IMPROVEMENT IN MASS TRANSPORT FOR TERNARY REACTION OPTIMIZATION IN A PROTON EXCHANGE MEMBRANE FUEL CELL ASSEMBLY AND STACK ASSEMBLY

Abstract: An improved proton exchange membrane fuel cell assembly and fuel cell stack assembly are provided for the economical and efficient production of electricity. The present invention comprises improved flow fields and reactant supply systems, which provide improved and more efficient mass transport of the reactants in the fuel cell and the fuel cell stack assembly. The improved flow fields comprise three-dimensional open-cell foamed metals that are preferably plated with gold. The improved reactant supply system comprises an improved distribution frame to house fuel cells wherein the reactants are directly connected to the improved flow fields.

Description: IMPROVEMENT IN MASS TRANSPORT FOR TERNARY REACTION OPTIMIZATION IN A PROTON EXCHANGE MEMBRANE FUEL CELL ASSEMBLY AND STACK ASSEMBLY BACKGROUND OF THE INVENTION The present invention relates in general to the field of proton exchange membrane ("PEM") fuel cell systems, and more particularly, to an improved PEM fuel cell system having improved discrete fuel cell modules with improved mass transport for ternary reaction optimization and a method for manufacturing same. A fuel cell is an electrochemical device that converts fuel and oxidant into electricity and a reaction by-product through an electrolytic reaction that strips hydrogen molecules of their electrons and protons. Ultimately, the stripped electrons are collected into some form of usable electric current, by resistance or by some other suitable means. The protons react with oxygen to form water as a reaction by-product. Natural gas is the primary fuel used as the source of hydrogen for a fuel cell. If natural gas is used, however, it must be reformed prior to entering the fuel cell. Pure hydrogen may also be used if stored correctly. The products of the electrochemical exchange in the fuel cell are DC electricity, liquid water, and heat. The overall PEM fuel cell reaction produces electrical energy equal to the sum of the separate half-cell reactions occurring in the fuel cell, less its internal and parasitic losses. Parasitic losses are those losses of energy that are attributable to any energy required to facilitate the ternary reactions in the fuel cell. Although fuel cells have been used in a few applications, engineering solutions to successfully adapt fuel cell technology for use in electric utility systems have been elusive. The challenge is for the generation of power in the range of 1 to 100 kW that is affordable, reliable, and requires little maintenance. Fuel cells would be desirable in this application because they convert fuel directly to electricity at much higher efficiencies than internal combustion engines, thereby extracting more power from the same amount of fuel. This need has not been satisfied, however, because of the prohibitive expense associated with such fuel cell systems. For example, the initial selling price of the 200 kW PEM fuel cell was about $3500/kW to about $4500/kW. For a fuel cell to be useful in utility applications, the life of the fuel cell stack must be a minimum of five years and operations must be reliable and maintenance-free. Heretofore known fuel cell assemblies have not shown sufficient reliability and have disadvantageous maintenance issues. Despite the expense, reliability, and maintenance problems associated with heretofore known fuel cell systems, because of their environmental friendliness and operating efficiency, there remains a clear and present need for economical and efficient fuel cell technology for use in residential and light- commercial applications. Fuel cells are usually classified according to the type of electrolyte used in the cell. There are four primary classes of fuel cells: (1) proton exchange membrane ("PEM") fuel cells, (2) phosphoric acid fuel cells, and (3) molten carbonate fuel cells. Another more recently developed type of fuel cell is a solid oxide fuel cell. PEM fuel cells, such as those in the present invention, are low temperature low pressure systems, and are, therefore, well-suited for residential and light-commercial applications. PEM fuel cells are also advantageous in these applications because there is no corrosive liquid in the fuel cell and, consequently, there are minimal corrosion problems. Characteristically, a single PEM fuel cell consists of three major components - an anode gas dispersion field ("anode"); a membrane electrode assembly ("MEA"); and a cathode gas and liquid dispersion field ("cathode"). As shown in Figure 1, the anode typically comprises an anode gas dispersion layer 502 and an anode gas flow field 504; the cathode typically comprises a cathode gas and liquid dispersion layer 506 and a cathode gas and liquid flow field 508. In a single cell, the anode and the cathode are electrically coupled to provide a path for conducting electrons between the electrodes through an external load. MEA 500 facilitates the flow of electrons and protons produced in the anode, and substantially isolates the fuel stream on the anode side of the membrane from the oxidant stream on the cathode side of the membrane. The ultimate purpose of these base components, namely the anode, the cathode, and MEA 500, is to maintain proper ternary phase distribution in the fuel cell. Ternary phase distribution as used herein refers to the three simultaneous reactants in the fuel cell, namely hydrogen gas, water vapor and air. Heretofore known PEM fuel cells, however, have not been able to efficiently maintain proper ternary phase distribution. Catalytic active layers 501 and 503 are located between the anode, the cathode and the electrolyte. The catalytic active layers 501 and 503 induce the desired electrochemical reactions in the fuel cell. Specifically, the catalytic active layer 501, the anode catalytic active layer, rejects the electrons produced in the anode in the form of electric current. The oxidant from the air that moves through the cathode is reduced at the catalytic active layer 503, referred to as the cathode catalytic active layer, so that it can oxidate the protons flowing from anode catalytic active layer 501 to form water as the reaction by-product. The protons produced by the anode are transported by the anode catalytic active layer 501 to the cathode through the electrolyte polymeric membrane. The anode gas flow field and cathode gas and liquid flow field are typically comprised of pressed, polished carbon sheets machined with serpentine grooves or channels to provide a means of access for the fuel and oxidant streams to the anode and cathode catalytic active layers. The costs of manufacturing these plates and the associated materials costs are very expensive and have placed constraints on the use of fuel cells in residential and light-commercial applications. Further, the use of these planar serpentine arrangements to facilitate the flow of the fuel and oxidant through the anode and cathode has presented additional operational drawbacks in that they unduly limit mass transport through the electrodes, and therefore, limit the maximum power achievable by the fuel cell. One of the most problematic drawbacks of the planar serpentine arrangement in the anode and cathode relates to efficiency. In conventional electrodes, the reactants move through the serpentine pattern of the electrodes and are activated at the respective catalytic layers located at the interface of the electrode and the electrolyte. The actual chemical reaction that occurs at the anode catalyst layer is: H 2 2H 1" + 2e " . The chemical reaction at the cathode catalyst layer is: 2H 1" + 2e " + 1 / 2 O 2 ** H 2 O. The overall reaction is: H 2 + 1 O 2 H 2 O. The anode disburses the anode gas onto the surface of the active catalyst layer comprised of a platinum catalyst electrolyte, and the cathode disburses the cathode gas onto the surface of the catalytic active layer of the electrolyte. However, when utilizing a conventional serpentine construction, the anode gas and the cathode gas are not uniformly disbursed onto the electrolyte. Nonuniform distribution of the anode and cathode gas at the membrane surface results in an imbalance in the water content of the electrolyte. This results in a significant decrease in efficiency in the fuel cell. The second most problematic drawback associated with serpentine arrangements in the electrodes relates to the ternary reactions that take place in the fuel cell itself. Serpentine arrangements provide no pressure differential within the electrodes. This prohibits the necessary ternary reactions from taking place simultaneously. This is particularly problematic in the cathode as both a liquid and a gas are transported simultaneously through the electrode's serpentine pattern. Another shortcoming of the conventional serpentine arrangement in the anode in particular is that the hydrogen molecules resist the inevitable flow changes in the serpentine channels, causing a build-up of molecular density in the turns in the serpentine pattern, resulting in temperature increases at the reversal points. These hot spots in the serpentine arrangement unduly and prematurely degrade the catalytic active layer and supporting membrane. In the typical PEM fuel cell assembly, a PEM fuel cell is housed within a frame that supplies the necessary fuel and oxidant to the flow fields of the fuel cell. These conventional frames typically comprise manifolds and channels that facilitate the flow of the reactants. However, usually the channels are not an integral part of the manifolds, which results in a pressure differential along the successive channels. Figure 2 is an illustration of a conventional frame for the communication of the reactants to a fuel cell. This pressure differential causes the reactants, especially the fuel, to be fed into the flow fields unevenly, which results in distortions in the flow fields causing hot spots. This also results in nonuniform disbursement of the reactants onto the catalytic active layers. Ultimately, this conventional method of supplying the necessary fuel and oxidant to a fuel cell results in a very inefficient process. As a single PEM fuel cell only produces about 0.30 to 0.90 volts D.C. under a load, the key to developing useful PEM fuel cell technology is being able to scale-up current density in individual PEM cell assemblies to produce sufficient current for larger applications without sacrificing fuel cell efficiency. Commonly, fuel cell assemblies are electrically connected in nodes that are then electrically connected in series to form "fuel cell stacks" by stacking individual fuel cell nodes. Two or more nodes can be connected together, generally in series, but sometimes in parallel, to efficiently increase the overall power output. These internal foils are often fabricated from graphite or metal. In conventional designs, the bonds between the internal foil and the anode gas flow field and the cathode gas and liquid flow field cause degradation of both the plate and the gas flow fields. This the results in efficiency losses in the fuel cell. Conventional PEM fuel stacks often flood the cathode due to excess water in the cathode gas flow field. Flooding occurs when water is not removed efficiently from the system. Flooding is particularly problematic because it impairs the ability of the reactants to adequately diffuse to the catalytic active layers. This significantly increases the internal resistance of the cathode which ultimately limits the cell voltage potential. Another problem is dehydration of the polymeric membranes when the water supply is inadequate. Insufficient supply of water can dry out the anode side of the PEM membrane electrolyte, causing a significant rise in stack resistance and reduced membrane durability. Further, conventional PEM fuel cells and stacks of such fuel cell assemblies are compressed under a large load in order to ensure good electrical conductivity between cell components and to maintain the integrity of compression seals that keep various fluid streams separate. A fuel cell stack is usually held together with extreme compressive force, generally in excess of 40,000 psi, using compression assemblies, such as tie rods and end plates. If tie rods are used, the tie rods generally extend through holes formed in the peripheral edge portion of the stack end plates and have associated nuts or other fastening means assembling the tie rods to the stack assembly to urge the end plates of the fuel stack assembly toward each other. Typically, the tie rods are external, i.e., they do not extend through the fuel cell electrochemically active components. This amount of pressure that must be used to ensure good electrochemical interactions presents many operational difficulties. For example, if the voltage of a single fuel cell assembly in a stack declines significantly or fails, the entire stack must be taken out of service, disassembled, and repaired, resulting in significant repair costs and down-time. Second, inadequate compressive force can compromise the seals associated with the manifolds and flow fields in the central regions of the interior distribution plates, and also compromise the electrical contact required across the surfaces of the plates and MEAs to provide the serial electrical connection among the fuel cells that make up the stack. Third, the extreme compressive force used unduly abrades the surfaces of the fuel cell modules within the stack, resulting in wear of components in the fuel cell assemblies such as the catalyst layers of the electrolyte, thereby leading to increased losses in fuel cell stack and fuel cell assembly efficiency. SUMMARY OF THE INVENTION Accordingly, there is a need for an economical and efficient fuel cell assembly and fuel cell stack assembly with an optimized supply and mass transport system. Herein provided is a fuel cell assembly and fuel cell stack with efficiency enhancements through several improvements to the anode gas flow field, the cathode gas and liquid flow field, and the fuel/oxidant distribution system. Further, maintenance and inspection of the fuel cell system of the present invention are less burdensome as very little compressive force is needed to ensure good electrochemical connection, enabling these fuel cell systems to be used effectively in residential and light-commercial applications. As a result, significant improvement in power density, efficiency, and life of the fuel cell are provided at the cell and stack level. Most broadly, the present invention comprises an improved gas flow field for a fuel cell assembly comprising a three-dimensional open cell foamed structure suitable for gas diffusion. In another embodiment, a method for making a three- dimensional open-cell foamed gas flow field is disclosed. Another embodiment of the present invention comprises a PEM fuel cell assembly having gas diffusion layer, gas and liquid diffusion layer, an anode gas flow field, and a cathode gas and liquid flow field. In still another embodiment, an improved fuel cell stack assembly is disclosed wherein the fuel cell assemblies of the stack comprise an open-cell foamed gas flow field and an open-cell foamed gas and liquid flow field. The present invention also provides for improved distribution for a fuel cell assembly providing for improved transport of the reactants to the fuel cell. One advantage of the present invention is that these improvements increase the life and decrease the maintenance operations for a fuel cell. This enables the fuel cells to be used in residential and light-commercial applications effectively. Another advantage is that the invention achieves optimal mass transport through the open cell foamed flow fields and the distribution frame of the present invention. This increases the overall efficiency and maximum power achievable by the fuel cell. Further, the anode gas and cathode gas are uniformly disbursed on the catalytic active layers of the electrolyte, resulting in optimal water balance in the fuel cell system. Flooding and drying out of the electrolyte are thereby avoided. In addition, hot spots that distort the fuel cell, resulting in maintenance to replace the damaged cell, are avoided. Maximum power is, thus, achievable. Other advantages of the present invention will be apparent to those ordinarily skilled in the art in view of the following specification claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like numbers indicate like features, and wherein: Figure 1 is a schematic of a typical PEM fuel cell assembly. Figure 2 is an illustration of a conventional frame for housing and supplying reactants to a fuel cell assembly. Figure 3 is a depiction of a distribution frame of the present invention housing a fuel cell assembly. Figure 4 is an exploded view of the distribution frame and a fuel cell assembly of the present invention. Figure 5 is a cross-sectional view of an internal foil assembly of the present invention. Figure 6 is an electron micrograph of a three-dimensional open-cell foamed cathode gas and liquid flow field with microchannels. Figure 6 A is an electron micrograph of the three-dimensional open-cell foamed cathode gas and liquid flow field with microchannels of the present invention magnified 10 times. Figure 6B is an electron micrograph of the three-dimensional open-cell foamed cathode gas and liquid flow field with microchannels of the present invention magnified 20 times. Figure 7 is an electron micrograph of the connections between a three- dimensional open-cell foamed gas flow field and an internal foil in an internal foil assembly of the present invention. Figure 8 is an electron micrograph of the connections between the three- dimensional open-cell foamed gas flow field magnified 150 times. Figure 9 is an electron micrograph of two individual connections between the three-dimensional open-cell foamed gas flow field and the internal foil of an internal foil assembly of one embodiment of the present invention. Figure 10 is an electron micrograph of a conventional internal foil assembly formed using conventional techniques. Figure 11 is an illustration of the fuel side of a distribution frame for a fuel cell assembly of the present invention. Figure 12 is an illustration of the air side of a distribution frame for a fuel cell assembly of the present invention. Figure 13 is an illustration of a fuel cell stack assembly of the present invention. DETAILED DESCRIPTION OF THE INVENTION Figure 3 depicts one embodiment of an individual fuel cell assembly of the present invention. As shown in Figure 3, fuel cell 11 is housed within distribution frame 10. Distribution frame 10 not only houses fuel cell 11, but also facilitates transportation of the fuel and the oxidant to the fuel cell necessary for the electrochemical exchange in the fuel cell. This individual fuel cell assembly can be combined with other fuel cell assemblies to form a fuel cell node, and ultimately a stack assembly, to provide higher voltages and current for power generation. Of note in Figure 3 are fuel inlet 22, fuel inlet 24, air inlet 12 and air and water outlet 14. The fuel inlets 22 and 24, air inlet 12, and air and water outlet 14 are apertures in the distribution frame extending completely through the distribution frame, and run perpendicular, or at 90° angles, from one another in the distribution frame to facilitate the efficient flow of the fuel and oxidant to and through the anode gas and liquid flow field and cathode gas flow field, respectively. Figure 4 more particularly illustrates the component parts of the fuel cell assembly of one embodiment of the present invention depicted in Figure 3, specifically distribution frame 10, primary internal foil assembly 64, fuel cell 11 and secondary internal foil assembly 30. Primary internal foil assembly 64 consists of primary anode gas flow field 52, primary internal foil 54 and primary cathode gas and liquid flow field 56. Primary internal foil 54 serves as a boundary layer between primary anode gas flow field 52 and primary cathode gas and liquid flow field 56 to keep air from flowing into the anode gas flow field from the cathode and water from flowing from the cathode gas and liquid flow field to the anode gas flow field. MEA 58 is composed of an electrolyte, primary cathode catalytic active layer 60, and secondary anode catalytic active layer 62. Any known ME As may be used in the present invention. Conventional fluorocarbon based polymeric membranes are particularly suitable for the present invention-including Nation membranes. Primary cathode catalytic active layer 60 is bonded to primary cathode gas and liquid flow field 56 when the fuel cell is assembled. Secondary internal foil 31 also serves as a boundary layer between the anode and cathode electrodes of the internal foil assembly as does primary internal foil 54. Secondary anode catalytic active layer 62 is bonded to secondary anode gas flow field 29 when the fuel cell assembly is assembled. Figure 4 illustrates the assembled fuel cell placed in distribution frame 10 wherein secondary cathode gas flow field 28 is in view. Secondary internal foil 31 is also illustrated in Figure 3. When the fuel cell assembly of the present invention is assembled as in the embodiments depicted in Figures 3 and 4, the procession of layers is: primary anode gas flow field 52, primary internal foil 54, primary cathode gas flow field 56, MEA 58, secondary anode gas flow field 29, secondary internal foil 31, and secondary cathode gas flow field 28. This defines the elements of one fuel cell of the present invention terminated by internal foil assemblies. Primary cathode catalyst layer 60 and secondary anode catalyst layer 62 of the MEA shown in Figure 4 may be comprised of platinum or a platinum/ruthenium catalyst. If platinum is used, it is typically combined with fibrous material, including suitable nonwovens, or suitable cotton muslin sheets or pieces of fabric. Primary cathode gas flow field 56 and secondary anode gas flow field 29 are bonded to primary cathode catalytic active layer 60 and secondary anode catalytic active layer 62, respectively, through mechanical bonding means such as compression or adhesion. However, there is no need for excessive compressive force in the present invention to create the electrochemical connections between the catalytic active layers and the gas flow fields. Compression may be provided by any known means, such as a tie-rod assembly. In general, the compressive force on a fuel cell stack should be less than 100 psi. Figure 5 is a cross-section of an internal foil assembly of the present invention. Internal foil assembly 64 is comprised of three parts: anode gas flow field 66, internal foil 68, and cathode gas and liquid flow field 70. The cross section of the anode gas flow field 66 may be preferably approximately half the size of cathode gas and liquid flow field 70 to accommodate the ratios of reactants necessary for the electrochemical exchange in the fuel cell. Both anode gas flow field 66 and cathode gas and liquid flow field 70 may be composed of a three-dimensional open-cell foamed structure suitable for gas diffusion that, preferably, may be plated with gold. In another embodiment of the present invention, cathode gas flow field 70 may be corrugated to create microchannels. Figure 6 illustrates a corrugated cathode gas and liquid flow field of the present invention. These microchannels facilitate the removal of free water and excessive heat from the fuel cell assembly. When the fuel cell is placed in the distribution frame, these microchannels in the cathode gas and liquid flow field 70 run parallel to the air inlet and air and water outlet, and perpendicular to the fuel inlets. The vertical distance between the peak of a corrugation and the trough next to it, herein referred to as the pitch, should be at least 2/3 of the horizontal distance between a peak of one corrugation to the peak of the next corrugation, herein referred to as the run. Whereas, as shown in Figure 5, anode gas flow field 66 is directly bonded to internal foil 68; in an alternative embodiment cathode gas and liquid flow field 70 is only bonded to the internal foil at the peaks of the corrugations. As shown in Figure 6, the cathode gas and liquid flow field is therefore intermittently bonded to the internal foil at the peaks of the microchannels. This structure effectively manages the ternary reactions necessary for fuel cell operability by adequately removing the water and facilitating the movement of hydrogen and air. Figures 6A and 6B depict magnified views of the microchannels shown in Figure 6. Suitable construction materials for the three-dimensional open-cell foamed gas flow fields and gas and liquid flow fields are conducive to flow distribution and possess good electrical conductivity properties. These may include: plastics, carbon filament, stainless steel and its derivatives, epitaxial substrates, nickel and its alloys, gold and its alloys, and copper and its alloys. Iridium may also be used if it has sufficient electrochemical properties. In one embodiment of the present invention, the anode gas flow field and the cathode gas and liquid flow fields are made from open-cell foamed nickel. The open-cell foamed nickel flow fields are produced by electroplating nickel over a p articulate plastic so that the voids created by the tangential intersections in the particulate plastic structure are filled with nickel. Although polystyrene maybe used in this method of producing the foamed flow field structure, other materials, such as other particulate thermoplastic resinous materials, would also be suitable in this process. Another suitable material, for example, would be Isinglass. If nickel is used, the nickel may be enhanced with 2.0% by weight of cobalt. The addition of cobalt enhances the mechanical strength of the nickel and reduces the drawing properties of the nickel. The addition of cobalt also strengthens the lattice structure of the finished open-cell foamed flow field. Once the nickel has cooled, the polystyrene plastic may be blown out of the foam with hot carbon dioxide gas or air leaving a three-dimensional nickel open-cell foamed flow field structure having substantially five-sided geometrically-shaped orifices. The nickel foamed flow field is autocatalytically microplated with up to 15 microns of gold, iridium, copper or silver. Preferably, the flow field is microplated, with between 0.5 to 2.0 microns of gold. Figures 7 and 8 are electron micrographs of a three-dimensional open- cell foamed flow field of the present invention wherein the substantially five-sided orifices are visible and have been plated with gold. The advantage obtained from utilizing a three-dimensional open cell foamed flow field in the present invention is that it enhances mass transfer within the flow fields. This is because the mass transfer rate is supplemented by the foamed flow field itself and its wicking ability, which allows the molecules to electromosaticaly move through the flow field. Another advantage associated with the foamed flow fields of the present invention is that they also facilitate the deposit of the reactants uniformly along the surface of the catalytic active layers. A further distinct advantage of the foamed flow fields over conventional serpentine arrangements is that the foamed flow fields enhance the ternary reactions of the fuel cell. The gold plating further enhances the electromosatic movement of the molecules through the flow fields by providing microridges, evident in Figure 7 and 8, on the surfaces of the foamed structure's orifices. These microridges facilitate the flow of the fuel, oxidant, and water in the flow fields. The gold plating enhances mass transfer by increasing the surface area of the foam by as much as a factor of nine. Another advantage of gold plating the foamed flow field of the present invention is that the leaflet potential of the gold preserves the structure of the foamed flow fields by preventing the flow fields from undergoing electrolysis. This enhances the life of the flow fields and the fuel cell assembly itself, making the fuel cell assemblies of the present invention suitable for residential and light-commercial uses. As shown in Figure 5, in internal foil assembly 64, anode gas flow field 66 and cathode gas and liquid flow field 70 are attached to primary internal foil 68 through mechanical bonding, such as sintering, plating, pressing, rolling, drawing, or extruding. Another connections means would include laminating through electrochemical adhesives. This increases the electrical conductivity through the internal foil assembly by decreasing the air gap between the flow fields and the internal foil. Preferably, internal foil 68 is plated with gold as are the flow fields so as to create an undisturbed electrical connection between the flow fields and the internal foil. When a gold-plated nickel foam is used, an alloy of copper and silver should be used to sinter the gold plated, nickel foam to internal foil assembly 64. Figure 9 is an electron micrograph of one embodiment of the internal foil assembly of one embodiment of the present invention illustrating the connection as shown in Figure 5 between anode gas flow field 66, cathode gas flow field 70, and internal foil 68, wherein all three elements have been gold plated. As can be particularly seen by the arrows in Figure 9, the substantially five-sided orifices of the open-cell foamed gas flow fields are not deformed by the bonding process of the present invention. Figure 10 comparatively illustrates the deformation the gas flow field suffer if bonded to the internal foil using conventional techniques. The electrically consistent connection achieved in the present invention between the flow fields and the internal foil which provides for more efficient mass transfer in the internal foil assembly of the present invention. Shown in Figure 11 is one embodiment of the anode side of distribution frame 10. Fuel inlet 12 and fuel inlet 14 provide the fuel to the fuel cell housed within the cavity of distribution frame 10 necessary for the electrochemical reaction. Specifically, the fuel is fed to the anode gas flow field through fuel supply channels 18 and 16 that stretch from the interior sides or surfaces of fuel inlet 12 and fuel inlet 14, respectively. Fuel supply channels 18 and 16 are shaped such that the supply of the fuel to the anode is preferably maintained at a constant velocity, i.e., the channels are of sufficient length, width and depth to provide fuel to the anode at a constant velocity. The velocity of the fuel entering the anode gas flow field via fuel supply channels 18 and 16 may be less than the velocity of oxidant entering the cathode gas flow field via air supply channels 25. The number of fuel supply channels in the distribution frame stoichiometrically balances the number of air supply channels so as to achieve a 2.0 to 1.0 to 2.8 to 1.0, preferably 2.0 to 1.0 to 2.4 to 1.0, air to fuel ratio. Fuel supply channels 18 and 16 also provide an edge-on connection between the fuel supply inlets and the anode gas flow field of the fuel cell housed within the cavity of the distribution frame to allow for enhanced dispersion of the fuel through the anode gas flow field. Suitable materials of construction for distribution frame 10 include nylon-6, 6, derivatives of nylon-6, 6, polyetheretherketone ("PEEK"), ABS styrene, mylar, textar, kevlar or any other nonconductive thermoplastic resin. Preferably, distribution frame 10 is formed from nylon-6, 6, and, if used in a stack assembly, the end plates of the fuel cell stack assembly are preferably formed from PEEK. Nylon-6, 6 is a particularly suitable material for distribution frame 10 because it dissipates electrical energy quickly so that it will not accumulate in the fuel cell assembly. It also has good compression properties. Distribution frame 10 is preferably substantially circular. Shown in Figure 12 is the cathode side of distribution frame 10. Air, is a necessary reactant for the electrochemical exchange, and may be fed to fuel cell 11 via air inlet 24 in combination with air supply channels 26. Air supply channels 26 stretch from the interior surface or side of air inlet 24 to fuel cell 11, and are of such sufficient size and shape that they enable air to be fed to the cathode gas flow field at a constant velocity, i.e., they are of sufficient height, width and depth. The number of fuel supply channels 18 and 16 will most often exceed the number of air supply channels 26 to maintain a stoichiometric balance of the reactants. Free water is formed continuously in the cathode gas and liquid flow field as a by-product of the electrochemical reaction. As described, the open-cell foamed of the cathode gas and liquid flow field facilitates the removal of this free water from the cathode gas and liquid flow field efficiently. In an alternative embodiment of the present wherein the cathode gas flow field is corrugated, the microchannels in the cathode gas flow field enhance free water removal from the system. Air and water outlet 22 and air and water outlet channels 25 facilitate the flow of this free water from fuel cell 11 to allow for optimal water management in the fuel cell, and to avoid flooding and the resultant loss in power. In a stack assembly, this free water may be transported for use in other parts of the fuel cell unit, unit here meaning the balance of plant assembly. Air and water outlet 22 and air and water outlet channels 25 also facilitate dissipation of the heat generated by the electrochemical reactions. Figure 13 is a cross-section of a fuel cell stack assembly shown generally at 200 that encompasses a plurality of fuel cell assemblies. Two or more individual fuel cell assemblies can be combined to form a node. Two or more nodes can be combined to form a fuel cell stack assembly. Typically, these individual fuel cells will be interposed between end plates, which are preferably substantially circular. Stacks can be placed in series to increase voltage. Stacks can be arranged in parallel to increase amperes. In one embodiment of the present invention, 1 end plate is used for every 6 fuel cell assemblies frames to provide desirable torsional properties to the fuel cell stack assembly. Although the present disclosure has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereto without departing from the spirit and the scope of the invention as defined by the appended claims.

Claims: WHAT IS CLAIMED IS: 1. A gas flow field for a fuel cell assembly comprising a three-dimensional open- cell foamed structure suitable for gas diffusion. 2. The gas flow field for a fuel cell assembly according to claim 1 wherein the three-dimensional open-cell foamed structure comprises nickel, nickel alloys, gold, gold alloys, copper, or copper alloys. 3. The gas flow field for a fuel cell assembly according to claim 1 wherein the three-dimensional open-cell foamed structure is plated with gold, iridium, copper or silver. 4. The gas flow field for a fuel cell assembly according to claim 2 wherein the three-dimensional open-cell foamed structure is plated with gold, iridium, copper or silver. 5. The gas flow field for a fuel cell assembly according to claim 1 wherein the three-dimensional open-cell foamed structure has corrugations, the corrugations creating microchannels, and the corrugations further having a pitch and a run. 6. The gas flow field for a fuel cell assembly according to claim 5 wherein the pitch of the corrugations is greater than or equal to 2/3 of the run of the corrugations. 7. A PEM fuel cell assembly comprising: (a) an MEA, the MEA having two catalytic active layers, the MEA further having an anode side and a cathode side; (b) a gas diffusion layer, the gas diffusion layer having a top face and a bottom face, the bottom face of the gas diffusion layer juxtaposed to the anode side of the MEA; (c) a gas and liquid diffusion layer, the gas and liquid diffusion layer having a top face and a bottom face, the top face of the gas and liquid diffusion layer juxtaposed to the cathode side of the MEA; (d) an anode gas flow field comprising a three-dimensional open-cell foamed structure suitable for gas diffusion, the anode gas flow field juxtaposed to the top face of the gas diffusion layer; and (e) a cathode gas and liquid flow field comprising a three-dimensional open-cell foamed structure suitable for gas and liquid diffusion, the cathode gas and liquid flow field juxtaposed to the bottom face of the gas and liquid diffusion layer. 8. The PEM fuel cell assembly according to claim 7 wherein the cathode gas and liquid flow field has corrugations, the corrugations creating microchannels, the corrugations further having a pitch and a run, and the microchannels running parallel to the air supply channels. 9. The PEM fuel cell assembly according to claim 8 wherein the pitch of the corrugations is greater than or equal to 2/3 of the run of the corrugations. 10. The PEM fuel cell assembly according to claim 7 wherein the anode gas flow field comprises nickel, alloys of nickel, copper, alloys of copper, gold or alloys of gold. 11. The PEM fuel cell assembly according to claim 7 wherein the cathode gas and liquid flow field comprises nickel, alloys of nickel, copper, alloys of copper, gold, and alloys of gold. 12. The PEM fuel cell assembly according to claim 7 wherein the anode gas flow field or the cathode gas and liquid flow field are plated with gold, iridium, silver or copper. 13. The PEM fuel cell assembly according to claim 7 wherein the MEA further comprises a platinum or a platinum/ruthenium catalyst. 14. The PEM fuel cell assembly according to claim 7 wherein the electrolyte is a Nafion electrolyte. 15. The PEM fuel cell assembly according to claim 7 wherein the gas diffusion layer and the gas and liquid diffusion layer comprise a fibrous layer. 16. A method for producing a three-dimensional open-cell foamed gas flow field and gas and liquid flow field for a fuel cell assembly comprising the steps of: (a) providing a particulate plastic resinous component; (b) providing a molten electrically conductive metal; (c) depositing the molten electrically conductive metal onto the particulate plastic resinous component; (d) cooling the molten electrically conductive metal to form a solid electrically conductive metal; and (e) removing the particulate plastic resinous component from the solid electrically conductive metal to form a three-dimensional open-cell foamed gas flow field. 17. The method for producing a three-dimensional open-cell foamed gas flow field for a fuel cell assembly according to claim 16 wherein the particulate plastic resinous component is polystyrene or Isenglass. 18. The method for producing a three-dimensional open-cell foamed gas flow field for a fuel cell assembly according to claim 16 wherein the molten electrically conductive metal comprises nickel, alloys of nickel, gold, alloys of gold, copper, or alloys of copper. 19. The method for producing a three-dimensional open-cell foamed gas flow field for a fuel cell assembly according to claim 16 that further comprising following step (e), plating the three-dimensional open-cell foamed gas flow field with gold, platinum or iridium. 20. The method for producing a three-dimensional open-cell foamed gas flow field for a fuel cell assembly according to claim 19 wherein plating the three-dimensional open-cell foamed gas flow field is accomplished by an autocatalytic reaction. 21. The method for producing a three-dimensional open-cell foamed gas flow field for a fuel cell assembly according to claim 16 further comprising following step (e) the step of corrugating the three-dimensional open-cell foamed gas flow field to create microchannels in the gas flow field. 22. A gas flow field produced by the method of claim 16. 23. A fuel cell stack assembly comprising: (a) a first end plate and a second end plate, the second end plate being aligned with the first end plate; (b) a plurality of fuel cell assemblies interposed between the first end plate and the second end plate, each fuel cell assembly comprising an open-cell foamed gas flow field, an open-cell foamed gas and liquid flow field, and an MEA; (c) an internal foil, the internal foil having an anode connection surface and a cathode connection surface, the anode connection surface being bonded to the gas flow field of a first fuel cell assembly and the cathode connection surface being bonded to the gas and liquid flow field of a second fuel cell assembly; and (d) a compression assembly. 24. The fuel cell stack assembly according to claim 23 wherein the first end plate or the second end plate are made of polyetheretherketone. 25. The fuel cell stack assembly according to claim 23 wherein the first end plate or the second end plate are substantially circular members. 26. The fuel cell stack assembly according to claim 23 wherein the first end plate and the second end plate further comprise apertures for use in conjunction with the compression assembly. 27. The fuel cell stack assembly according to claim 23 wherein the compression assembly is a tie rod assembly, the tie rod assembly exerting less than 100 psi of compressive force on the fuel cell stack assembly. 28. The fuel cell stack assembly according to claim 23 wherein the gas flow field and the gas and liquid flow field are comprised of nickel, alloys of nickel, copper, alloys of copper, gold, or alloys of gold. 29. The fuel cell stack assembly according to claim 23 wherein the gas flow field, the gas and liquid flow field, or the internal foil are plated with gold. 30. The fuel cell stack assembly according to claim 23 wherein the electrolyte is a fluorocarbon-based electrolyte. 31. The fuel cell stack assembly according to claim 23 wherein each fuel cell assembly further comprises a gas diffusion layer, the gas diffusion layer being located between the gas flow field and the electrolyte, and a gas and liquid diffusion layer, the gas and liquid diffusion layer being located between the gas and liquid flow field and the electrolyte. 32. The fuel cell stack assembly according to claim 31 wherein the MEA further comprises a platinum or a platinum/ruthenium catalyst. 33. A distribution frame for a fuel cell assembly comprising: (a) a substantially planar frame, the substantially planar frame having an anode side, a cathode side, and a central cavity suitable for housing the fuel cell assembly; (b) at least 2 fuel inlet apertures, the fuel inlet apertures extending completely through the distribution frame and each fuel inlet aperture being located 180° from the other, and each fuel inlet aperture having an interior side; (c) an air inlet aperture, the air inlet aperture extending completely through the distribution frame and the air inlet aperture being located 90° from each fuel inlet aperture and 180° from an air and water outlet aperture, the air and water outlet aperture extending completely through the distribution frame, the air inlet aperture and the air and water outlet aperture each further having an interior side; (d) a plurality of fuel supply channels, the fuel supply channels located on the anode side of the distribution frame and extending from the interior side of each fuel inlet aperture to the central cavity and being integral to each fuel inlet aperture; (e) a plurality of air supply channels, the air supply channels located on the cathode side of the distribution frame and the air supply channels extending from the interior side of the air inlet aperture to the central cavity and being integral to the air inlet aperture; and (f) a plurality of air and water outlet channels, the air and water outlet channels located on the cathode side of the distribution frame, the air and water outlet channels extending from the interior side of the air and water outlet aperture to the central cavity, and being integral to the air and water outlet aperture. 34. The distribution frame for a fuel cell assembly according to claim 33 wherein the distribution frame is substantially circular. 35. The distribution frame for a fuel cell assembly according to claim 33 wherein the distribution frame comprises nylon 6,6, derivatives of nylon 6,6, polyetheretherketone, ABS styrene, mylar, textar, or kevlar. 36. The distribution frame for a fuel cell assembly according to claim 33 wherein the number of fuel supply channels balances the number of air supply channels so as to achieve an air to fuel stoichometric mixture of between 2.0 to 1.0 to 2.4 to 1.0. 37. A fuel cell comprising: (a) a distribution frame having: (i) an anode side, a cathode side and a central cavity suitable for housing a fuel cell assembly; (ii) at least 2 fuel inlet apertures, the fuel inlet apertures extending completely through the distribution frame and each fuel inlet aperture being located 180° from the other, and each fuel inlet aperture having an interior side; (iii) an air inlet aperture, the air inlet aperture extending completely through the distribution frame and the air inlet aperture being located 90° from each fuel inlet aperture and 180° from an air and water outlet aperture, the air and water outlet aperture extending completely through the distribution frame, the air inlet aperture and the air and water outlet aperture each further having an interior side; (iv) a plurality of fuel supply channels, the fuel supply channels located on the anode side of the distribution frame and extending from the interior side of each fuel inlet aperture to the central cavity and being integral to each fuel inlet aperture; (v) a plurality of air supply channels, the air supply channels located on the cathode side of the distribution frame and the air supply channels extending from the interior side of the air inlet aperture to the central cavity and being integral to the air inlet aperture; and (vi) a plurality of air and water outlet channels, the air and water outlet channels located on the cathode side of the distribution frame, the air and water outlet channels extending from the interior side of the air and water outlet aperture to the central cavity, and being integral to the air and water outlet aperture; (b) a fuel cell assembly having: (i) an MEA having two catalytic active layers, the MEA further having an anode side and a cathode side, the MEA having an electrolyte; (ii) a gas diffusion layer, the gas diffusion layer having a top face and a bottom face, the bottom face of the gas diffusion layer juxtaposed to the anode side of the electrolyte; (iii) a gas and liquid diffusion layer, the gas and liquid diffusion layer having a top face and a bottom face, the top face of the gas and liquid diffusion layer juxtaposed to the cathode side of the electrolyte; (iv) an anode gas flow field comprising a three-dimensional open- cell foamed structure suitable for gas diffusion, the anode gas flow field juxtaposed to the top face of the gas diffusion layer; and (v) a cathode gas and liquid flow field comprising a three- dimensional open-cell foamed structure suitable for gas and liquid diffusion, the cathode gas and liquid flow field juxtaposed to the bottom face of the gas and liquid diffusion layer; the fuel cell assembly being located within and integral to the central cavity of the distribution frame, and being located such that the gas and liquid flow field is contiguous to the air supply channels and the air and water outlet channels so as to form an edge-on connection with the air supply channels and the air and water outlet channels, and located such that the gas flow field is contiguous to the fuel supply channels so as to form an edge-on connection with the fuel supply channels. 38. The fuel cell according to claim 37 wherein the cathode gas and liquid flow field has corrugations, the corrugations creating microchannels, the corrugations further having a pitch and a run. 39. The fuel cell according to claim 37 wherein the pitch of the corrugations is greater than or equal to 2/3 of the run of the corrugations. 40. The fuel cell according to claim 37 wherein the anode gas flow field comprises nickel, alloys of nickel, copper, alloys of copper, gold or alloys of gold. 41. The fuel cell according to claim 37 wherein the cathode gas and liquid flow field comprises nickel, alloys of nickel, copper, alloys of copper, gold, and alloys of gold. 42. The fuel cell according to claim 37 wherein the anode gas flow field or the cathode gas and liquid flow field are plated with gold, platinum or iridium. 43. The fuel cell according to claim 37 wherein the MEA further comprises a platinum or platinum/ruthenium catalyst. 44. The fuel cell according to claim 37 wherein the electrolyte is a Nafion electrolyte. 45. The fuel cell according to claim 37 wherein the gas diffusion layer and the gas and liquid diffusion layer comprises a cotton fibrous layer and a platinum or platinum/ruthenium catalyst. 46. The fuel cell according to claim 37 wherein the distribution frame is substantially circular. 47. The fuel cell according to claim 37 wherein the distribution frame comprises nylon 6,6, derivatives of nylon 6,6, polyetheretherketone, ABS styrene, mylar, textar, or kevlar. 48. The fuel cell according to claim 37 wherein the number of fuel supply channels exceeds the number of air supply channels. 49. A fuel cell stack comprising: (a) a first end plate and a second end plate, the second end plate being aligned with the first end plate; (b) at least one fuel cell, the fuel cell being interposed between the first end plate and the second end plate and the fuel cell further comprising: (i) a distribution frame having: (A) an anode side, a cathode side and a central cavity suitable for housing an MEA; (B) at least 2 fuel inlet apertures, the fuel inlet apertures extending completely through the distribution frame and each fuel inlet aperture being located 180° from the other, and each fuel inlet aperture having an interior side; (C) an air inlet aperture, the air inlet aperture extending completely through the distribution frame and the air inlet aperture being located 90° from each fuel inlet aperture and 180° from an air and water outlet aperture, the air and water outlet aperture extending completely through the distribution frame, the air inlet aperture and the air and water outlet aperture each further having an interior side; (D) a plurality of fuel supply channels, the fuel supply channels located on the anode side of the distribution frame and extending from the interior side of each fuel inlet aperture to the central cavity and being integral to each fuel inlet aperture; (E) a plurality of air supply channels, the air supply channels located on the cathode side of the distribution frame and the air supply channels extending from the interior side of the air inlet aperture to the central cavity and being integral to the air inlet aperture; and (F) a plurality of air and water outlet channels, the air and water outlet channels located on the cathode side of the distribution frame, the air and water outlet channels extending from the interior side of the air and water outlet aperture to the central cavity, and being integral to the air and water outlet aperture; (ii) a fuel cell assembly having: (A) an MEA, the MEA having two catalytic active layers, the MEA further having an anode side and a cathode side; (B) a gas diffusion layer, the gas diffusion layer having a top face and a bottom face, the bottom face of the gas diffusion layer juxtaposed to the anode side of the MEA; (C) a gas and liquid diffusion layer, the gas and liquid diffusion layer having a top face and a bottom face, the top face of the gas and liquid diffusion layer juxtaposed to the cathode side of the MEA; (D) an anode gas flow field comprising a three-dimensional open-cell foamed structure suitable for gas diffusion, the anode gas flow field juxtaposed to the top face of the gas diffusion layer; and (E) a cathode gas and liquid flow field comprising a three- dimensional open-cell foamed structure suitable for gas and liquid diffusion, the cathode gas and liquid flow field juxtaposed to the bottom face of the gas and liquid diffusion layer; the fuel cell assembly being located within and integral to the central cavity of the distribution frame, and being located such that the gas and liquid flow field is contiguous to the air supply channels and the air and water outlet channels so as to form an edge-on connection with the air supply channels and the air and water outlet channels, and located such that the gas flow field is contiguous to the fuel supply channels so as to form an edge-on connection with the fuel supply channels; and (c) a compression assembly. 50. The fuel cell stack according to claim 49 wherein the first end plate and the second end plate are constructed of polyetheretherketone. 51. The fuel cell stack according to claim 49 wherein the first end plate and the second end plate are substantially circular. 52. The fuel cell stack according to claim 49 wherein the first end plate and the second end plate further comprise apertures for use in conjunction with the compression assembly. 53. The fuel cell stack according to claim 49 wherein the compression assembly includes a plurality of tie rod assemblies. 54. The fuel cell stack according to claim 49 herein the distribution frame of the fuel cell is substantially circular. 55. The fuel cell stack according to claim 49 wherein the cathode gas and liquid flow field has corrugations, the corrugations creating microchannels, the corrugations further having a pitch and a run. 56. The fuel cell stack according to claim 49 herein the pitch of the corrugations is greater than or equal to 2/3 of the run of the corrugations. 57. The fuel cell stack according to claim 49 wherein the anode gas flow field comprises nickel, alloys of nickel, copper, alloys of copper, gold or alloys of gold. 58. The fuel cell stack according to claim 49 wherein the cathode gas and liquid flow field comprises nickel, alloys of nickel, copper, alloys of copper, gold, and alloys of gold. 59. The fuel cell stack according to claim 49 wherein the anode gas flow field or the cathode gas and liquid flow field are plated with gold, platinum or iridium. 60. The fuel cell stack according to claim 49 wherein the electrolyte further comprises a platinum or a platinum/ruthenium catalyst. 61. The fuel cell stack according to claim 49 wherein the electrolyte is a Nafion electrolyte. 62. The fuel cell stack according to claim 49 wherein the gas diffusion layer and the gas and liquid diffusion layer comprise a fibrous layer. 63. The fuel cell stack according to claim 49 wherein the distribution frame is substantially circular. 64. The fuel cell stack according to claim 49 wherein the distribution frame comprises nylon 6,6, derivatives of nylon 6,6, polyetheretherketone, ABS styrene, mylar, textar, or kevlar. 65. The fuel cell stack according to claim 49 wherein the number of fuel supply channels stoichiometrically balances the number of air supply channels so as to achieve an air to fuel mixture of between 2.0 to 1.0 to 2.4 to 1.0. 66. A method of inducing an electrochemical reaction so as to generate electricity comprising: (a) providing a fuel cell stack comprising: (i) a first end plate and a second end plate, the second end plate being aligned with the first end plate; (ii) at least one fuel cell, the fuel cell being interposed between the first end plate and the second end plate and the fuel cell further comprising: (A) a distribution frame having: (1) an anode side, a cathode side and a central cavity suitable for housing an MEA; (2) at least 2 fuel inlet apertures, the fuel inlet apertures extending completely through the distribution frame and each fuel inlet aperture being located 180° from the other, and each fuel inlet aperture having an interior side; (3) an air inlet aperture, the air inlet aperture extending completely through the distribution frame and the air inlet aperture being located 90° from each fuel inlet aperture and 180° from an air and water outlet aperture, the air and water outlet aperture extending completely through the distribution frame, the air inlet aperture and the air and water outlet aperture each further having an interior side; (4) a plurality of fuel supply channels, the fuel supply channels located on the anode side of the distribution frame and extending from the interior side of each fuel inlet aperture to the central cavity and being integral to each fuel inlet aperture; (5) a plurality of air supply channels, the air supply channels located on the cathode side of the distribution frame and the air supply channels extending from the interior side of the air inlet 5 aperture to the central cavity and being integral to the air inlet aperture; and (6) a plurality of air and water outlet channels, the air and water outlet channels located on the cathode side of the distribution frame, the air and water 10 outlet channels extending from the interior side of the air and water outlet aperture to the central cavity, and being integral to the air and water outlet aperture; (B) a fuel cell assembly having: 15 (1) an MEA, the MEA having two catalytic active layers, the MEA further having an anode side and a cathode side; (2) a gas diffusion layer, the gas diffusion layer having a top face and a bottom face, the bottom 20 face of the gas diffusion layer juxtaposed to the anode side of the MEA; (3) a gas and liquid diffusion layer, the gas and liquid diffusion layer having a top face and a bottom face, the top face of the gas and liquid diffusion 25 layer juxtaposed to the cathode side of the MEA; (4) an anode gas flow field comprising a three- dimensional open-cell foamed structure suitable for gas diffusion, the anode gas flow field juxtaposed to the top face of the gas diffusion 30 layer; and (5) a cathode gas and liquid flow field comprising a three-dimensional open-cell foamed structure suitable for gas and liquid diffusion, the cathode gas and liquid flow field juxtaposed to the bottom face of the gas and liquid diffusion layer; the fuel cell assembly being located within and integral to the central cavity of the distribution frame, and being located such that the gas and liquid flow field is contiguous to the air supply channels and the air and water outlet channels so as to form an edge-on connection with the air supply channels and the air and water outlet channels, and located such that the gas flow field is contiguous to the fuel supply channels so as to form an edge-on connection with the fuel supply channels; and (iii) a compression assembly; (b) conveying hydrogen to the fuel cell stack; (c) and conveying air to the fuel cell stack; and (d) generating electricity via an electrochemical reaction using the fuel cell stack.

Inventors: KING GEORGE R, KING, GEORGE, R.
Applicants: RELIANT ENERGY POWER SYSTEMS I, RELIANT ENERGY POWER SYSTEMS, INC.
Application year: 2001
Main classification: H01M8
IPC codes: H01M8