US5773162A — Direct methanol feed fuel cell and system

Claim 1

Independent Claim 63 words

A method of forming a material for a fuel cell, comprising: forming a solution of platinum, ruthenium, and an extra material which maintains a separation between the platinum and the ruthenium; mixing said solution; operating on said solution, said operating including at least heating said solution; and after said operating, further operating on said solution in a way to remove the extra material.

Claim 2

Independent Claim 63 words

A method of forming a material for a fuel cell, comprising: forming a solution of platinum, ruthenium, and an extra material which maintains a separation between the platinum and the ruthenium; mixing said solution; operating on said solution, said operating including at least heating said solution; and after said operating, further operating on said solution in a way to remove the extra material.

Claim 3

Dependent Claim 19 words

Method as in claim 1, wherein said extra material includes chlorides, and said further operating includes washing the material.

Claim 4

Dependent Claim 51 words

Method as in claim 2, wherein said forming a solution comprises forming a slurry of platinum salts and ruthenium salts in hydrochloric acid, said slurry including a chloroplatinic acid hexahydrate salt and a ruthenium salt K 2 RuCl 5 ·H 2 O, and stirring said slurry to obtain a homogeneous mixture.

Claim 5

Dependent Claim 21 words

A method as in claim 1, wherein said forming a solution further comprises adding sodium carbonate while maintaining a specified pH.

Claim 6

Dependent Claim 23 words

A method as in claim 1, further comprising replacing at least some of the ruthenium with a material that has characteristics like ruthenium.

Claim 7

Dependent Claim 23 words

A method as in claim 5, wherein said material that has characteristics like ruthenium is one of iridium, titanium, osmium, chromium and/or manganese.

Claim 8

Dependent Claim 23 words

A method as in claim 1, further comprising replacing at least some of the platinum with a material that has characteristics like platinum.

Claim 9

Dependent Claim 26 words

A method as in claim 7, wherein said material that has characteristics like platinum is at least one of palladium, tungsten, rhodium, iron, cobalt, and/or nickel.

Claim 10

Independent Claim 47 words

A method of forming a fuel cell electrode, comprising: obtaining a backing material; treating said backing material with a waterproofing solution, while limiting an amount of waterproofing impregnation into the material, said limiting said material in an amount effective to render the material wettable but not porous.

Claim 11

Independent Claim 47 words

A method of forming a fuel cell electrode, comprising: obtaining a backing material; treating said backing material with a waterproofing solution, while limiting an amount of waterproofing impregnation into the material, said limiting said material in an amount effective to render the material wettable but not porous.

Claim 12

Dependent Claim 19 words

A method as in claim 9, wherein said backing material is carbon paper, and said waterproofing solution is Teflon.

Claim 13

Dependent Claim 34 words

A method as in claim 10, wherein said treating comprises: forming a Teflon solution, and dipping the carbon paper into the Teflon solution while making minimal contact with any surface of the carbon paper.

Claim 14

Dependent Claim 18 words

A method as in claim 11, wherein said dipping comprises holding the carbon paper with Teflon coated tweezers.

Claim 15

Dependent Claim 14 words

A method as in claim 10, further comprising drying the treated carbon paper backing.

Claim 16

Dependent Claim 16 words

A method as in claim 13, wherein said drying comprises laying the backing material across supports.

Claim 17

Dependent Claim 16 words

A method as in claim 14, wherein said supports are Teflon coated wires with kinks therein.

Claim 18

Dependent Claim 38 words

A method as in claim 13, further comprising weighing the dried paper, and determining if sufficient Teflon has been added from an amount of weight gain of the dried paper relative to an original weight of the paper.

Claim 19

Independent Claim 40 words

A method of forming a fuel cell comprising: obtaining catalyst materials; mixing said catalyst materials with an ionomer and with a water repelling material to form a mixed catalyst material; and applying the mixed material to an electrode backing material.

Claim 20

Independent Claim 40 words

A method of forming a fuel cell comprising: obtaining catalyst materials; mixing said catalyst materials with an ionomer and with a water repelling material to form a mixed catalyst material; and applying the mixed material to an electrode backing material.

Claim 21

Dependent Claim 25 words

A method as in claim 17, wherein said mixing comprises first mixing the catalyst materials with the water repelling material, and then adding the ionomer.

Claim 22

Dependent Claim 18 words

A method as in claim 18, wherein water repelling material is PTFE, and said ionomer is liquid nafion.

Claim 23

Independent Claim 66 words

A method of forming a porous electrode for a fuel cell, comprising: sputtering a mixture of a first catalyst material and a second material onto a backing to form a combined sputtered material of said first material and said second material; and washing away said second material using a washing element that does not remove said first material, to leave said first material with pores therebetween.

Claim 24

Independent Claim 66 words

A method of forming a porous electrode for a fuel cell, comprising: sputtering a mixture of a first catalyst material and a second material onto a backing to form a combined sputtered material of said first material and said second material; and washing away said second material using a washing element that does not remove said first material, to leave said first material with pores therebetween.

Claim 25

Dependent Claim 25 words

A method as in claim 20 wherein said second material is an aluminum material, and said washing technique uses KOH to remove said aluminum material.

Claim 26

Dependent Claim 14 words

A method as in claim 21, wherein said first material is a platinum-containing material.

Claim 27

Independent Claim 107 words

A method of forming a membrane electrode assembly, comprising: forming a stack including an anode electrode that has an appropriate fuel cell catalyst thereon, a proton conducting solid electrolyte member, and a cathode electrode including an appropriate fuel cell catalyst thereon; and heating and pressing the stack by an amount which is effective to bond the materials into a bonded membrane electrode assembly, by first pressing the stack between elements of a pressing machine, then, some time after said first pressing, heating the stack while maintaining pressure thereon by said pressing, and then, some time after said heating under pressure, cooling the stack while maintaining the pressure.

Claim 28

Independent Claim 107 words

A method of forming a membrane electrode assembly, comprising: forming a stack including an anode electrode that has an appropriate fuel cell catalyst thereon, a proton conducting solid electrolyte member, and a cathode electrode including an appropriate fuel cell catalyst thereon; and heating and pressing the stack by an amount which is effective to bond the materials into a bonded membrane electrode assembly, by first pressing the stack between elements of a pressing machine, then, some time after said first pressing, heating the stack while maintaining pressure thereon by said pressing, and then, some time after said heating under pressure, cooling the stack while maintaining the pressure.

Claim 29

Dependent Claim 29 words

A method as in claim 23, wherein said first pressing comprises pressing the materials to between 1000 and 1500 psi, said heating comprises increasing the heat to 140°-150° C.

Claim 30

Dependent Claim 151 words

A fuel cell comprising: at least anode and cathode electrodes; a fuel supply conduit; and a flow field element, operating to supply fuel from said fuel supply conduit to at least one of said anode and cathode electrodes, said flow field element being pressed against said one electrode, and comprising a plurality of island areas, each having a pressing surface and side surfaces, the pressing surface pressed against said one electrode, and a flow field area surrounding said side areas, said flow field in communication with said fuel supply conduit, wherein said fuel supply conduit includes at least one opening to the flow field which extends in a direction and supplies the fuel to the flow field in said direction, said direction extending in a line which directly intersects one of said side surfaces, such that said fuel supply conduit supplies the fuel directly against said one of said side surfaces.

Claim 31

Dependent Claim 151 words

A fuel cell comprising: at least anode and cathode electrodes; a fuel supply conduit; and a flow field element, operating to supply fuel from said fuel supply conduit to at least one of said anode and cathode electrodes, said flow field element being pressed against said one electrode, and comprising a plurality of island areas, each having a pressing surface and side surfaces, the pressing surface pressed against said one electrode, and a flow field area surrounding said side areas, said flow field in communication with said fuel supply conduit, wherein said fuel supply conduit includes at least one opening to the flow field which extends in a direction and supplies the fuel to the flow field in said direction, said direction extending in a line which directly intersects one of said side surfaces, such that said fuel supply conduit supplies the fuel directly against said one of said side surfaces.

Claim 32

Dependent Claim 42 words

A fuel cell as in claim 25, wherein said island areas are rectangular, and have a long axis which is parallel to said direction, and said fuel is supplied directly to one of said side surfaces which extends perpendicular to said direction.

Claim 33

Dependent Claim 33 words

A fuel cell as in claim 26, wherein said fuel supply conduit includes a plurality of nozzles, all extending in said direction and all supplying fuel directly against one of said side surfaces.

Claim 34

Independent Claim 89 words

A method of supplying fuel to an electrode of a type that requires pressure thereagainst, comprising: pressing a flow field element against the electrode, said flow field element comprising a plurality of island areas, each having a pressing surface having a top surface and side surfaces, the pressing surface top surface pressed against said one electrode, and a flow field area surrounding said side areas, and supplying fuel directly against one of said side surfaces of one of said flow field elements to increase turbulence in the fuel flow.

Claim 35

Independent Claim 89 words

A method of supplying fuel to an electrode of a type that requires pressure thereagainst, comprising: pressing a flow field element against the electrode, said flow field element comprising a plurality of island areas, each having a pressing surface having a top surface and side surfaces, the pressing surface top surface pressed against said one electrode, and a flow field area surrounding said side areas, and supplying fuel directly against one of said side surfaces of one of said flow field elements to increase turbulence in the fuel flow.

Claim 36

Dependent Claim 68 words

A fuel cell comprising: at least anode and cathode electrodes; means for supplying fuel; and a flow field element, operating to supply fuel from said fuel supplying means to at least one of said anode and cathode electrodes, said flow field element being pressed against said one electrode, and comprising a plurality of island areas, said flow field element further comprising means for agitating turbulence in said fuel.

Claim 37

Dependent Claim 68 words

A fuel cell comprising: at least anode and cathode electrodes; means for supplying fuel; and a flow field element, operating to supply fuel from said fuel supplying means to at least one of said anode and cathode electrodes, said flow field element being pressed against said one electrode, and comprising a plurality of island areas, said flow field element further comprising means for agitating turbulence in said fuel.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2001-06-29	2001-12-29	2002-06-30	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2005-06-29	2005-12-29	2006-06-30	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2009-06-29	2009-12-29	2010-06-30	$7700.00	Window Closed / Lapsed

Direct methanol feed fuel cell and system

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