Flexible Air-Breathing Micro Fuel Cell Without Rigid Substrates

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Solution Overview

Problem

The miniaturization of fuel cells faces challenges in achieving high volumetric efficiency and cost-effectiveness due to the need for rigid substrates and complex packaging, which hinders the development of compact, lightweight, and efficient portable energy sources.

Innovation Solution

The development of flexible, air-breathing microscale fuel cells using ion-exchange polymer membranes without silicon substrates, featuring direct hydrogen flow-through porous anodes and air-breathing cathodes, which allows for the creation of thin, high-energy-density devices with reduced material usage and simplified system requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If rigid substrates (silicon wafers, glass) are used for micro fuel cell assembly, then structural stability is improved, but volumetric efficiency deteriorates and device complexity increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidvolumetric efficiency

Core Design Contradiction:

Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

The patent uses flexible polymeric substrates instead of rigid silicon wafers or glass plates. These thin film substrates provide sufficient structural stability for fuel cell operation while occupying minimal volume, thereby resolving the contradiction between structural stability and volumetric efficiency. The flexible nature of these substrates also enables conformal mounting and integration into compact portable devices.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent extracts and eliminates the need for rigid substrate support structures by directly assembling fuel cell components (membrane electrode assemblies, flow fields, seals) onto flexible polymeric substrates. This removal of unnecessary rigid structural elements reduces overall device volume and complexity while maintaining operational stability through the flexible substrate's inherent mechanical properties.

Inventive Principle:

Principle #2Taking out (Extraction)

2Stability of the object's composition

If rigid substrates and complex packaging are used, then structural integrity is improved, but device complexity and weight increase

Engineering Contradiction:

Improvestructural integrityVSAvoidpackaging complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into the flexible polymeric substrate: it serves as the structural base, the sealing layer, and the support for all fuel cell components. This integration eliminates the need for separate rigid substrate assemblies and complex packaging structures, thereby reducing device complexity and weight while maintaining structural integrity through the unified flexible structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible polymeric substrate and thin film components replace traditional rigid packaging and structural elements. This approach simplifies the overall device architecture by using compliant materials that can accommodate thermal expansion, mechanical stress, and assembly tolerances without requiring complex rigid packaging structures.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If traditional polymeric fuel cell assembly with rigid substrates is used, then ease of fabrication is improved, but volumetric efficiency deteriorates

Engineering Contradiction:

Improvefabrication easeVSAvoidvolumetric efficiency

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent maintains the fabrication advantages of polymeric materials (flexibility, low-cost processing, rapid prototyping) while eliminating the volume penalty associated with rigid substrate assemblies. The flexible thin film substrates can be fabricated using the same adaptable polymeric fabrication methods as traditional designs, but achieve superior volumetric efficiency due to their thin profile and elimination of rigid support structures.

Inventive Principle:

Principle #30Flexible shells and thin films

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in long-life, high-energy-density, low-cost, and compact energy sources with improved power generation capabilities, enhancing the performance and efficiency of portable electronics by maximizing surface-to-volume ratios and reducing chemical consumption.

Implementation Method 1

flexible air-breathing microscale fuel cells having ion-exchange polymer membranes

Methodology Applied

Scientific EffectIon exchange: Ion Exchange

Implementation Method 2

direct hydrogen flow-through porous anode electrode

Methodology Applied

Scientific EffectElectrochemical oxidation: Oxidation

Implementation Method 3

pair of air-breathing cathodes

Methodology Applied

Scientific EffectElectrochemical reduction: Reduction

Data Source

PatentUS12009524B2Flexible, planar, double sided air breathing microscale fuel cell

Publication Date: 2024.06.11 STEVENS INSTITUTE OF TECHNOLOGY

AI summary

Flexible air-breathing microscale fuel cells are produced using ion exchange polymer membranes without silicon substrates or other rigid components. The microscale fuel cells provide long-life energy supply sources in portable electronics due to reduced volume, high energy density, and low cost. More particularly, the microscale fuel cell has a direct hydrogen flow-through porous anode electrode with a pair of air-breathing cathodes.