite side, coat the membrane and pores with a plasma deposited PTFE hydrophobic coating. Liquid water on the surface of the fuel cell will migrate through the membrane following the path of hydrophobicity.

[0660] Circulated Electrolyte Contained in Semi-permeable Membrane

[0661] Shown In Fig 1. Near the anode surfaces of the fuel cell electrodes 116 selectively permeable membrane tubes 141 with a liquid wicking fiber holding electrolyte fluids 111, 135 such as phosphoric acid, sulfuric acid, sodium chloride, or sodium hydroxide are placed in the gas flow manifolds 125, 119. Each is filled with an electrolyte acid, salt or salt solution 111, 135 that can be selectively used to deliver reduced relative humidity water vapor and vapors such as sulfuric acid to the acidic solid polymer ion electrolyte. Sodium hydroxide electrolyte 159 in the semi- permeable membrane 158 can be used to capture, carry away and vent carbon dioxide from the air to protect alkaline solid polymer electrolyte within the dielectric substrate 115 from forming solid carbonates. The electrolyte 11 1 is circulated in the semi-permeable membrane tube network 151 with pumps going from a supply of electrolyte such as sea water 152. As the electrolyte 111 flows in parallel to the hydrogen gas 101 inflow 103, water vapor, through a selectively permeable membrane 141, can diffuse into the hydrogen gas. Both the electrolyte inflow and hydrogen gas inflow are in thermal contact and heated by heat transfer from the counter flow of exhaust 109, 162, 139, 156 from the catalytic heater and fuel cell outflow of electrolyte 152, 158, 154, 147. Air flows in and is heated by the counter flow of exhaust gases without humidification in the example of the proton mobile electrolyte. The situation is reversed for anion mobile fuel cell electrolytes 115, with the air inflow 157 being humidified and the hydrogen 104 kept dehumidified. In the electrolyte circulation loops 111, 135, 115, 142, 159, 155, 154, 153, 152, 151, 102, 132, 143, 167, 168, 146, 147, 148, 149,150, fresh low concentration electrolyte is pumped into the 152, 149 circulation loop. The electrolyte flows to the semi-permeable membrane 141, such as urethane polymer network with wicking threads 142 or wall groove features to wet the membrane tubes 125 uniformly. Water diffuses through the membrane tube walls 141 to the fuel cell electrode 116, 127 along with the hydrogen fuel 125. An electrolyte 111, 159, 135, 102,143, 168 is held within the tubular semi-permeable membrane 158, 167 that is permeable to water vapor but impermeable to the electrolyte salts. It acts to maintain a homeostasis of the electrolyte in the fuel cell electrolyte 115, 128 by having a relative humidity less than 100% of the gas water concentration in the fuel gas 104, in the fuel gas manifold 125, and the very near proximity gas gap to the fuel cell electrodes 116, 127. This enables the water vapor to rapidly diffuse into the fuel cell electrolyte such that if the fuel cell electrolyte is dehydrating, moisture will be diffused into that fuel cell electrolyte 115, 128 and if it is fully hydrated the diffusion gradient would reverse and moisture would diffuse into electrolyte contained within the semi-permeable membrane 142, 132, 135, 143. Water vapor will be delivered to the low relative humidity fuel gas 125 and to the fuel cell electrolyte 115, 128. The water depleted electrolyte 135, 143 flows to the oxygen side of the fuel cell manifolds 119, 162 and again flows through a semi-permeable membrane tube wall network 158, 168, 167 with wicking within the tubes 167, 159 and captures diffusion of water vapor and condensed liquid 121, 145 from the exhaust from the fuel cell and the catalytic heaters to rehydrate the flowing electrolyte. The electrolyte flows in the exhaust flow heat exchange 158, 159, 168 with the incoming air 105, 157 and hydrogen flows 103 and transfers heat and water vapor to the heat exchanger walls 106. The temperature difference between the hot exhaust flow 139, 156, 162, 109 saturated with water vapor and the exchanger surfaces enables water to condense 113, 107 on the exchanger surface 106. The surfaces 106 are cooled by their contact with the cool incoming fuel 103, 104 and the air flow 105, 157. This enables the condensation 113, 107, 112, 108 and water collection in the exhaust flow channels 110, if the temperature difference between the flowing electrolyte 168, 159 and cool surfaces 106, 107, 113 is to the point where the heat exchanger is below the dew point of the air in contact with the flowing electrolyte 168, 159 in the semi-permeable membrane 158. To maintain this temperature difference and optimize the condensation effect over a wide range of flowing electrolyte concentrations, waste heat generation rates from the fuel cell 117, 129, catalytic heater 120, 166 or electrolysis cells 117, 129, a separator aperture membrane with small relative humidity actuating valves 169, 170 is placed between the flowing electrolyte 159, 168 and the condensation surfaces 106, 113, 107 in exhaust flow channels 110. The separator aperture’s membrane and the actuating valves 170, 169 can have surface treatments that lower surface tension energy such that condensed liquid water will be held away from the flowing electrolyte membranes and keep condensed liquid water from wetting the actuating valves 169, 170. Wicking materials and surface treatments can be applied to the condensation surfaces 106 to move liquid water 107, 113 out through the heat exchanger channels 110 to be collected outside of the heat exchanger into a reservoir. These arrays 169, 170 of opening and closing valves act to keep a constant temperature gradient between the humid exhaust flow and the condensation surface over a wide range of flow rates, heat transfer rates and moisture contents of the incoming air 105, 157. At high heat and moisture outputs the flow rates will be higher and the heat and mass transfer rates will not be proportionately higher due to fluid flow effects of turbulence. If the fuel cell, catalytic heater, or electrolysis cells change their heat and relative humidity in the exhaust such as due to change in electrical loads or relative humidity or in startup or shutdown, the thermal gradient can change and the condensation can be stopped or inefficient. The waste heat to relative humidity of the exhaust airflow 156, 109 can vary if the heat pipes 171, 131, 165, 144, 137 in the fuel cell are removing heat from the exhaust 162, 139 and condensing water 145, 121. The temperature of the heat pipe 131, 144 is dependent upon the temperature of the delivered temperature of the external load. The micro-actuated valves 169, 170 can increase mass flow of exhaust flow to condensation surfaces 106, 170, 113 when relative humidity is close to 100%. This high relative humidity air can be diverted to condensing surfaces and maintain a dew point condensation on the cool surfaces. Once the exhaust flow 109, 156 reaches the outlet of the heat exchanger 110, the condensed water is collected into a reservoir not shown and all or a portion of the circulated electrolyte 147, 154 is returned to the electrolyte reservoir. A pump 148, 153 that regulates flow between the outlet and inlet can be placed in the flowing electrolyte channel network to maintain circulation. A pump on the electrolyte inlet 149, 152 can be used to maintain flow of electrolyte into the fuel cell system. The flow rate can be adjusted to match the needs of the fuel cell and optimize the desalination. Within the air exhaust flow 156, 109, 110 condensed water 112, 108 can by channeled with hydrophilic grooves or with wicking fibers.

[0662] Catalytic Heaters

[0663] Shown in Fig f . To provide a means of rapid startup and for starting up from temperatures as low as -40° C, a catalytic heater can be built into the fuel cell. This catalytic heater has a microvent valve 163, 140 that releases hydrogen 125 and impurity gases - including oxygen, nitrogen, argon, and carbon dioxide - into a cavity 164, 123, 122 at a set closing pressure that the microvalve 140, 163 can be set to open at a pressure that is proportional to the temperature of the valve. This micro-valve 140, 163 can act as a thermostatic control of the heater 166, 120 such that at temperatures below -5°C, the micro-valve will open with atmospheric hydrogen pressure 125. The micro-valves 140, 163 for the catalytic heater can be formed by the same techniques of the micro-valves 169, 161, 133, 170 in the diffusion regulating valves. Thus, to start up, the hydrogen 103, 104, 125 passes through the fuel cell to the catalytic heater. The catalytic heater has a catalyst coated porous refractory substrate or high temperature polymer substrate 120, 166. Typical catalyst coatings are highly dispersed Pt, Pd, Rh, Ru, Ir metal clusters on its surface 120, 166. The hydrogen and impurity gases 164, 122 diffuse into the catalytic porous bed 166, 120 and simultaneously, oxygen diffuses from the air flows 157, 105, 139, 162 through the fuel cell oxygen manifold 139, 162. Catalytic combustion can occur within the catalytic bed. This releases heat and water vapor that can diffuse and condense 121, 145 on the cooler adjacent fuel cell electrodes 117, 129, its electrolyte 115, 128 and membrane 158, 168 containing electrolyte 121, 167. A tubular semi-permeable membrane 158, 168, such as expanded porous polytetrafluoroethylene, polyethylene, polypropylene, urethane, or silicone polymers can contain an electrolyte 159, 167. The removal of water is vital to prevent condensed liquid water 117, 129 from building on the outer surfaces of the fuel cell or electrolysis electrodes 1 17, 1 9, 117, 127. This can block the diffusion and flow of hydrogen and oxygen to and from the electrodes. The catalytic heater 120, 166 can heat the fuel cells or electrolysis cells to the point where the electrolytes have sufficient conductivity and the catalytic electrodes are active enough to start the operation of the fuel cell or electrolysis cells, and produce internal heating sufficient to reach the optimum cell operational conditions. A heat pipe 144, 131 is shown in intimate contact with the catalytic heater 120, 166 and fuel cells 116, 127, and the gas flow manifolds 106, 119, 125. The heat pipe 144, 131 can distribute heat from the catalytic heater 166, 120, fuel cell 129, 117, or electrolysis cells 129, 117 across the fuel cell / electrolysis electrodes 129, 117 and to external thermal loads such as batteries, electronics, surface heating windows, lenses, floors, and space heating. The heat pipes 144, 131 are generally sealed metal chambers such as pipes or flat metal manifolds with welded points. Inside the heat pipe chamber is a pure working fluid 137, 171 such water, ammonia, butane, propane, or pentane without air. A wicking material 138, 165 or grooving of the walls is done to wet the interior walls to wick the liquid working fluid to the higher temperature contact areas where the working fluid vaporizes. The vapor of the working fluid flows and condenses 137, 171 on the lower temperature contact areas. The condensate wets the wick and moves back to vaporization 165, 138 by capillary attraction minimizing the surface tension energy of the fluid, repeating the heat transfer cycle of the heat pipe. Transferring heat with heat pipes can be particularly useful because it can deliver heat at uniform temperature over large or small areas and distances at nearly the temperature of the heat source. Keeping windows and lenses ice free can be very challenging in snowy environments and heat pipes can be used to deliver heat to windows and lenses. A heat pipe placement in the heat exchanger thermal gradient can set the heat source temperature of the heat source of the heat pipe allowing for a set temperature management of the heat pipe output. When the temperature of the fuel cell reaches its optimum operational temperature, the flow of hydrogen 122, 164 to the catalytic heater 120, 166 can be stopped by the thermal micro-valve 140, 163 that can close if desired. The set point for flow cutoff can be set by either the hydrogen gas pressure difference 125 or the thermal actuation of the micro-valve 140, 163. It is also possible to build into the valve 140, 164 piezo electrical actuation to allow electrical actuation as well. The vent valve 140, 164 can be designed to open with an increased pressure of hydrogen 125 to safely release hydrogen if the hydrogen pressure surges and avoid bursting the fuel cell or electrolysis membranes. The catalytic heater startup system 120, 166 can also transfer heat and moisture to the fuel cell if the fuel cell has been stored in dry conditions and has dehydrated electrolytes 115, 128.

[0664] Downstream of the catalytic heater and fuel cell, the air exhaust flow 156, 109 from both the catalytic heater and the fuel cell, air is humidified from the diffusion contact with the electrolyte 159, 168 circulating in the semi-permeable membrane 158, 168 and the fuel cell and catalytic heater. By cooling exhaust 156, 109 with the incoming fuel 103, 105, 157 and air in the heat exchanger, the dew point can be reached on the surface of the air incoming heat exchange surfaces 106. Water will condense 113, 107 on these surfaces if they are at the dew point. Within the heat exchanger 106 are laminate actuator arrays 169, 170 separating the semi- permeable membrane contained electrolyte and the cooling surfaces that will open when the relative humidity is near 100% and fully open at the dew point. This lets saturated air press through to the condensation surfaces 106, 107, 113 of the heat exchangers. The laminate actuator micro-valves 133, 161 act as variable insulation that sets a temperature difference between the hot exhaust 139, 162 that is initially not at the dew point because of the diffusion contact with electrolytes 115, 128 of both fuel cells or electrolysis cells or the circulated electrolyte within the semi-permeable membrane 135, 143. These micro-valves actively 133, 161 set the condensation temperature difference between the condensation surface 121, 145 and the evaporation surface to maintain a steady and efficient rate of condensation from the exhaust flow and the condensation surfaces. Condensation surfaces 121, 145, 169, 107, 113 can have a wicking network of texture or fibers that allow water to flow through to external reservoirs. Distilled water can be a valuable byproduct of the fuel cell and electrolysis systems. This is a multiple effect distillation system. The lower the electrolyte concentration 159, 167 contained in the semi-permeable tubes 158, 168 the more condensation cycles can be completed. An ideal multiple effect distillation combined with electrolyte ion water cluster drag effects of lowering the electrolyte concentration 115, 128 on one side of the fuel cell or electrolysis cell, and heat transfer between fuel cells or electrolysis cells at 80°C and 20°C air temperature and sea water electrolyte can obtain an estimated 27 times the single condensation of the product water from a fuel cell exhaust if the cell is flowing stoichiometric air flow. The laminate actuated microvalves 170, 133, 161, 169 are inserted between the evaporating surfaces and the condensation surfaces to act to maintain an optimum diffusion and thermal resistance for efficient condensation 113, 121, 145, 107. This enables the mass and heat exchanger to adapt to the range of operating conditions of the fuel cell or electrolysis system such as; higher than stoichiometric air flows, changes in waste heat production rates, changes in heat removal routes, inefficiency changes in the electrolysis cells, changes in relative humidity and temperature in the incoming air, changes in salinity of the circulated electrolyte.

[0665] Multiple Effect Distillation Combined with Electrochemical Cell

[0666] There are multiple routes to remove waste heat from the fuel cell or electrolysis cell. The waste heat from the fuel cell operating at 80°C and full power output is typically half of the input chemical energy to the fuel cells. The waste heat from the hydrogen and oxygen fuel cell is 50% of the Higher Heating Value (15.9MJ / kg H2O) of the heat of combustion of hydrogen and oxygen: 8 MJ / kg H2O.

[0667] The heat of condensation of water is 2.26 MJ / kg H2O.

[0668] Multiple effect distillation operating on sea water in commercial operations in reduced atmospheric pressures has achieved 20 times the yield of a single condensation of the vaporized water with a high temperature of 80°C and low temperature of 20°C. Gap Membrane Distillation uses a stagnant air gap between evaporation surface and condensation surface and can practically achieve increased water gains ratio of 3.5 to 15 multiple effect distillation in counter flow heat exchangers (US Patent 9,956,528 B2). The heat transfer rate through the porous barrier has an optimizing effect. For a given heat flux rate of the hot water input there is an optimum heat transfer coefficient (W / m2K) of the porous barrier and in parallel likewise the diffusion coefficient m2 / sec for water vapor changes over a factor of 10 in the range for the porous barrier component. At the extreme very low flux rate there will be no condensation because the low temperature difference through the gap does not counter the vapor pressure difference sufficiently for condensation. If there was no air and conduction through the water molecules and no radiant heat transfer, in theory the multiple effect distillation could achieve 27.5 times the yield of a single condensation from sea water with a high temperature of 80°C and low temperature of 20°C. Therefore, we expect an average of 3°C per stage ((80°C-20°C) / 20 stages) temperature difference between the exhaust gas and the condensing surfaces to maintain distillation. The heat of condensation is going to be transferred by heating the incoming air, fuel, and circulated electrolyte. The drop in water vapor pressure for each 3°C is 16.9 mmHg. The water vapor pressure at 20°C is 17.3 mmHg and the water vapor pressure at 80°C is 355 mmHg. The water vapor pressure reduction due to salt dissolved in water is 12.3 mmHg. Therefore, if we have 20 evaporation conduction stages, we will have a water vapor pressure gradient of 4.6 mmHg (16.9 mmHg-12.3 mmHg - the distance between evaporation surface and condensation surface).

[0669] The estimated heat conducted through the 1 mm gap of stagnant air at 80°C is 90 W / m2. The ratio of heat moved with condensation divided by total heat transfer is 0.89 or 89%.

[0670] The last cycle of the condensation occurs near 20°C. If we assume the same water vapor pressure gradient of 4.6 mmHg over a 1 mm gap, the estimated ratio of heat moved by condensation divided by total heat transferred is 0.97 or 97% efficiency. The average evaporation condensation efficiency from 80°C to 20°C is 93%. These estimates are high as they did not account for radiant heat energy and structural thermal conductivity. The amount of water vapor heat transfer to achieve multiple effect distillation is 45 MJ / kg H2O (20 X 2.26 MJ / kg H2O). To achieve this total heat transfer for multiple effect the heat exchanger needs to exchange 5.6 times the waste heat of the fuel cell. The gas that is cycled through the fuel cell at 80°C is 405 mmHg and with 20 cycles is 10.7 cycles of air per kg of H2O produced. With the air composed of 20% oxygen O2, the amount of oxygen delivered to form water O2 is 4.26 times what would be needed to form the H2O in the fuel cell. So, an excess of oxygen supply is delivered and 20 times the primary fuel cell formation of product water is extracted from the circulated electrolyte while removing the excess heat of the fuel cell.

[0671] Adaptive Diffusion Impedance

[0672] Shown in Fig 1. The membrane separator with laminate actuator micro-valves 170, 133, 161, 169 can have hydrophobic coatings such as plasma deposited polytetrafluoroethylene and have hairs or fibers to enable the micro-valves to repel liquid water condensate and prevent return of liquid water back to the evaporation side in the heat exchanger. The laminate actuator micro-valve arrays 170, 133, 161, 169 can be formed to be an array of valves on a membrane that separates the vaporizing and condensing surfaces in the heat exchangers with a diffusion air gap. Microvalves that are placed between the hot water vapor source and the condensation surface can act to open when conditions for condensation is reached. Due to the variable power output, temperature of the fuel cell, and the heat sink temperature, the temperature gradient can vary as well. By having an auto adjustment of the diffusion impedance, we can maintain the conditions for efficient distillation over a wide range of fuel cell conditions.

[0673] Water Purification with Ion Drag

[0674] Shown in Fig 1. Water is supplied to the anode of the fuel cell by evaporation from the circulated electrolyte contained within the semi-permeable membrane tubes and subsequently condensed into the fuel cell electrolyte 115, 128. When operating, the proton conductive electrolyte membrane fuel cell will drag approximately 6 water molecules per proton attracted to this ion in the PEM electrolytes from the anode to the cathode of the fuel cell. These water molecules can diffuse back to the anode 116, 127, but with steady high current density flow most of these water molecules will flood the cathode electrode 117, 129 or evaporate. On the anode electrode 116, 127 the fuel cell electrolyte is dehydrated with the ion drag and water vapor re-hydrates the fuel cell electrolyte 115, 128 from the semi-permeable circulated electrolyte 111, 102 to maintain a dynamic balance. The circulated electrolyte is dehydrated and flows through the tubing over to the cathode side of the fuel cell air manifold 135, 143. If the electrolyte 115, 128 in the fuel cell is a polymer electrolyte the cations in the polymer are immobile. When the proton ions unite with the oxygen ions on the catalytic surface of the fuel cell cathode the water molecules that were attracted to the proton ions will be released near the surface of the cathode fuel cell 116, 127 as pure liquid water without electrolyte ions. This is hydrating the electrolyte 115, 128 on the cathode electrode 117, 129 by being attracted to proton ions, but without an exit, the water will flood the electrodes with water. This water can be removed by wicking off the surface, evaporation using waste heat of the fuel cell to condense onto cooler surfaces, or diffused to the close proximity circulated electrolyte 135, 143 contained within the semi-permeable membrane tubes 167 with a lower vapor pressure. In the diffusion process the water is evaporating and exchanges the heat of condensation back from the elevated temperature of the condensation into the dehydrated circulated electrolyte 135, 143. The diffusion of gas from the fuel cell cathode to the circulated electrolyte is driven by the water vapor pressure difference between the pure excess water on the electrode 117, 129 and the circulated electrolyte 143, 135. A dynamic equilibrium of exchange of heat and water vapor is established to maintain a stable humidification of the electrolyte 115, 128 in the fuel cell and the circulated electrolyte 135, 143. The flow rate of the circulated electrolyte and concentration of the circulated electrolyte can set the humidification of the fuel cell electrolyte. In the fuel cell operation, the flow rates will he adjusted to match the waste heat generation and water drag rates. An innovation in this design is to place laminated actuators in the air flow manifolds that open when near 100% relative humidity to increase the diffusion and flow to remove excess water vapor over the fuel cell electrodes and diffusion layers and close when dehydrating to decrease the water removal and decrease the oxygen to reduce local heating to maintain humidity in the fuel cell electrolyte. This device is the function of stomata in plants to maintain local water homeostasis in plant leaves. A critical function of the laminate actuators 133, 161 is to not allow the heat removal as with a heat pipe to cool and dehydrate the fuel cell such that it is pulled too far from the optimum operation. A maximum of approximately 12 molecules can be in excess on the surface of the cathode per water molecule formed at the cathode electrode. The excess water that leaves the solid polymer electrolyte surface 115, 128 is effectively pure water. In operation this liquid water is on the surface and the fuel cell can flood and block the diffusion of oxygen 139, 162 to the surface. Wicking fibers such as fiber glass or carbon fibers in the diffusion layer could enable liquid water to leave the surface of the fuel cell electrodes and electrolytes. Some of the water molecules can diffuse back through the solid polymer electrolyte 115, 128. When a fuel cell operates on hydrogen and oxygen at approximately 50% efficiency at steady state, 8 MJ of heat energy is produced per 1 kg of water produced. That heat will need to be removed from the fuel cell surface. The heat can be removed by evaporation. When water evaporates from the surface of the electrode, 2.22 MJ / kg of heat energy per evaporated kg of water can be removed. However, we need to remove evaporate 3.6 times the water created by the hydrogen / oxygen reaction to keep the fuel cell cool. The evaporation of the chemically created water is not sufficient to remove all the heat, but the excess water created with a maximum of 12 times the created water by the ion drag is more than enough and there will be excess water on the surface of the cathode. Therefore, the lower water vapor pressure gradient to the circulated electrolyte 135, 143 can be used to attract and condense the excess water and provide heat of vaporization back to the fuel cell electrodes to continue drawing water from the surface of the fuel cell 117, 129 onto the semi-permeable membrane enclosed electrolytes. Circulation air flow, hydrogen, or oxygen over stoichiometric requirement can also be used to remove the excess water by evaporation. The semi-permeable membrane enclosed tubes with electrolyte would need to have a vapor pressure lower than the fuel cell to maintain removing excess water and prevent the fuel cell from flooding the cathode electrodes. The heat pipe surfaces, or the surfaces of the heat exchanger can also be cooler to also capture excess water. Reducing ion drag water effects or having a liquid return route or wicking route could improve the fuel cell’s ability to maintain homeostasis, and we have included both these features in this system. A portion of the circulated dehydrated electrolyte from the cathode side of the fuel cell can be routed further out into the heat exchangers or ejected as concentrated product from the fuel cell, to lower the salt concentration of the circulated electrolyte. The ion drag effect will lower the concentration of the circulated electrolyte and will increase the water recovered in the condensation inside the heat exchanger. A potential water recovery gain of approximately 0 to 12 times more distilled water from the ion drag effect over the hydrogen and oxygen formation of water from the fuel cell or electrolysis cell is possible.

[0675] Distilled Water

[0676] Distilled water from the fuel cell or electrolysis system can have many uses, such as drinking water, municipal water, agricultural water, chemical processes or mixtures, and hydroponics irrigation water. There are many regions of the world where if fresh water were available terrestrial life could be sustained and could flourish. The condensed water removal is shown in Fig 1 as droplets 113, 112, 107, 108 within air exhaust flow. Many types of wicking surfaces can be used to channel the condensed liquid water and move that liquid water to collection reservoir. Examples of wicking surfaces are polyester fibers, grooves in the surface of the tubes, and rutile titanium dioxide coating on the surfaces of the condensation surfaces.

[0677] Concentrated Electrolytes

[0678] The concentrated electrolyte 135, 143 contained within the semi-permeable membrane 125, 126, after delivering water through the manifold in the fuel cell or electrolysis cell where pure water is delivered, can be partially diverted from going to cathode (oxygen) 117 side of the fuel cell or electrolysis cell. This diverted electrolyte contained within semi-permeable membranes can be used to dehydrate air flows. Dehydration of air can be useful in high humidity spaces and climates as air-conditioning by increasing the impact of evaporation and transpiration on plants and animals to increase cooling effect and thereby their comfort and survival at elevated air temperatures. The partially rehydrated electrolyte flow with the semi-permeable membrane can be returned to the fuel cell or electrolysis cell in the lower temperature zone of the heat exchanger 159, 158 or returned to the original reservoir of electrolyte 154, such as the ocean. The portion of the electrolyte contained within the semi-permeable membrane that is not diverted will be used to remove excess water from the electrodes 117 in the fuel cell or electrolysis cell that is producing excessive water. This diversion of concentrated electrolyte subsequent more dilute electrolyte coming out of the excess water from the fuel cell or electrolysis cell can reduce the vapor pressure difference between the electrolyte 159 and the condensation surfaces 113 in the counter flow heat exchange with the incoming reactants 157 so more cycles of distillation can occur and the benefit of water purification effect of ion drag in the fuel cell can be realized.

[0679] Heat Pipes

[0680] In Fig 1. Heat pipes 144, 131 with wicking 138, 165 and condensate liquid 137, 171 are shown. Heat pipes can move heat from a fuel cell or catalytic heater at nearly constant temperatures with the vaporization of the working fluid from the heat source, catalytic heater 120, or fuel cell 117. Condensation of water vapor 121 can occur on the permeable membrane 158, containing circulated liquid electrolyte 159 that is in thermal contact with the heat pipe 117. The heat can be removed via the heat pipes 144 to external surfaces 144, 131 to be heated uniformly at the temperature of the fuel cells 114, 101, 118, 127 or the catalytic heater. Electrochemical batteries need to be heated to an optimum temperature. The catalytic heater can start at low temperatures such as -40°C with hydrogen 103 and air or oxygen 105, 157 when the fuel cells cannot operate and deliver heat to both the heat pipes and by removing water vapor from the catalytic heater by condensation and osmosis into the semi-permeable circulated electrolyte 102, 111. Heat pipes made of metal are difficult to incorporate into bipolar plate fuel cells because they can be planar conductive surfaces that are competing for the same space as a bipolar electrically conductive plate. Therefore, a planar electrical collection with dielectric gas flow channels electrically separating the heat pipe from the fuel cell electrodes eliminates their competition for space and prevents electrifying the heat pipe 144, 171. The heat pipes in this planar fuel cell configuration can be electrically grounded and electrically insulated from the high voltage 101, 114 output of the fuel cell arrays. Heating and Cooling System

[0681] The heating system of the heat pipes 144, 131, heating of air 105 in the heat exchanger 130, 106, 168, 158, can be tapped to heat interior spaces, machinery, and batteries if diverted. Heating the hydrogen 104, 125, air inlet gases 105, 157, and circulated electrolytes 167 with the outlet air exhaust 162, 139, 109, 156 counter flow heat and water vapor exchange 168, 107, 159, 113 results in a saltier electrolyte 159, 168 and pure condensed water vapor 108, 107, 113, 112 as byproducts. A cooling effect does occur with the hydrogen and air inlet gases 103, 104 by evaporation from the electrolyte 111, 102 contained in the semi-permeable membrane 168, 158. This cooling effect can be transferred to a counter flow of air or the exhaust flow 109, 156 that can be transferred to the space, batteries, or equipment that needs to be cooled. If the air and hydrogen 103, 105, 157 is compressed into the heat exchangers 130, 106, 168, 158, cooled to near ambient temperatures in the exhaust air, and then expanded in a decompressor, then the exhaust 109, 156 will be cooler than ambient air and useful for space heating and cooling machinery.

[0682] Liquid Wicking Within Semi-Permeable Membrane Tubes

[0683] To evaporate water from the circulated electrolyte How within the semi-permeable membrane tubes 141, 126 are wicking fibers 142 and / or channeled hydrophilic surfaces. This enables liquid water to more uniformly cover the interior surfaces of the semi-permeable membranes. The semi-permeable membranes, such as hydrophobic porous Teflon polytetrafluoroethylene tubes, prevent liquid water from flowing through the pores because of its high surface tension energy but it also causes liquid water to bead and agglomerate and not wet on the surface of the membrane tube. The evaporation areas of the semi-permeable membranes can be partially liquid filled. Effectively, a bubble of gas fills the semi-permeable membrane tube. This gas filled semi-permeable tube reduces the diffusion rates from the liquid water to be lower and create non-uniform diffusion of water vapor over larger length of the tubes. Wicking fibers 142 such as polyester threads within the semi-permeable tube can wick the electrolyte liquid and by surface tension equilibrium spread the liquid electrolyte more uniformly along the wicking fiber and over the length of the semi-permeable membrane tubing 141, 126. Combining Ion Drag, Gas Compression, Heat and Mass Exchange and Gas Decompression to Provide Water Purification and Cooling

[0684] The fluid flows in Fig 1 do not show compressors or decompressors that move the fluids through the system. To achieve higher system performance, air 105, 157 and hydrogen fuel 103 can be compressed and flow through the fuel cell or electrolysis system. Heat and mass water are transferred in the heat exchange system to heat the fluids to the operational temperature of the fuel cell. When the fluids are exiting the system 198, 109, 149, 154, 156, 112, the heat and mass exchange is reversed; the exhaust flow of oxygen depleted air in the case of a fuel cell, and hydrogen and oxygen in the case of an electrolysis flow. The fluid flow 149, 155, 109, 156 goes through constriction or a decompressor to cool. This cooled flow can be used to chill interior spaces, equipment, or batteries. Water condensation of water in the flow can also occur.

[0685] Fig 2A shows a cross-sectional view of the membrane electrode assembly, a hydrogen anode and oxygen cathode, electrolytes, a porous dielectric substrate proton permeable membrane within the electrolyte, with permeable liquid retaining membrane, wicking fibers, gas manifolds, microvalves and circulated electrolytes. In the core of this fuel cell is a porous dielectric membrane 215, 212 made by irradiation and etching a polyester membrane 25 to 100 microns thick with charged argon atoms. These are commonly available by Nuclepore® filters or RoTrac® filters OXYPHEN GMBH - Life Science Giesserstrasse 1, 8620 Wetzikon, Switzerland. They may have polyester or fiber glass fiber reinforcement. These membranes can be coated with a range conductive metal coatings 216, 210 such as gold, nickel, silver, stainless steel, MoSi2, Ta, carbon, and graphene to form electrically conductive electrodes and circuits on the dielectric substrate. Catalytic deposits 216, 210 of Pt, Pd, Ir, Ni, Ag, Ir, Ru, RuO2, IrCh. and many alloy combinations such as IrMn, on the surface of the electrically conductive electrodes 216, 210 can be deposited as a coating or powder onto the conductive coating. A graphene layer 213 is deposited on the opposite side to the electrode on the polyester substrate to cover the pores of the electrolyte 214, 211 on the surface of a polymer electrolyte 214, 211 that impregnated the porous substrate 215, 212. Two membranes 215, 212 with anode 210 and cathode 216 are sandwiched together with the solid polymer electrolyte 214, 211 or a liquid electrolyte 211, 214. The electrolyte 211, 214 can be a solid polymer membrane (PEM) such as proton conductive Nafion, or anion electrolyte membrane (AEM) such as made by Enapter, Via di Lavoria 56G, 56040 Crespina Lorenzana (PT), Italy, or a liquid electrolyte such as sulfuric acid or potassium hydroxide. Reactant gas channels 217, 209 into the electrolyte and catalyst coated electrodes 216, 210 form a triple interface of reactant gas 209, 217, electrolyte 211, 214 and catalytic surface 210, 216 needed to perform the exchange of electrons and ions on the surface of the fuel cell electrodes. The circulated electrolyte is contained in a hydrophobic permeable or porous dielectric tube 205, 208 or membrane 208 made of urethane or expanded PTFE polytetrafluoroethylene or Teflon. Within this tube or membrane is a fiber or wicking surface 207 made of polyester thread, and / or grooves in the wall of the tube with a hydrophilic coating or stripe pattern of titanium dioxide coating. A circulated electrolyte 206 is wicked onto the wicking fibers 207 and placed close to the anode electrode 210. An anode gas manifold 201 and heat exchanger channels 202, 204, 203 are made of dielectric plastics such as urethane, neoprene, Viton®, EDPM, silicone robbers, polyester, propylene, PVF (KelF®), Polyimide (Kapton®), polyaramid, PBI (Polybenzimidazole) PBO Polyfp-phenylene benzobisoxazole) , and ceramics such as alumina, quartz, or zirconia or combinations and placed in contact with permeable membrane tube 205, 208 and anode 210. The separating walls 203 of the channels 202, 204 can be semi-permeable to diffuse hydrogen between the channels. Hydrogen gas or other hydrogen bearing fluids counter flow though the channels exchanging heat and molecules. The flow through the channels 202, 204 will be flowing in 202 counter flow into the page for one channel and out of the page for the neighbor channel 204. To optimize the heat and mass transfer, the channels 202, 204 are paired to have similar mass flow rates. On the opposite side of the cell at the cathode 216, a dielectric polyester fiber 219 non-woven or woven layer is placed close to the cathode 216. The purpose of the wicking layer 219 is to remove liquid water from the surface of the cathode 216. Hydrophilic fibers 219 coated with PTFE create a surface tension gradient to move liquid water 218 off the surface of the cathode. Hydrophobic fibers 219 can be blended or woven with hydrophilic fibers and can be created to have a surface tension gradient such that liquid water 218 will move off the surface of the cathode 216. The laminate actuators 221, 222 are made of two membranes with different expansion properties laminated together. For optimal actuation, the two layers must have similar stiffness. A membrane 220 of apertures 223 and laminate actuators membrane 221, 222, made with hydroscopic expansion property of two materials laminated together with similar stiffness, functions so that when relative humidity is high it will open the aperture 223 and allow diffusion and flow of oxygen to the fuel cell 216. This actuating array performs 220, 223, 221 , 222 to reduce oxygen supply and loss of moisture from the surface of the cathode 216 when dehydrating, such as when the fuel cell power output is reduced, locally overheating, or turned off. A dielectric heat exchanger 226 of paired channels 232, 237 made of urethane, polyester, silicone rubber, allows oxygen or air to flow over the surface of the cathode. The walls of the channels 224 can be made semi- permeable or porous to allow diffusion of oxygen and between the counter flows in the channels 232, 237. Tubular semi-permeable membranes 231, 235 that can contain and allow flow of liquids 230, 234 can be incorporated as part of flow channels 224, 226, 220 of the heat exchangers and mass exchange manifolds. Semi-permeable membrane tube 231, 235 made of micro-porous PTFE, silicone rubber, or urethane are placed inside the heat and mass exchanger 226. On the outside and inside the semi-permeable tubes, a wick 225, 229, 233 can be placed to wick condensed liquid water on the outside 225 and on the inside 233 with the electrolyte 230, 234 on the inside of the semi-permeable membrane and liquid water 228 on the outside 225 of the semi-permeable membrane tube 231. Condensed water 227 can form on the side of the heat exchanger channels 226 and wick 225 on the surface of the semi-permeable membrane tubes 231 and by osmotic drag remove the liquid water into the circulated electrolyte 230.

[0686] Fig 2B shows an illustration of the molecule diffusion of reactants, products, and impurities are shown in the cross-sectional view of the membrane electrode assembly 208, 209, 210, 212, 213, 214, 215, 216, 217, 218, 219, a hydrogen anode 210 and oxygen cathode 216, electrolytes 214, 211, a porous dielectric substrate 212, 215, proton permeable membrane 213 within the electrolyte 211, 214 with permeable liquid retaining membrane 208, 205, 231, 235, wicking fibers 207, 228, 229, 233, gas manifolds 202, 204, 232, 237, micro-valves 220, 221 , 222, and circulated electrolytes 206, 230, 234 arc shown. The four arrows 238, 239, 240, 241 indicate heat flux to the flow in the exchanger 201, 226. When the hydrogen enters 202 the hydrogen is heated to the temperature of the fuel cell by heat transfer 238 through the manifold wall 201, 203. The hydrogen exhaust 204 shows the heat being removed 239 from the exhaust 204. On the upper side of the drawing the heat of condensation 240 is being removed from both the inlet oxygen 237 and outlet oxygen flows 232 and the electrolyte flows 234, 230. The hydrogen gas manifold 201 has hydrogen flow 202 dominated by hydrogen molecules 242 and a few nitrogen molecules 243 that diffuse through the electrolyte 212, 215, substrate 212, 215, and graphene layer 213 from the air supply 232, 237 to the cathode 216. Hydrogen molecules 242, water 246, and inert gasses such as nitrogen 245 can diffuse through 244, 245 the scmi-pcrmcablc walls 203, 205 of the heat and mass transfer manifold 201 to the counter flowing exhaust flow 204 to maintain a needed hydrogen concentration 258 for the fuel cell anode 210. While nitrogen molecules 245 diffuse and at much slower rates than hydrogen 244 through the semi-permeable membrane 203, 205. The desired effective molecular exchange is to maintain a needed hydrogen flux 249 to the fuel cell anode 210 while concentrating the crossover nitrogen 245 to enable an efficient exhausting of nitrogen 259 while removing a much smaller amount of hydrogen 258. The hydrogen molecules 248 diffuse from the manifold channels 242 through the semi- permeable membrane tube 205, 208 to the anode 210 and react 250 with catalyst giving up two electrons to the catalyst and electrical conductor 210 of the fuel cell. A proton ion 250 is created and moves into the electrolyte with a cluster of roughly 6 molecules 211. Water molecules 247, 246, 260 diffuse from the electrolyte 206 and off the wicking contact 207 with the semi- permeable tubular membrane 208, 205. The water molecules 247 go into the fuel cell electrolyte 260 and cluster 211 about the hydrogen ions 250 in the electrolyte. The proton 250 with the cluster of water molecules 211 travels toward the cathode 216 by a voltage and concentration gradient. At the graphene monolayer 213 the hydrogen proton 251, 252 passes through the graphene layer 213 and leaves the water molecules 247 behind. On the other side of the graphene layer 213, water molecules, approximately 6 molecules per proton cluster 214 about the hydrogen ion 253, then travel to the cathode electrode. On the catalytic cathode electrode 216 protons 253 unite with single oxygen atoms 254 that are chemi- absorbed on the surface of the cathode 216. The formed water molecules 256 leave the surface of the cathode 216 and diffuse 256 and evaporate from the surface of the electrolyte 217. The water molecules can condense 218 on the nearby wicking surfaces 219 and be drawn away from the surface of the cathode 216 or travel through the laminate actuating valves 220, 221, 222. Water molecules 257 will diffuse through the gas flow channels 226 to condense 227, 228 on the surfaces of the heat and mass exchange manifold 226, 224. Liquid water 228 wicks onto the semi-permeable membrane 231, 235 by osmosis and subsequently diffuses into the circulated electrolyte 234, 230. The liquid electrolyte 234 is shown in the semi-permeable membrane tube 235 that has a concentrated electrolyte 234 flowing inside the inlet air flow channel 237 as well as atmospheric oxygen concentration 237. In the adjacent channel 232, the water in the semi-permeable tube 230 is flowing out with a larger amount of liquid and diluted electrolyte 230 and a depleted oxygen supply 232. The oxygen 237, 232 diffuses from the input gas channel through the gas channels 232, 237, through the laminate actuators 223, 255, 222, 221, 219, past the wicking fibers 219, through the microchannels 217, and then to the cathode catalytic surface 216, 254 of the fuel cell.

[0687] Fig 3 shows a cross-section view of a single double back U-flow heat and mass exchanger. The reactant flow is paired with itself. In this drawing the hydrogen enters the heat exchanger.

[0688] Heat, as indicated by the small arrow 303, is transferred through the semi-permeable membrane 304 from the outgoing depleted gas flow 302 to the incoming flow 301. The inlet gas 301 concentration is high in hydrogen 305 and low in cross-over impurity molecules 306 through the fuel cell electrolyte such as nitrogen and oxygen. Hydrogen molecules 305 can readily diffuse through the membrane separator 304 while impurity gases 306 diffuse at a much lower rate. The impurity gases 306 build up in concentration while the hydrogen molecules 305 diffuse through the separator and diffuse laterally in the diffusion layer of the fuel cell to maintain a sufficient concentration to operate the fuel cell. The impurity molecules 306 are removed with a low concentration of hydrogen 305 when gas flows out 302. In this double back heat exchange the heat transfers from the fuel cell to the flows while the highest heat and concentration gradients will be at the entrance 300. Pairing of the flows 301, 302 and heat and mass exchange, with the fuel cell being a third diffusion source or sink removing reactants and adding heat, results in a more uniform temperature and concentration average on the electrodes that span the two flow channels.

[0689] Fig 4A shows a cross-section view of a hydrogen manifold, with a double back flow with a serpentine pattern. The reactant flows 402, 401 are paired with itself. In this drawing the hydrogen 406 enters the heat exchanger 403. Heat, as indicated by the small arrow 405, is transferred through the semi-permeable membrane 404 from the outgoing depleted gas flow 411 to the incoming flow 412. The inlet gas concentration 402 is high in hydrogen 406 and low in cross-over impurity molecules 409 such as nitrogen and oxygen through the fuel cell electrolyte. Hydrogen molecules can readily diffuse 408 through the membrane separator 404 while impurity gases 409 diffuse at a much lower rate. The impurity gases 410 build up in concentration while the hydrogen molecules 407 diffuse though the separator and diffuse laterally in the diffusion layer of the fuel cell to maintain a sufficient concentration of hydrogen 407 to operate the fuel cell. The impurity molecules 410 are removed with the exhaust with a low concentration of hydrogen 407 when the gas is exhausted 401. In this double back heat exchange the heat transfers from the fuel cell to the flows while the highest heat and concentration gradients will be at the entrance 403. Pairing of the flows 402, 401 and heat 405 and mass exchange 408, with the fuel cell being a third diffusion source or sink removing reactants and adding heat, results in a more uniform temperature and concentration average on the electrodes that span the two flow channels 411,412.

[0690] Fig 4B shows a cross-sectional view of a hydrogen manifold with paired counter flow and a serpentine pattern. The reactant in flows 452, 472 are paired with the outflows 451 and 471 respectively. In this drawing two streams of hydrogen 452, 472 enter the heat exchanger 453, 470. Heat, as indicated by the small arrow 455, 469 travels through the semi-permeable membrane 454, 468 and is transferred from the outgoing depleted gas flow 451, 471 to the incoming flow 452, 472. The inlet gas concentration 452, 472 is high in hydrogen 456, 465 and low in cross-over impurity molecules 459, 463 such as nitrogen and oxygen through the fuel cell electrolyte. Hydrogen molecules can readily diffuse 458, 466 through the membrane separator 454, 468 while impurity gases 459, 463 diffuse at a much lower rate. The impurity gases 460, 464 build up in concentration while the hydrogen molecules 457, 467 diffuse through the separator 454, 468 and diffuse laterally in the diffusion layer of the fuel cell to maintain a sufficient concentration of hydrogen 457, 467 to operate the fuel cell. The impurity molecules 460, 464 are removed with the exhaust with a low concentration of hydrogen 457, 467 when the gas is exhausted 451, 471. In this counter flow heat exchange, the heat transfers from the fuel cell to the flows while the highest heat and concentration gradients will be at the entrance 453, 470. Pairing of the flows 452, 472 and heat 455, 469 and mass exchange 458, 466, with the fuel cell being a third diffusion source or sink removing reactants and adding heat, results in a more uniform temperature and concentration average on the electrodes that span the two flow channels 462, 461. Fig 5 shows a cross-sectional view of a hydrogen manifold with a double back flow with a spiral pattern. The reactant flow 502 is paired with itself 501. In this drawing the hydrogen 502 enters the heat exchanger 503. Heat, indicated by the small arrow 504, is transferred through the semi-permeable membrane 505 from the outgoing depleted gas flow 501 to the incoming flow 502. The inlet gas concentration is high in hydrogen 508 and low in cross-over impurity molecules 510, such as nitrogen and oxygen, through the fuel cell electrolyte. Hydrogen molecules 507 can readily diffuse through the membrane separator 505 while impurity gases 511 diffuse at a much lower rate. The impurity gases 510 build up in concentration while the hydrogen molecules diffuse 507 through the separator 505 and diffuse laterally 511 in the diffusion layer of the fuel cell to maintain a sufficient concentration to operate the fuel cell. The impurity molecules 509 are removed with a low concentration of hydrogen 506. In this double back heat exchange 503 the heat transfers 504 from the fuel cell to the flows while the highest heat and concentration gradients will be at the entrance. Pairing of the flows 502, 501 and heat and mass exchange 507,511, with the fuel cell being a third diffusion source or sink removing reactants and adding heat, results in a more uniform temperature and concentration average on the electrodes that span the two flow channels.

[0691] Fig 6 shows a cross-section view of the laminate actuator for humidity and temperature actuation with membrane substrate aperture. The laminate actuator 602, 603 is formed by laminating a porous polyester or polyethylene membrane 602 impregnated with a polymer electrolyte, such as Nafion® dissolved in alcohol, is inkjet-printed into the porous volume of the porous polyester membrane layer over the aperture area. This Nafion® impregnated layer 607, 602 of polyester is bonded onto an aperture polyester substrate 606, 604 with an ultrasonic friction weld. The solvents are evaporated from the Nafion® at the expected operational temperature and relative humidity in the neutral flat position of the actuator 602. The top surface of the Nafion® and porous membrane 602 are ion milled to promote adhesion. A second polymer, metallic, or ceramic layer or membrane such as Kapton®, nickel, or silicon dioxide 601, 603 is deposited by ultrasonic welding, inkjet printing chemical vapor deposition, sputtering, or evaporation. A computer-controlled laser is then used to perforate and cut through the top two layers 602, 603 of the actuating layer in a pattern to form a flap such as V or U pattern to leave an attached bend line on the non-cut side opening of the V or U pattern. By not coating the porous layer 607, 602 with the electrolyte where the V and U pattern are cut or a pre-coating of a release agent on the substrate 606, the actuator valves can release from the substrate and form a shelf seal region 608. An option in construction is to laser cut through the laminated layers with the V or U cuts within the aperture and thereby have no shelf 608. A third coating 609, 610 of such as a biocide such as nickel, silver, or rutile titanium dioxide, can be added to the low coefficient of expansion layer such that the surface of this coating will be an anti-bio-fouling surface. This surface can also be a hydrophilic surface to wet and spread water across it’s surface and prevent condensed water droplets from interfering with the opening of the aperture and laminate actuators. Alternatively, hydrophobic coatings 609, 610 such as polytetrafluorethylene PTFE be deposited on the low coefficient of expansion surface to act lower the surface tension of the surface to repel condensed water droplets. In operation the laminate actuator will be placed within the gas manifolds and heat exchangers to regulate relative humidity. When the relative humidity is low the laminate aperture will remain closed. When the relative humidity is high, the Nafion®, a solid polymer electrolyte, will hydrate and expand causing the laminate actuator flap to curl due to the differential expansion of the Nafion® impregnated porous layer and open the aperture 605, 608. This will allow gases to diffuse and / or flow through the aperture 605, 608 to deliver more oxygen and remove more water vapor from the fuel cell electrodes. When the relative humidity around the laminate value declines, the Nafion® impregnated layer 602 will contract and the laminate valve can proportionately close over the aperture 605 depending upon the relative humidity. Thus, this relative humidity regulating mechanism can be used to maintain optimum operation humidity over the fuel cell over a wide range of power outputs and relative humidity in the incoming air to fuel cell. There are a wide range of hygroscopic materials that expand when humidified and have a range of modulus of elasticity and layer thickness such that the laminate motion and strength of motion can be adjusted to be a lower or higher radius of curl and change the mechanical force generated by the expansion curl 602.

[0692] Fig 7 shows an exterior view of the laminate actuators perpendicular to the plane of the actuator membrane substrate. The frame of the apertures 701 is shown. The top surface low expansion layer 702, seen on edge 703, can be a sputter deposit or laminated metal coating such as nickel, stainless steel, molybdenum, or a dielectric such as quartz or polyester, onto the expansion layer. The low humidity reactive expansion layer 705 and edge view 704 can be made of a porous polyethylene or polyester membrane impregnated with a solid polymer electrolyte such as Nafion®. The reactive expansion layer 705 can be a bonded welded line of a stiffer substrate 701 that can range from thicker porous polyester impregnated with electrolyte, plastic membranes, metal, or ceramics along the frame of the aperture of the substrate layer. The laminate actuators 702,705 are shown partially open to allow gases to flow and diffuse through the apertures 706.

[0693] Fig 8A shows an integrated planar’ fuel cell 817, 820, reactant manifolds 807, 808, 805 heat exchanger 810 and catalytic heater 812 in sheet print air side. Construction of this printed sheet starts with a dielectric membrane 801, 814 that can be formed to have porous and non-porous areas. The dielectric material 801, 814 may be made as laminated layers that can include fibers, ceramic layers, metal layers, graphene layers or sensors inside the dielectric material in patterns. The porosity can be tortuous or collimated. The thickness and porosity can be varied over the membrane 801. The first region is the perimeter weld seal area 801 that is non-porous and is capable of thermal welding of mechanical sealing, The perimeter seal 801 can have deposits of polymers or rubbers 811. Within the perimeter seal electrical contacts are deposited by vapor deposition, electroplating, inkjet printing or lamination on the dielectric substrate 801, 814. These contacts will be the grounded electrodes 802. Apertures for electrolyte flow 803, 804 in the membrane are formed by laser cutting, waterjet cutting, or die cuts. Further into the dielectric membrane air exhaust 805, air inlet 807 and hydrogen fuel inlets 809 and outlet, apertures 805 are formed by laser cutting, waterjet cutting, or die cutting. Seals 808, 801 can be formed by depositing polymers and / or rubbers onto the dielectric substrate membrane 801, 814. Non-porous areas of the membrane substrate 814 can be formed to provide a foundation area for flow manifold walls. Porous catalytic layer of ceramic and catalyst 812 is deposited onto the porous membrane substrate 801, 814. Electrical vias 815, 818 are formed through the dielectric substrate by charged particle bombardment and etching, laser cutting, waterjet cutting or die cutting. Gaps 816, 819 are dielectric substrate materials or coated with a hydrophobic material to repel condensed liquid water or electrolyte, and are adjacent to, and on the insulator. Electrolyte and catalytic coatings 817, 820, conductive coatings and powders are deposited as layers onto porous dielectric substrate areas to form the air cathode side of the fuel cell arrays. Electrical contact layers are formed by vacuum depositing, inkjet printing or lamination. These contacts 821 will be the high voltage contacts 823 from this array of fuel cells. Air flow apertures 822 arc cut through the dielectric substrate and electrical contacts with lasers, waterjet or die cutting. Apertures 813 for the circulated electrolyte are cut through the dielectric substrate 801. Gas flow manifold walls 811, 801 made of dielectric polymers or rubbers are deposited by 3D printing onto the dielectric substrate 801. The flow of air in this configuration flows into the manifold through apertures 807. It flows down the channel 810 over the catalytic heater 812, across the array of fuel cells 817, 820 to the end of the channels 821, and over and / or through the apertures 822. The air flows through the second aperture in Fig 8C 851 to emerge in aperture Fig 8D 871. The electrolyte retained within the semi-permeable membranes flows through the inlet aperture, through the contact electrode 804, through in Fig 8B through the non-porous dielectric substrate 825, and flows into the membrane tube network 830. In Fig 8B, the membrane tubes 830 also form part of the gas flow manifold and heat exchanger walls 839. In Fig 8B, this electrolyte can cross connect parallel membrane tubes 839 such as over the cell gaps 819. In Fig 8B, the electrolyte flows 811 to reach the exit aperture 837 and flows through the substrate membrane 825 to emerge out of aperture 822 in Fig 8A. In Fig 8A, the electrolyte flow travels along and through the manifold walls 811 to the electrolyte exit apertures 804.

[0694] Fig 8B shows an integrated planar fuel cell 835, reactant manifolds 828, 829, 830, 843 heat exchanger and catalytic heater in sheet print fuel side. Construction of this printed sheet starts with a dielectric membrane 824 that can be formed to have porous 835 and non-porous areas 836. The dielectric material 824 may be made as laminated layers that can include fibers, ceramic layers, metal layers, graphene layers or sensors inside the dielectric material in patterns. The porosity can be tortuous or collimated. The thickness and porosity can be varied over the membrane 824. The first region is the perimeter weld seal area 824 that is non-porous and is capable of thermal welding of mechanical sealing, The perimeter seal 824 can have deposits of polymers or rubbers. Within the perimeter seal, electrical contacts 836, 838 are deposited by vapor deposition, electroplating, inkjet printing, or lamination on the dielectric substrate. These contacts 836, 838 will be high voltage electrodes. Apertures for electrolyte flow 830. 840 in the membrane are formed by laser cutting, waterjet cutting, or die cuts. Further into the dielectric membrane 825 and hydrogen fuel inlets 828 apertures are formed by laser cutting, waterjet cutting, or die cutting. Seals can be formed by depositing polymers or rubbers onto the dielectric substrate membrane 824. Non-porous areas of the membrane substrate 825 can be formed to provide a foundation area for flow manifold walls 827, 832. A porous catalytic layer of ceramic and catalyst 831 is deposited onto the porous membrane substrate 825. Lanate actuator micro valves to control flow of impurity with the high thermal expansion coefficient material 840 and low coefficient thermal expansion material 841 on a substrate aperture 842. This laminate actuator valve is designed open when cold and close near the optimum operating temperature of the fuel cell to allow the catalytic heater to purge hydrogen through system and heat up to the operating temperature. Electrical vias 834 are formed through the dielectric substrate by charged particle bombardment and etching, laser cutting, waterjet cutting or die cutting. Gaps 833 are dielectric substrate materials or coated with a hydrophobic material to repel condensed liquid water or electrolyte, and are adjacent to, and on the insulator. Electrolyte and catalytic coatings, conductive coatings and powders are deposited as layers onto porous dielectric substrate areas to form the air cathode side of the fuel cell arrays 835. Electrical contact layers 836 are formed by vacuum depositing, inkjet printing, or lamination. These contacts 838 will be the high voltage contacts from this array of fuel cells. Air flow apertures 837 are cut through the dielectric substrate and electrical contacts with lasers, waterjet or die cutting. Apertures for the circulated electrolyte are cut through the dielectric substrate 826, to connect with aperture 813 shown in Fig8A. Gas flow manifold walls 827, 830, 839. 843, 824 made of dielectric polymers or rubbers are deposited by 3D printing onto the dielectric substrate 825.

[0695] Fig 8C shows an integrated planar fuel cells 853, 854, 855, 858 reactant manifolds 856, 860, 863, heat exchanger 863, 856 and catalytic heater in sheet print fuel side 863. Construction of this printed sheet starts with a dielectric membrane 866, 863 that can be formed to have porous 853 and non-porous areas 863. The dielectric material may be made as laminated layers that can include fibers, ceramic layers, metal layers, graphene layers, or sensors inside the dielectric material in patterns. The porosity can be tortuous or collimated. The thickness and porosity can be varied over the membrane. The first region is the perimeter weld seal area 866 that is non- porous and is capable of thermal welding of mechanical sealing, The perimeter seal 866 can have deposits of polymers or rubbers. Within the perimeter seal 866, electrical contacts 852 are deposited by vapor deposition, electroplating, inkjet printing, or lamination on the dielectric substrate 863. These contacts 852, 850 will be the high voltage electrodes. Apertures for electrolyte flow 865 in the membrane are formed by laser cutting, waterjet cutting, or die cuts. Electrolyte flow return aperture with seal 867 from the oxygen side of the array Fig 8D is shown. Non-porous areas of the membrane substrate 852, 856, 863 can be formed to provide a foundation area for flow manifold walls 858, 860, 865. Porous catalytic layers of ceramic and catalyst 859 are deposited onto the porous membrane substrate. Laminate actuating micro valves 857 to control the hydrogen flow to the catalytic heater 859 are deposited at the end on the hydrogen flow manifold 856. Electrical vias 854 are formed through the dielectric substrate by charged particle bombardment and etching, laser cutting, waterjet cutting or die cutting. Gaps 855 are the dielectric substrate materials or coated with a hydrophobic material to repel condensed liquid water or electrolyte, and are adjacent to, and on the insulator. Electrolyte and catalytic coatings, conductive coatings and powders are deposited as layers onto porous dielectric substrate areas to form the air cathode side of the fuel cell arrays 853. Electrical contact layers 852 are formed by vacuum depositing, inkjet printing or lamination. These contacts 852, 850 will be the high voltage contacts from this array of fuel cells. Air flow apertures 851 are cut through the dielectric substrate and electrical contacts with lasers, waterjet or die cutting. Apertures for the circulated electrolyte semi permeable membrane tubes 860, 865 are cut through the dielectric substrate 864, 867. Gas flow manifold walls 858, 860 made of dielectric polymers or rubbers are deposited by 3D printing onto the dielectric substrate.

[0696] Fig 8D shows an integrated planar fuel cell 873, reactant manifolds 876, heat exchanger and catalytic heater in sheet print air side. Construction of this printed sheet starts with a dielectric membrane 884, 877 that can be formed to have porous and non-porous areas. The dielectric material 884, 877 may be made as laminated layers that can include fibers, ceramic layers, metal layers, graphene layers, or sensors inside the dielectric material in patterns. The porosity can be tortuous or collimated. The thickness and porosity can be varied over membrane 884, 877. The first region is the perimeter weld seal area 884 that is non-porous and is capable of thermal welding of mechanical sealing, The perimeter seal 884 can have deposits of polymers or rubbers. Within the perimeter seal 884, electrical contacts 883 are deposited by vapor deposition, electroplating, inkjet printing, or lamination on the dielectric substrate 884. These contacts 883 will be the grounded electrodes. Apertures for electrolyte outlet flow 882 in the membrane are formed by laser cutting, waterjet cutting, or die cuts. Further into the dielectric membrane 884 are air exhaust 880, and air cross manifold flow apertures 881 . Non-porous areas of the membrane substrate 884, 877 can be formed to provide a foundation area for flow manifold walls. Porous catalytic layer 878 of ceramic and catalyst is deposited onto the porous membrane substrate. Electrical vias 875 are formed through the dielectric substrate by charged particle bombardment and etching, laser cutting, waterjet cutting or die cutting. Adjacent to and on the insulator, gaps 874 are the dielectric substrate materials or coating with a hydrophobic material 874 to repel condensed liquid water or electrolyte. Electrolyte and catalytic coatings, conductive coatings and powders are deposited as layers 873 onto porous dielectric substrate 884 areas to form the air cathode side of the fuel cell arrays. Electrical contact layers 872 are formed by vacuum depositing, inkjet printing, or lamination. These contacts 872, 870 will be the high voltage contacts from this array of fuel cells. Air flow apertures 871 are cut through the dielectric substrate and electrical contacts with lasers, waterjet or die cutting. Apertures for the circulated electrolyte 882, 885 are cut through the dielectric substrate 884. Gas flow manifold walls 876, 884 made of dielectric polymers or rubbers are deposited by 3D printing onto the dielectric substrate. The flow of air in this configuration flows into the manifold through apertures 881. It flows down the channel 872, over the catalytic heater 879, 878, 877, across the array of fuel cells 875, 874, 873, to the end of the channels 872, and over and / or through the apertures 871. The air flows through aperture in Fig 8C to emerge in aperture in Fig 8A 822. In Fig 8C, the electrolyte retained within the semi-permeable membranes flows through the inlet aperture 865, through the manifold wall network 860, through to the exit aperture 868. In Fig 8D, the electrolyte emerges through the apertures 871, flows through the membrane tube manifold network 876, to exit out to apertures 882.

[0697] Fig 9A shows an exterior view of a spool 913 to make fluid and electrical connections and wind planar membrane fuel cells. The spool 913 can be made with electrically conductive materials such as stainless steel, nickel, electrically conductive carbon fiber and / or graphene composites, and metal coated polymers. The spool has two circular flange plates 901, 914 at either end that are joined to a flow distribution tube 913. The flow distribution tube 913 has at least 5 flow channels within the tube: air inflow 909, hydrogen inflow 911, exhaust air outflow 903, electrolyte in flow 906 with seal 905, electrolyte outflow 907, and seal 908. The flanges 901, 914 on the tube 913 are designed to mate with a flat gasket surface and be secured through threaded holes 902, 915 and holts. The flanges 901 , 914 are also designed to make the grounding connection and electrically connect to the ground connection of the fuel cell. In this system the design maxim for safety is to keep all the in and out fluid flows and connections at the ground voltage. Along the length of the cylinder 913 of the spool, apertures are located to match the membrane planar array gas connections when wrapped about the spool. Shown are the 8 hydrogen gas inlets 912, air gas inlets 910, exhaust air gas outlets with the apertures in the tube machined by drilling, molding, waterjet cutting, 3D printed.

[0698] Fig. 9B shows an exterior view of the spool with mount planar membrane fuel cells rotated 180 degrees. The spool can be made with electrically conductive materials 965 such as stainless steel, nickel, electrically conductive carbon fiber, and / or graphene composites, and metal coated polymers. The spool has two circular flange plates 950, 963 at either end that are joined to a flow distribution tube 965. The flow distribution tube 965 has at least 5 flow channels within the tube: air inflow 952, hydrogen inflow 954, exhaust air outflow 955, electrolyte in flow 958 with seal 959 and electrolyte outflow 957 and seal 956. The flanges 950, 963 on the tube are designed to mate with a flat gasket surface 950 and be secured through threaded holes 951, 964 and bolts. The flanges 950, 963 are also designed to make the ground connection and electrically grounding the fuel cells. In our design for safety, we keep all the fluid flows at the ground voltage. Along the length of the cylinder 965 of the spool, apertures are located to match the membrane planar array gas connections when wrapped about the spool. Shown are the 8 air gas inlets 962, air gas exhaust 961, in the tube machined by drilling, molding, waterjet cutting, or 3D printed. Also shown are the electrolyte apertures inlet 958 with a connection seal 959, electrolyte outlet 957, and outlet seal 956.

[0699] Fig 10 shows a cross-section view of two fuel cell arrays and mass and heat transfer gas manifolds being wrapped on a spool with an inserted heat pipe. The fuel cell arrays are wrapped about a metal spool 1004 with metal coated membrane substrate polymer sheet 1027 being attached to the apertures 1022, 1061, 1063, 1002, 1006 and to the channels inside the spool tube 1044, 1008, 1023, separated by metal walls 1004. Hydrogen inflow 1008, air inflow 1044, air exhaust 1023, and electrolyte in 1063 and out flow electrolyte 1061. The fuel cell arrays 1050 contact layer 1030 can be aligned and attached to the tube 1032 with a metal-to-metal weld or a polyester conductive epoxy glue. The fuel cell planar arrays contact layer 1031 , 1030 is aligned to make the flowed electrolyte apertures of the fuel cell array align first with the outlet tube 1061. The electrolyte inlet tube 1063 is the second aligned with the apertures 1002, 1006, 1022 and sealing aperture surfaces 1005, 1009,1020, 1021, 1025, 1026, 1001, 1007, 1024 of the fuel cell array 1050. The third aperture to align is the fuel cell array aperture 1001, and the hydrogen spool aperture 1002. The fourth aperture alignment is the air inlet of the fuel cell array 1007 to the spool aperture 1006. The fifth aperture alignment is the alignment of the fuel cell aperture 1024 to the exhaust aperture 1022 of the manifold tube 1032. Two catalytic heaters 1029, 1040 that are built into the array are shown with a hydrogen gas supply 1038 between the heaters 1029, 1040 and air supply on their exteriors 1034, 1041. The thermal micro valve 1035 allows the flow of hydrogen when cold and restricts flow to minimum venting when at the operational temperature. The air inlet flow 1003 travels through the fuel cell array manifold over the first catalytic heater surface 1029. The air in the manifold 1003 travels around the seals 1005, 1009, around the hydrogen inlet 1007, around the seals 1020, 1025, around the exhaust air flow 1022 to deliver oxygen by flowing from inlet 1003 over the first fuel cell arrays 1018, 1017, 1016, out to the end of planar fuel arrays manifold 1073, flows through apertures 1052 where the arrays are sealed and welded together 1053. The air flow then travels back over through a manifold 1072, and the second planar arrays 1013, 1014, 1015 to deliver oxygen by flowing over the second fuel cell arrays 1013, 1014, 1015 to the exit through the exhaust port 1022 of the spool. Within the oxygen flow manifolds are the semi-permeable membrane tubes 1057 carrying the rehydrating electrolyte. Following the hydrogen flow through spiral wound planar fuel cell arrays the hydrogen enters through a channel inside of the spool 1008. The hydrogen flows through the apertures 1006, 1007 through the manifold 1019 diffusing fuel hydrogen into the fuel cells arrays 1016, 1017, 1018, 1015, 1014, 1013. Within the hydrogen manifold 1019, 1042 is the semi- permeable membrane 1055 which holds the circulated electrolyte 1054. At the end of the fuel cell array sheet 1053 where the dielectric substrate is welded and sealed the hydrogen flow goes to a second parallel manifold channel 1080, flows back to a return aperture 1081 to pass through a thermal micro-valve 1035, into a manifold 1038, through pores in catalytic heater metal layer 1039, 1037, diffusing into the porous catalytic bed 1040, 1036, 1029. Within the catalytic heater, the hydrogen diffuses through pores 1039, 1037 into a porous catalytic bed 1040, 1036, 1029. The catalytic beds 1040, 1036, 1029 catalytically oxidize the hydrogen with oxygen that diffuses from the air manifold 1034, 1041 . The product water and impurity gases carried with the depleted hydrogen stream diffuse into the air manifolds 1034, 1041. The flow of products and heat from the catalytic heater 1040, 1036, 1029 transfers heat to the planar fuel cell arrays 1016, 1017, 1018, 1015, 1014, 1013 by conduction, convection, and condensation on the semi- permeable membrane enclosed electrolyte tubes 1057, 1064, 1061. This flow of products 1043, 1072 also carries the product water and impurities out the exhaust port of the spool 1022. Heat transfer into the electrolyte flow 1064, 1060 and air flow are the dominate means of evaporating and condensing distilled water from the fuel cells 1016, 1017, 1018, 1015, 1014, 1013 and catalytic heater 1040, 1036, 1029. Distilled water and oxygen depleted air flow out through the exhaust channel in the spool. Within the fuel cells arrays there are hydrogen 1042 and air manifolds 1041, the semi-permeable membrane 1055 tubes, and electrolyte 1054, anodes 1015,

[0700] 1016, cathodes 1013, 1018, electrolytes 1014, 1017, electrical conductors 1010, 1053, 1050, a porous dielectric membrane substrate 1027, 1012 impregnated with solid polymer electrolyte

[0701] 1017, vias 1010, and dielectric breaks 1011. At the high voltage edge of the fuel cell array and perimeters, the substrate membrane 1012 and conductive layers are welded and sealed 1053. The electrolyte in the tube manifold 1063 is connected between the hydrogen manifold 1019 to the air manifold 1072 to switch 1070, 1056 from water evaporation to the anode electrodes 1016, 1015 to water condensation from the air cathodes 1018, 1013 of the fuel cells. At the high voltage portion of the fuel cell arrays 1053, the air manifold 1073, 1075, 1074 routes air through apertures 1052 in the dielectric substrate 1012, and the metallic conductors 1050 to the opposite side air manifold. Outside of the air manifold 1075, 1074 the electrically conductive layer 1050 and dielectric layer 1012 have periodic apertures 1051 to enable a metal-to-metal clamp contact with bolts to attach, compress, and grip the electrical coatings 1050 and the dielectric substrate 1012. Outside of the fuel cell array 1050 is a heat pipe 1077 that makes physical contact with the air manifold 1073. The heat pipe can be made of two stainless steel metal sheets each 50 microns thick and formed and welded as a hollow cavity with metal mesh, fibers, woven dielectric fibers 1078, and a working fluid 1076, 1079 such as ethanol, methanol, or water. This planar heat pipe 1077 can be connected to radiators, pipes, or make direct contact with thermal loads such as air transfer radiators, chemical process heat, machinery, batteries, and water tanks that need the fuel cell core temperature heat of 80°C to 100°C. The circulated electrolyte flows in the inlet from the spool 1063. It goes into the air manifold channels 1003 and will be contained within a semi -permeable membrane tube 1064 on the walls of the air flow manifolds 1034, and heat exchangers. The heat and mass transfer exchange between hydrogen inflow 1006, air inflow 1002, electrolyte water exchange 1064, and the exhaust air 1041 will occur in the first loop or loops of the dielectric membrane substrate 1033 and the catalytic heater 1036. Controlling the input 1044, 1008, 1063 and output flows 1023, 1061 and heat transfer and water distillation can control the operating temperature of the fuel cells. Temperature and humidity responsive microvalves 1035, 1039, 1037 can be used to control local condensation rates, heat transfer rates, and flow rates. The membrane contained electrolyte tubes 1055 contained in the hydrogen flow manifolds and heat exchangers go up to the high voltage end of the array 1053. Evaporation of water occurs along the way to the return connection 1070 where the membrane contained electrolyte goes into the air manifold 1072 and returns condensing water in the electrolyte 1014 or onto the walls of air manifold 1072 channels. The membrane contained electrolyte 1054 returns through electrolyte tube connection 1060 on the spool 1032 where it can be recycled or returned to a reservoir such as the sea. Condensed distilled water will occur on the membrane 1041 separating the counter flow of incoming cool dry air flow 1003 and the high relative humidity outgoing flow 1072 with the exchange of heat through the membrane 1041. High humidity activated laminate actuators over apertures as shown in Fig 1 133, 169, 161, 170, can be placed inside the outgoing air manifold flow 1072 to maintain a sufficient temperature gradient to allow the condensation of water onto the air manifold separation membrane 1041. Condensed water can flow and wick along the air manifold heat exchanging separation membrane 1041 out the exhaust air aperture 1022 into the spool 1032. The fuel cell array is built upon the porous dielectric substrate 1017, 1012, 1014 and is shown in a cross-section view with electrolyte 1017, 1014, anode 1016, 1015, cathode 1018, 1013, electrodes 1053 that include coatings and dielectric diffusion layers, via electrical contacts 1010, electrical breaks 1011, and circulated electrolyte 1054 membrane tubes 1055. In this system two sets of fuel cell arrays are shown with a common hydrogen manifold 1038 and two air manifolds 1073, 1072 with circulated electrolyte in hydrogen 1055 and air manifolds 1072. Only two membrane tubes are visible in this drawing but all the manifolds 1038, 1073, 1072 will have membrane tubes in them paralleling the layers above the fuel cell electrodes 1018, 1016, 1015, 1013. The electrical current and voltage from the cells makes electrical ground contact on the spool 1038 and travels through the two planar arrays 1017, 1014, goes through the seals of the hydrogen manifolds 1053 and seals of the air manifold 1075, 1074 to be the high voltage electrical contact 1050 on a dielectric substrate 1012. In this spiral design it is intentional to make all the fluid connections at electrical ground 1032, spiral the accumulated voltage within layers of dielectric out to an electrical high voltage contact 1051, 1050. This arrangement attempts to minimize voltage gradients throughout the system to minimize electrical discharges and accidental contact with the high voltage 1050. The heat pipe 1077 is shown as a cross-section of a planar metal cavity 1077 with a working fluid 1076, 1079 and wicking fibers or mesh 1078. This heat pipe can be wrapped inside the coiled fuel cell arrays 1073, 1072 making physical contact with the dielectric material exterior of the air manifolds 1073, 1072 insulated from electrical contact. In operation, the heat pipe can remove heat from the fuel cells electrodes 1018, 1016, 1015, 1013 at the core temperature of the fuel cell and deliver heat by liquid evaporation 1076 and condensation 1079 at the load near the temperature of the cell core 1018, 1016, 1015, 1013. This can be useful for machine heating, air heating, or process heating for loads outside the fuel cell that need a high thermal gradient to rapidly deliver heat or at a constant temperature. Water vapor condensation is expected on the interior surface of the air manifold 1073, 1072 when the heat pipe draws a high rate of heat energy out of the fuel cell. Condensed water and associated saturated water vapor will diffuse through the semi-permeable membranes 1057 into the flowing electrolyte and act to reduce the rise in relative humidity to maintain a uniform temperature and humidity homeostasis at the fuel cell electrodes 1018, 1016, 1015, 1013 and electrolytes 1017, 1014.

[0702] Fig 11 A shows a cross-section view of a wound planar fuel cell system with electrical contacts 1108, 1118, 1115, air compressor 1137, 1136, 1134, 1133, 1132, decompressor 1127, 1128, 1126, 1125, connectors to fuel line 1104, input electrolyte 1103, output electrolyte 1102, bypass inflow air 1130, outflow air cooling exhaust 1101, exhaust air and condensed water outlet 1129. An air compressor 1127, 1136, 1135, 1134, 1133, 1132 with an electric motor 1137 is shown schematically. Air 1135 is compressed to elevate the pressure within the fuel cell 1170 to increase the concentration of oxygen and operate at elevated temperatures where water vapor concentration would excessively dilute hydrogen 1106 and oxygen 1170 in the fuel cell 1170. The compressed air has two flow routes 1131, 1130 into the spool 1169, 1107. The first is to distribute air to the fuel cell air manifolds 1107 through apertures 1107 in the spool channel. The second possible route 1130 is to divert low pressure air from the compressor to flow air through and out 1 101 through the spool channel 1171 to remove heat with heat exchange 1 172 with the outgoing air exhaust flow channel 1129, 1171 in the spool 1169, 1107. This heated bypass air 1101 can be used for human occupied space heating, machinery, or batteries. Heat transfer and exchange can go on within the spool 1169, 1107. The amount of air heat transfer can be adjusted by controlling the flow rates through these channels 1170, 1171, 1172, 1173,1105, 1106 and thereby control the upper temperature, besides the electrolyte flow, and operating temperature of the fuel cell. Electrolyte flow in 1103 and out 1102 of the fuel cell system are shown. The exhaust air apertures 1171, channel in the spool 1169, and flow through the decompressor 1129, 1128, 1121 is shown. Condensed distilled water can flow out through the exhaust flow channel 1171, 1129 in the spool 1169. The heat exchange with incoming air 1131 and the low pressure bi-pass air 1130 can cool the exhaust air 1171, 1129 down before going into the decompressor 1126, 1125. Condensed water, or electrolyte water could be evaporated in the by-pass flow 1172 to further transfer and remove heat from the pressurized exhaust air, or the concentrated circulated electrolyte contained within the membrane can be used to dehydrate the pressurized exhaust 1129. The decompressed exhaust flow 1128, 1121 will expand in the decompressor 1126, 1125 and cool. Heat can be transferred from the exhaust 1121 of the decompressor through a heat exchanger 1120, 1122, 1123 and deliver cooled air 1124 to human occupied spaces or machinery. The oxygen depleted exhaust air 1129, 1128 that is expansion cooled and low humidity may also usefully cool non-human occupied spaces and machinery. Within the spool, the hydrogen gas supply enters in channels 1104 and flows through apertures 1106 to the fuel cell array gas manifold 1149, 1161. The hydrogen manifold distributes the hydrogen through the manifold gas channels 1149, 1161 with the semi-permeable membrane containing electrolytes in each channel 1149, 1160. The components of the diffusion layer hydrogen anode 1163, 1159, solid polymer electrolyte and porous substrate 1164, 1158, oxygen cathode and diffusion layers 1159, 1165, the air flow channel 1167, 1155, 1143 and the semi-permeable membrane contained electrolyte 1141, 1148, 1154, 1160, 1166. The fuel cell arrays and gas manifolds a e wound about the spool 1169. Metal spool end plates 1108, 1118 can be attached to spool to act as the hose connection interface and pressure housing of fuel cell array 1168. The fuel cell array 1168 is made of thin metal coating and dielectric membranes such that to pressurize the fuel cell array, fuel cell array 1168 is placed inside a pressurized environment with both the hydrogen and air manifolds vented through the porous catalytic heater 1144, 1153 to maintain pressure equilibrium. The spiral wound fuel cell array 1 168 makes electrical ground contact with the metal spool 1169. It is wound under tension and then the metal coated dielectric membrane 1109 is secured to an outer dielectric cylinder 1110, 1117 with a metal clamp 1111, 1112, 1113, 1114, 1116, and threaded post electrical contact 1115. The heat pipe is placed in the outer wind of the fuel cell array 1110, 1176, 1175, 1145, 1146 and is shown protruding out through the electrically grounded end plate 1108 with connection to the spool flange 1169, 1107. Within the heat pipe 1110, the working fluid 1145 evaporation 1146, wicking fibers 1175, condensed working fluid 1176, 1174 is shown.

[0703] Fig 1 IB shows an enlarged view of a portion of the cross-section view of heat exchangers, catalytic layers, fuel cells and electrolyte membrane tubes of planar array as wound on the cylindrical manifold of Fig 11 A. The air inlet and air outlet apertures in the spool are shown. The metal conductive spool wall 1138 is shown making contact with the metal film coating on the dielectric substrate of the fuel cell array 1140. This could be a welded contact between the metal coating 1139 and the metal spool 1138 or assured with a metallic epoxy bond to eliminate slipping. The air manifold channel 1143 is next to the porous catalytic membrane layer 1144. Within the air channel 1143 is a semi-permeable membrane holding the circulated electrolyte 1141. Porous apertures 1147 are in the metal layer on the porous catalytic layer. These apertures 1147 could have thermally actuated flaps to open when cold and close when at a chosen temperature limit. Residual hydrogen and inert impurities manifold 1149 has side walls

[0704] 1150 and semi-permeable membrane tube containing the circulated electrolyte 1148. Metal layer

[0705] 1151 and pores 1152 could also be thermal actuate micro-valves. A porous catalytic layer 1153, the air manifold 1155 with channel walls 1156 has a semi-permeable membrane containing electrolyte 1154. The air manifold 1155 also delivers air to the catalytic fuel cell cathode 1157 on a solid polymer electrolyte infused into a porous dielectric substrate 1158. On the opposite side of the electrolyte 1158 is a catalytic anode 1159 of the fuel cell that is in contact with the hydrogen gas in the manifold 1161 that has support walls 1162, and a membrane tube containing the circulated electrolyte 1160. A second fuel cell anode 1163 is in contact with the hydrogen manifold 1161 and the solid polymer electrolyte 1164. Fuel cell oxygen cathode electrode 1165 is in contact with the solid polymer electrolyte 1164. Oxygen from the air manifold 1166 is supplied to the cathode 1165. Humidity control is provided by a circulated electrolyte contained within a semi-permeable membrane 1166 and air supply 1167 channel walls. Welded edge seals arc on the dielectric plastic substrate or manifold walls 1167, 1168, 1177.

[0706] The wound fuel cell array is contained within a spool 1169 connected to metal end plates 1118, and bolted to a dielectric cylindrical spool 1117. A heat pipe 1100 is placed within the dielectric cylinder spool 1117 and goes through the end plates 1108, 1118 and is in thermal contact with the air manifold 1167. Within the heat pipe is a working fluid 1145 such as water, methanol, or ethanol. It vaporizes 1146 the working fluid 1145 to remove heat and radiation, conduction, and convection from the fuel cell 1167 air manifold.

[0707] Features of the device described herein include:

[0708] 1. Counter flow heat and mass exchanger within the fuel cell.

[0709] 2. Use of parallel counter flow channels to mass exchange and heat exchange through concentration and heat gradients through a diffusion limiting layer for spatially uniform delivery of heat and molecules.

[0710] 3. Use of parallel counter flow in channels where the flow double backs on itself to mass exchange and heat exchange through concentration and heat gradients through a diffusion limiting layer for spatially uniform delivery of heat and molecules triple interface exchangers.

[0711] 4. An effect of counter flow and double back with diffusion between the flows with concentration changes due to consumption or production of molecular species creates a recirculating flow driven by concentration gradients.

[0712] 5. Designed optimizations to keep metal to insulator ratio low to realize intrinsic open fusing in fuel cell and reduce cost of system.

[0713] 6. Designed optimization to safely maximize specific power per unit mass and specific energy per unit mass of fuel cell power systems.

[0714] 7. Designed optimization to use high specific tensile strength to density ratio materials to enable the system to withstand high acceleration forces.

[0715] 8. Designed optimization to be robust, fail safe and have self-correcting and ability of parallel series arrays fuse and isolate ability. 9. Design fuel and oxidizer channels to have low volumes to reduce the chance of explosive failure and micro check valves that stop flow in the case of excessive gas flow or excessive temperature within system.

[0716] 10. Designed optimization to make mass producible and lower the cost of fuel cells.

[0717] 11. Combine counter flow heat and mass transfer with planar micro-fuel-arrays to counter act the weakness that planar arrays are more affected by reactant and temperature concentrations and depletions across an array of discrete fuel cells and need a more uniform distribution of reactants and temperature than bipolar stacked fuel cell systems.

[0718] 12. Use planar micro fuel cell electrical system to avoid high voltage on the heat transfer system of water cooling, humidification, desalination, and heat pipes.

[0719] 13. Use planar micro fuel cell electrical collection system to enable printing production of fluid manifolds heat and mass exchangers onto fuel cell array.

[0720] 14. By using the planar electrical collection system, porous and / or semi-permeable dielectric hydrophobic membranes can be pressed, built on, or in proximity to the liquid gas electrode interface and prevent flooding and hold back ion drag electrolyte flow effectively containing the position of the electrolyte in the electrodes. Planar arrays of electrical collection systems can have cell to cell discharges between adjacent cell electrical breaks as compared to bipolar stacked fuel cell systems. Therefore, a porous hydrophobic layer to prevent shorting is more vital to planar array fuel cells to function well.

[0721] 15. Use porous planar substrate to enable solid polymer electrolytes to immobilize the electrolytes and impregnate the porous planar substrate.

[0722] 16. The planar fuel cell system, in contrast to the bio-polar plate stack system, allows continuous electrical collection circuits to be formed and avoid wet mechanical contact that occurs in bipolar plate stacking.

[0723] 17. The planar fuel cell system with elastic gas channels built integrally to the planar array allows for elasticity in the gas channel structures. This enables the expansion and contraction of the fuel cell electrolytes and thermal expansion of the entire system without exterior spring loading to maintain electrical contact and integrity used in bio-polar plate stacks. 18. Use surface tension energy, surface tension gradients, and wicking control of the position of the electrolyte and ion exchange electrolytes in the gas diffusion layer of the fuel cell and condensed water.

[0724] 19. Lateral wicking of water and / or electrolytes through the electrolyte spaces of the planar fuel cell array.

[0725] 20. Selectively permeable membrane containing a water electrolyte circulation system to move water to the fuel cells, remove water from fuel cells, move reactants, ions, and remove heat from fuel cell.

[0726] 21. Use membrane contained water circulation system to capture water from heat exchangers, remove water from fuel cells and remove heat from fuel cells.

[0727] 22. Use of salts, acids, bases, or vapor pressure reducing additives to hold water contained within selectively permeable membrane and controlled delivery that maintains a constant relative humidity environment for the fuel cell and prevents flooding, freezing, and dehydration of fuel cells.

[0728] 23. The use of the membrane contained water circulation system can effectively circulate salt water including sea water and extract the pure water to the electrolyte. It can return saltier water to the source and condense the distilled water from condensation in the heat exchangers or recycle a portion of the salt water within the circulated fluid tube system.

[0729] 24. Condensed water within the fuel and air channels needs to be removed, recycled, or exhausted. Water delivery lines can have chemicals, liquid fuels, hydrocarbons, salts, acids, or bases in them and have electrical conductivity.

[0730] 25. The selectively permeable membrane, containing a water vapor reducing additive to control relative humidity with dynamic equilibrium between vapor gradient and vapor pressure of the electrolytes separated by the selectively permeable membrane is a tube that does not allow liquid water or electrolyte flooding or dehydration. Liquid flooding can lead to electrical shorting of the planar arrays and prevent fuel and oxidizer from reaching catalytic sites in catalytic heaters and fuel cells. This membrane and fluid can also be a source of vapor delivered acid such as sulfuric acid or hydrochloric acid. This membrane system can also deliver hydrogen and hydrogen bearing fuels such as methanol liquid or methanol vapor and removal of inert gas impurities from the fuel cell. This membrane system can also deliver hydrogen peroxide and oxidizers such as oxygen and chlorine. Use a dynamic vapor pressure equilibrium established between electrolyte held within a selectively permeable membrane, solid electrolyte, diffusion gap and temperature differences between the electrolyte and solid electrolyte to maintain a desired relative humidity and ionic conductivity of the solid electrolyte and electrochemical catalyst performance. This will maintain a stable triple interface between electrolyte, catalyst, and gas. The selectively permeable membrane containing electrolyte, in close proximity to the fuel cell or electrolysis cell electrolyte, can be pressurized or un-pressurized to increase equilibrium in favor of delivery of water to the electrolyte of the fuel cell or electrolysis cell, including direct osmotic water delivery to electrolyte. Circulated water with vapor pressure reducing dissolved salts in selective permeable membranes tubes can be used to deliver moisture and remove heat by evaporation from the fuel cell and dehydrate air in the cabin or structures. This can be used to counteract the effects of ionic drag in the fuel cell electrolyte that dehydrates one electrode and floods the other electrode. This can also provide air-cooling by evaporation and dehydration. And it can provide distilled water from salty or impure water. The input water to electrolysis cells and fuel cells can be salty water that exchanges water and heat with the electrolysis or fuel cells but holds the salts within the membrane. Use selectively permeable membrane tubes filled with electrolytes that are inside and parallel to the heat transfer channels that flow reactants to and from the fuel cell. Heat and mass transfer exchangers for the inflow and outflow of reactants to the fuel cells that also condense and collect water. Provide optimum operating environments by effectively providing heating and humidification in fuel cell, cabin, or machinery. This includes heating or cooling of batteries. Use counter flow mass exchange to concentrate cross-over impurities and efficiently deplete the fuel or oxidizer gases. Use catalytic heater within heat exchangers to heat fuel cells, hum depleted fuel gas, and eject impurities. Can use metal or dielectric heat exchangers in fuel cell that can be incorporated into bipolar cell stacks or planar array cell stacks. Bipolar stacks will require electrical conductivity through the heat exchangers and require electrical gaps between cells and flow reactants and heat transfer fluids. This system focuses on the implementation of using planar fuel cell arrays because of the amenability to incorporation of precision deposition 3D printing and elimination of separate components in the assembly, which also make it more amiable to mass production. These techniques can be used in flow batteries to include delivery of uniform reactant electrode fluids, heat transfer, 3D print production, and electrical safety features. Use of 2D printing, 3D printing, folds, cuts and folding or rolling to assemble structure. Use of printing with multiple materials that can be delivered simultaneously or sequentially in the printing process to create separate areas of components such as dielectric areas, electrically conductive and catalytic areas. Porous, electrolyte, and impermeable areas can be formed. Gas permeable, gas selectively permeable and gas impermeable areas can be formed. The selectively permeable areas of the components can be formed in different areas of the fuel cell to different selective permeability, or rates of permeability, to enable control of the rates of diffusion. Formation with printing techniques of channels, dimples, turns, spirals, bumps, fins, denticles, shaped fins that induce vortex flow and / or turbulent flow, and barchans to affect mixing flow, turbulence and increased heat and mass transfer in the fluid flow in heat exchangers and heat and mass exchangers. Ease of printing and a wider selection of materials are enhanced with dielectric material, including dielectric heat exchangers. Heat exchangers and heat pipes made of metal can be corroded by electrolytes, and the fuel cell is better served and safer by not having high voltage on the heat exchangers and exterior plumbing. 41 . Use of dielectric gas diffusion layer over the fuel cells / electrolysis cells to electrically insulate the cells, distribute condensed water, provide gas diffusion, and heat diffusion medium between the gas manifolds and the fuel cells or electrolysis cells.

[0731] 42. Use of dielectric heat exchanger surfaces and structures.

[0732] 43. Use of gas-to-gas heat transfer through dielectric tubular heat exchangers.

[0733] 44. Reduction of wasted fuel and efficient removal of diffused inert gas cross over.

[0734] 45. Catalytic heaters within the fuel cell stack and / or electrolysis stack and heat exchangers to purge out inert gas impurities from fuel manifolds. Detect leaks with temperature sensors in the catalytic heater to detect temperatures and temperature gradients. Equalize or set the pressure across the fuel cell membranes by catalytically burning excess fuel with air. Also provide heat for cold start-up and maintaining temperature in cold and idled conditions.

[0735] 46. Use of micro valves to purge gas.

[0736] 47. High voltage output of the fuel cell to match the electrical loads and reduce conductor to dielectric ratio for ability to safely contain and eliminate internal electrical shorting.

[0737] 48. Common pressure vessel for reliability and lower weight, and no high voltage on the bulk of the pressure vessel. Package fuel cell array as a wound cylinder to fit efficiently into the pressure vessel.

[0738] 49. Pressure equilibrium between hydrogen and oxygen manifolds and use of catalytic heater venting to correct excessive pressure mismatch across the cell electrolytes. May also use a set pressure relief valve or valves to release and close to maintain differential pressures.

[0739] 50. Cell gaps can have dielectric surface deposits and geometries that repel condensed water and keep the cell electrical separations.

[0740] 51. Humidity and / or temperature responsive auto actuating micro valves in the gas diffusion layer of the fuel cells to increase or decrease heat and mass transfer to manage relative humidity, thermal gradients, temperature differences between fuel cell and condensation surfaces, and optimize fuel cell system performance.

[0741] 52. Use of micro valves to change flow of reactants and fluid flow to change flow patterns to remove or retain heat in fuel cells and / or heat removal from the system. Particularly useful to maintain optimum thermal gradients in multiple effect distillation heat and mass exchangers when heat source output varies.

[0742] 53. In the multiple effect distillation heat exchanger, place a porous hydrophobic low thermal conductivity layer separating the evaporating surfaces and the condensing surfaces to maintain a diffusion gap between evaporator and condenser and maintain sufficient temperature difference to affect reaching the dew point on the condensing surface.

[0743] 54. Put a coating on the condensing surface in the multiple effect distillation heat exchanger that reduces the dew point temperature to initiate condensation. (Roughened surfaces or electrolytic properties can enhance the condensation.)

[0744] 55. Multiple flow channels in multiple effect distillation heat exchangers can be selectively blocked by micro valves to increase the flow in other channels. This can be used to raise the temperature difference between evaporator and condensing surfaces thereby optimizing the distillation effect. This is particularly relevant when the fuel cell is being operated at lower power levels, and heat production is low, leading to the thermal gradients between evaporator and condenser being low.

[0745] 56. Conversion of heat to vapor and distilled water from electrolytes is an internal heat transfer and absorption mechanism that can be used as needed to remove heat from the fuel cell to maintain optimum operating conditions.

[0746] 57. Micro valves and flow continuity interrupt devices can be used as safety devices and fluid flow continuity and electrical path interrupts. Micro valves can also be electrical switches. They can also be actuated or heated by electrical flow. This can be useful to block fluid leakage, prevent explosions, and electrical shorts. A design feature of using small and many distributed valves to keep leakages small and localized is a strategy that can prevent catastrophic explosions that can occur if larger amounts of reactants in larger spaces are allowed to build up.

[0747] 58. Micro valves can act as check valves to isolate breaches in a pressurized flow system. The valves can close ahead and behind an excessive flow condition in a flow channel.

[0748] 59. Use of a constriction Bernoulli effect suction flow configuration at the entrance of the high velocity fuel gas flow to circulation flow in the counter flow back track loop.

[0749] 60. Use of micro valves that auto actuate in the Bernoulli effect suction flow. 61 . Use of electrostatic filtration to remove dust and salts from air inflow and prevent contamination of the electrolytes.

[0750] 62. Use of photocatalytic and catalytic surfaces on filtration and heat exchange surfaces to decompose contaminates and catalytically combust any leaked fuel or oxidizer in reactant streams preventing them from reaching explosive concentrations.

[0751] 63. Temperature, molecular reactant sensors, voltage, and humidity sensors printed into the fuel cell and heat exchangers.

[0752] 64. Electronic communions, such as AC signals through the fuel cell arrays and electrical circuits.

[0753] 65. Electronics and computer codes to analyze and respond to environmental conditions in and outside of the fuel cell to optimize the operation of the fuel cell. Control reactant flows, membrane electrolyte flows, and micro valves. Use experience-based adaptive computer codes to diagnose and respond and correct fault conditions in the fuel cell. The system would have the ability to adapt to changing weather conditions and anticipate the timing of startup, shutdown, oxygen, fuel, air, heating, and cooling.

[0754] 66. Utilize an air compressor and decompressor to pressurize the fuel cell. During operation the heat exchanger, with electrolytes within membrane tubes and with the inflow and out flow of air, a cool exhaust output can result that can be used directly, or through the integrated heat exchanger, to provide cool dry air, chilled water, or cooled humidified air.

[0755] List of Physical Features

[0756] 1. Planar fuel cell array.

[0757] 2. Fuel and oxidizer manifolds with counter flow and diffusion into and out of the fuel cell electrodes. These are paired counter flow with membranes and / or diffusion layers two counter flows or double back flow that are in diffusive contact with fuel cell electrodes that arc obtaining or delivering selective molecular diffusion transfer between paired flows and fuel cell electrodes.

[0758] 3. Use selective molecular diffusion barriers between flow channels in the gas manifolds of the fuel cell to evenly distribute fuel or oxidizer molecular species and heat with the flow. Also make concentration changes through the channels to deliver gas or fuel or oxidizer molecules to fuel cell, transfer product molecules, and concentrate inert gases in flow into flow jet cavity catalytic heater that catalytically combusts remaining fuel molecules and ejects inert gases.

[0759] 4. Use fuel and oxidizer manifolds with counter flow and diffusion into and out of fuel cell electrodes. They have paired counter flow and membrane and / or diffusion layers that are in diffusive contact with fuel cell electrodes. These are obtaining or delivering selective molecular diffusion transfer between paired flows and fuel cell electrodes. At the end of the paired flows, they make concentration changes through the channels to deliver gas or fuel or oxidizer molecules to the fuel cell, transfer product molecules, and concentrate inert gases in the flow into flow jet cavity catalytic heaters. These heaters catalytically combust remaining fuel molecules and eject inert gases.

[0760] 5. Counter flow heat exchanger in thermal contact with fuel cell and / or electrolysis cells, fuel, and oxidizer manifolds.

[0761] 6. Counter flow heat exchanger that condenses and collects water from exhaust flow from fuel cell and / or electrolysis cells, fuel and oxidizer manifolds, and transfers water to incoming fuel or oxidizer flow by evaporation into flow.

[0762] 7. Counter flow heat exchanger that condenses and collects water from exhaust flow from fuel cell and / or electrolysis cells, fuel and oxidizer manifolds, and transfers water to incoming fuel cell electrode or oxidizer electrode through wicking and / or through water permeable membranes.

[0763] 8. Counter flow heat exchanger that condenses and collects water from exhaust flow from fuel cell and / or electrolysis cells, fuel, and oxidizer manifolds.

[0764] 9. Collects condensed water from exhaust from fuel cell and used to evaporatively cool air through evaporative heat exchanger to cool air into cabin air.

[0765] 10. Collects condensed water from exhaust from fuel cell and transfers water through water permeable membranes in heat exchanger to humidify air in vehicle.

[0766] 11. Collects condensed water from exhaust from cabin and transfers water through water permeable membranes in heat exchanger to humidify air in vehicle.

[0767] 12. Form counter flow heat exchanger and fuel and oxidizer manifold out of dielectric materials. 13. Heat exchangers that contain electrets and electrostatically filter the air.

[0768] 14. Heat the incoming air and cooling that air through heat exchangers to sterilize the air entering the cabin.

[0769] 15. Heat exchangers that incorporate dielectrics, electrets, photocatalyst, and / or biocide surfaces.

[0770] 16. Place a jet cavity heater or membrane catalytic heater within the counter flow heat exchanger.

[0771] 17. The fuel from the fuel manifold has fluid connection to the catalytic heater in counter flow heat exchanger.

[0772] 18. The oxidizer from oxidizer manifold has fluid connection to the counter flow heat exchanger.

[0773] 19. To control relative humidity and hydration of the fuel cell electrodes, laminate actuating micro valves as part of a membrane or built into walls of the manifold channels such that with high humidity they open to increase transpiration and with low humidity they close to reduce transpiration and dehydration.

[0774] 20. Elastic structural features of elastic polymorphic surfaces of heat exchangers, and / or diffusion membranes that increase heat and molecular transfer.

[0775] 21. Printing components of fuel cells, catalytic heaters, heat exchangers, diffusion layers, and diffusion membranes.

[0776] 22. 3D printing the components or entire system of fuel cells, catalytic heaters, heat exchangers, diffusion layers, and diffusion membranes.

[0777] 23. Use a heat pipe in thermal contact with catalytic heater, fuel cell / electrolysis cell, heat exchangers, heat, and molecular transfer manifolds.

[0778] 24. The fuel cell / electrolysis cell reactant manifolds, catalytic heater, heat exchangers, and heat pipes can be spiral wound or layer stacked to form a compact assembly of multiple layered, repeating, functioning component system of series electrically connected fuel cells or electrolysis cells.

[0779] 25. Pressurization of the fuel cell with compressor and decompressor and cooling of exhaust gases with ambient air flow in heat exchanger. Cooling exhaust in mass exchange with circulated electrolyte contained in selectively permeable membrane tube to remove moisture from cooled exhaust and then decompress air to produce sub ambient temperature air. Heat exchanger at atmospheric pressure cools atmospheric air from decompressed air. Also has a selectively permeable membrane tube to remove moisture to provide cool air flow to structures and machinery. Printed fluid micro-pumps to pump electrolyte within selectively permeable membrane tubes within fuel cells / electrolysis cells and heat exchangers.

Claims

CLAIMS1. An electrochemical cell apparatus consisting of: a dielectric porous membrane, electrolyte within porous membrane, catalytic electrodes on either side of electrolyte, electrical conductors in contact with catalytic electrodes, reactant fluid flow channels in contact with catalytic electrodes, reactant fluid flow channels in thermal and diffusion contact with catalytic electrodes with the reactant fluid flow channels paired such that counter flow heat and mass transfer can occur between the paired channels with heat and diffusion contact with catalytic electrodes.

2. The apparatus of claim 1 consisting of: a dielectric porous membrane, electrolyte within membrane, catalytic electrodes on either side of electrolyte, at least one hydrophobic porous layer in contact with one catalytic electrode, electrical conductors in contact with catalytic electrodes, reactant fluid flow channels in contact with hydrophobic porous layer, reactant flow channels have semi-permeable diffusion between flow channels, the reactant channels are paired such that counter flow heat and mass transfer can occur between the paired channels, in diffusion contact of paired channels are semi-permeable membrane conduits that contain circulated electrolyte that can diffuse water vapor and retain salts.

3. The apparatus of claim 1 wherein the electrical current collection and electrical interconnections between cells are planar to the electrochemical cells.

4. The apparatus of claim 1 wherein a catalytic combustor between the reactant fluids, in thermal and diffusive contact and connected to flow channels with electrochemical cells, can consume reactants.

5. The apparatus of claim 1 wherein humidity actuating micro valves regulate water diffusion between counter flow paired channels.

6. The apparatus of claim 1 wherein temperature actuating micro valves regulate water diffusion between counter flow paired channels.

7. The apparatus of claim 1 wherein temperature and humidity actuating micro valves regulate water diffusion between counter flow paired channels.

8. The apparatus of claim 1 wherein a catalytic combustor between the reactant fluids in thermal and diffusive contact regulate flow and / or diffusion of reactants with temperature, pressure, and / or humidity micro valves and connected to flow channels with electrochemical cells can consume reactants.

9. The apparatus of claim 1 wherein the semi-permeable membrane conduits have wicking surfaces in the membrane surfaces, or wicking fibers within the conduits.

10. The apparatus of claim 1 wherein a heat pipe is in thermal contact with the reactant fluid flow channels such that counter flow heat exchange occurs with heat pipe.

11. The apparatus of claim 1 wherein condensation of water vapor on surfaces of heat exchange surfaces of reactant fluid conduits, separated with humidity actuated micro valve arrays, from circulated semi-permeable contained electrolyte, contained within reactant fluid heat exchange conduits.

12. The apparatus of claim 1 wherein circulated electrolyte contained within semi-permeable membrane is used to humidify and heat fuel cell electrolyte through vapor and dehumidify circulated electrolyte, and ion drag through fuel cell electrolyte is used to move water to opposite electrode in fuel cell. The circulated electrolyte is used to remove excess heat and water as vapor and re-humidify circulated electrolyte contained in semi- permeable membrane.

13. The apparatus of claim 1 wherein circulated electrolyte contained within semi-permeable membrane is used to humidify and heat fuel cell electrolyte through water vapor and dehumidify circulated electrolyte, and ion drag through fuel cell electrolyte is used to move water to opposite electrode in fuel cell. The circulated electrolyte is used to remove excess heat and water as vapor and re-humidify with a smaller portion of the circulatedelectrolyte contained in semi -permeable membrane that was used to humidify fuel cell electrode.

14. The apparatus of claim 1 wherein circulated electrolyte contained within semi-permeable membrane is used to humidify and heat fuel cell electrolyte through water vapor and dehumidify circulated electrolyte, and ion drag through fuel cell electrolyte is used to move water to opposite electrode in fuel cell. The circulated electrolyte is used to remove excess heat and water as vapor and re-humidify a smaller portion of the circulated electrolyte contained in semi-permeable membrane that the diverted portion of circulated electrolyte is used to dehumidify fluid flows including de-humidification of air.

15. The apparatus of claim 1 wherein the circulated electrolyte contained within semi- permeable membrane is used to humidify and heat fuel cell electrolyte through water vapor and de -humidify circulated electrolyte, and ion drag through fuel cell electrolyte is used to move water to opposite electrode in fuel cell. The circulated electrolyte is used to remove excess heat and water as vapor and re-humidify a smaller portion of the circulated electrolyte contained in semi-permeable membrane that if reactant fluids are pressurized into the fluid reactant flow channels, circulated electrolyte, and fuel cells and contained within a pressure housing, the depressurization through an expander will provide cool air exhaust to cool machinery and space.

16. The apparatus of claim 1 wherein circulated electrolyte contained within semi-permeable membrane is used to humidify and heat fuel cell electrolyte through water vapor and dehumidify circulated electrolyte, and ion drag through fuel cell electrolyte is used to move water to opposite electrode in fuel cell The circulated electrolyte is used to remove excess heat and water as vapor and re-humidify circulated electrolyte, the exhaust air flow with water vapor from fuel cell and vaporized water from circulated electrolyte will flow and / or diffuse on counter flow heat exchange surfaces containing incoming cool air, hydrogen, and circulated electrolyte, and condense water on the exchanger surfaces and is collected.

17. The apparatus of claim 1 wherein circulated electrolyte contained within semi -permeable membrane is used to humidify and heat fuel cell electrolyte through water vapor and dehumidify circulated electrolyte, and ion drag through fuel cell electrolyte is used to move water to opposite electrode in fuel cell. The circulated electrolyte is used to remove excess heat and water as vapor and re-humidify circulated electrolyte, the exhaust air flow with water vapor from fuel cell and vaporized water from circulated electrolyte will flow and / or diffuse through humidity actuated laminate actuator arrays on counter flow heat exchange surfaces containing incoming cool air, hydrogen and circulated electrolyte and condensed water on the exchanger surfaces and is collected.

18. The apparatus of claim 1 wherein the fuel cells are printed onto porous dielectric substrate or substrates, deposits of solid polymer electrolytes, graphene, catalytic particles, metal films, metal vias, dielectric films, hydrophilic surfaces, hydrophobic surfaces, hydrophobic porous surfaces, hydrophilic porous surfaces, semi-permeable conduits, fluid flow channels, catalytic combustor, laminate actuating valves, wicking surfaces, wicking fibers, and sealing surfaces, electronic sensors.

19. The apparatus of claim 18 wherein the fuel cells are wound onto an electrically conductive spool with internal flow channels and apertures to mate with fluid flow conduits of printed fuel cells.

20. The apparatus of claim 18 wherein the fuel cells are wound onto an electrically conductive spool with internal flow channels, that transfer and exchange heat, and apertures to mate with fluid flow conduits of printed fuel cells.

21. The apparatus of claim 19 wherein the wound fuel cells are contained with end plates attached to spool and dielectric cylinder.

22. The apparatus of claim 21 wherein the wound fuel cells are contained with end plates attached to spool and dielectric cylinder with fluid sealed high voltage connection passingthrough the dielectric cylinder.

23. The apparatus of Claim 1 wherein the printed fuel cells on dielectric substrates are welded or glued on perimeter edges and stacked with fuel heat and mass flow conduits in contact and air flow and conduits on outside.

24. The apparatus of Claim 23 wherein fuel cells, heat and mass flow conduits, spool, end plates, circulated electrolyte, pass-through heat exchange pipes, and heat pipes, are pressurized with fuel, and oxidizer gas through a compressor or compressors, and the exhaust fluids are depressurized with a decompressor.

25. The apparatus of Claim 24 wherein a heat exchanger in the fluid flow from the decompressor exchanges heat to and from ambient fluids.

26. The fuel cell apparatus of Claim 1 wherein all the electrical and fluid connections are electrically grounded except for the end of the series of the connections of fuel cell arrays to bring out the high voltage.

27. The apparatus of Claim 1 wherein the water desalinated is used in evaporative cooling and heat transfer through heat exchangers with semi-permeable membranes to cool fluids for cooling of machinery, and / or spaces below ambient temperatures.

28. The apparatus of claiml where in that the pressurized exhaust oxidizer gas is cooled by thermal exchange with ambient fluids and expanded through decompressor to provide cool fluids below ambient temperatures.

29. The apparatus of claim 2 wherein the fluid flow channels, and semi-permeable membrane incorporate large expansion range coefficient materials greater than 1%, dielectrics with low adhesion properties, photocatalyst, and / or and electrets as antifouling features of actuating surfaces and semipermeable membranes such that they can remove mineral scaling, dust, and biological organisms.

30. The apparatus of claim 5 wherein the laminate actuator surfaces arc coated with antifouling films that are hydrophilic or hydrophobic.

31. A planar cell electrical collection system wherein the fuel cell membrane electrode assemblies are three dimensionally printed onto a porous membrane substrate, selective permeable barriers, solid polymer electrolytes, catalytic electrodes, current conductors, electrical vias, hydrophobic porous gas diffusion manifolds, selectively permeable electrolyte retaining circulation tubes, reactant fluid manifold heat exchangers, fluid heat exchangers, micro valves, micro-pumps, sensors, electronics, hydrophilic surfaces, wicking tubes, catalytic heaters, and seals.

32. The apparatus of Claim 27 where in two pairs of planar electrochemical cell arrays sealed at the perimeter with common fuel manifold.

33. The apparatus of Claim 31 Membrane contained electrolyte and / or water circulation system to capture water from heat exchangers, add and remove water from electrochemical cells and add and remove heat from the electrochemical cell.

34. The apparatus of Claim 31 wherein wicking surfaces inside and outside of the semi- permeable membrane containing the water circulation system to maintain high concentrations for higher diffusion transport through membrane when there is liquid water contact and collect condensed water to semipermeable membrane.

35. The apparatus of Claim 31 wherein use of salts, acids, bases, or vapor pressure reducing additives to hold water contained within selectively permeable membrane and controlled delivery that maintains a constant relative humidity environment for the electrochemical cell and prevents flooding, freezing, and dehydration of electrochemical cells.

36. The apparatus of Claim 31 wherein selectively permeable membrane contained water vapor reducing additive to control relative humidity that can also be a source of vapordelivered acids, bases, oxidizers, hydrogen, and hydrogen bearing fuels and removal of poisons, and inert gas impurities from electrochemical cell.

37. The apparatus of Claim 31 configured to use counter flow mass exchange to concentrate cross-over impurities and efficiently deplete the fuel or oxidizer gases.

38. The apparatus of Claim 31 further comprising catalytic heater within heat exchangers to heat electrochemical cells, burn depleted fuel gas, and eject impurities.

39. The apparatus of Claim 31 wherein the heat exchangers comprise dielectric materials.

40. The apparatus of Claim 31 further comprising catalytic heaters within the electrochemical cell stack and / or electrolysis stack and heat exchangers to purge out inert gas impurities from fuel manifolds and detect leaks, equalize, or set the pressure across the electrochemical cell membranes, provide heat for cold start-up and maintaining temperature in cold and idled conditions.

41. The apparatus of Claim 31 wherein a common pressure vessel holding electrochemical cell system with pressure equilibration through venting through catalytic heater,42. The apparatus of Claim 31 wherein electrochemical cell apparatus has dielectric mass to metal mass ratio or volume ratio greater than 1 to act as electrical fuse in the event of internal electrical shorts.

43. The apparatus of Claim 31 wherein there is a single exterior point of high voltage on pressure vessel.

44. The apparatus of Claim 31 wherein electrochemical cell array is packaged as a cylinder to fit efficiently into the pressure vessel.

45. The apparatus of Claim 33 wherein fluid heat exchangers and perform multiple effect distillation using exhaust heat from electrochemical cell within the heat exchangers to collect water from selectively permeable membrane tube filled with electrolyte to water wicking in tube.

46. The apparatus of Claim 45 wherein the electrolyte contained in selectively permeable membrane tube is sea water, brackish water, or recirculated acidic or basic electrolyte.

47. The apparatus of Claim 31 wherein cylindrical wound planar arrays with gas manifolds, and heat exchangers, and selectively permeable membrane electrolyte filled tube with the gas flows, liquid flows and at least one electrical connection in contact with an electrically conductive cylindrical tube that holds one end of the planar electrochemical cell array and heat exchangers by wrapping around tube.

48. The apparatus of Claim 31 wherein air flow, fuel flow, and selectively permeable electrolyte tube flow, and wicking tube interface go through the electrically conductive tube.

49. The apparatus of Claim 31 wherein at least one electrical connection is made to the wrapped planar array of electrochemical cells on the outside of the wound cylinder of planar arrays.

50. The apparatus of Claim 41 wherein the pressure vessel cylinder that wraps about outside of the planar array makes electrical contact and secures the wrapped planar array sheets.

51. The apparatus of Claim 50 wherein fluid compressor, decompressor, and blowers make connections to the electrically conductive cylindrical tube.

52. The apparatus of Claim 31 wherein two planar electrochemical cell arrays are arranged such that they are in parallel and can use a common hydrogen manifold between them.

3. The apparatus of Claim 31 wherein four planar electrochemical cell arrays are arranged such that they arc in parallel and can use a common oxygen manifold between the pairs of electrochemical cell arrays.

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