U.S. patent application number 12/053366 was filed with the patent office on 2008-12-18 for fluid manifold and method therefor.
This patent application is currently assigned to Angstrom Power Inc.. Invention is credited to Jeremy Schrooten, Paul Sobejko, Joerg Zimmermann.
Application Number | 20080311458 12/053366 |
Document ID | / |
Family ID | 39765335 |
Filed Date | 2008-12-18 |
United States Patent
Application |
20080311458 |
Kind Code |
A1 |
Schrooten; Jeremy ; et
al. |
December 18, 2008 |
FLUID MANIFOLD AND METHOD THEREFOR
Abstract
A electrochemical cell system includes a fluid manifold having a
layered structure. The fluid manifold includes at least one conduit
layer having a first side and a second side. The at least one
conduit layer has at least one conduit channel.
Inventors: |
Schrooten; Jeremy; (Mission,
CA) ; Sobejko; Paul; (North Vancouver, CA) ;
Zimmermann; Joerg; (Vancouver, CA) |
Correspondence
Address: |
SCHWEGMAN, LUNDBERG & WOESSNER, P.A.
P.O. BOX 2938
MINNEAPOLIS
MN
55402
US
|
Assignee: |
Angstrom Power Inc.
North Vancouver
BC
|
Family ID: |
39765335 |
Appl. No.: |
12/053366 |
Filed: |
March 21, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60919472 |
Mar 21, 2007 |
|
|
|
Current U.S.
Class: |
429/443 ; 137/7;
137/833 |
Current CPC
Class: |
H01M 8/0271 20130101;
Y02B 90/10 20130101; Y02E 60/50 20130101; Y10T 137/2224 20150401;
H01M 2250/30 20130101; H01M 8/026 20130101; H01M 8/0258 20130101;
H01M 8/2483 20160201; H01M 8/2485 20130101; H01M 8/04201 20130101;
Y10T 137/0352 20150401 |
Class at
Publication: |
429/34 ; 137/833;
137/7 |
International
Class: |
H01M 8/04 20060101
H01M008/04; F15C 4/00 20060101 F15C004/00 |
Claims
1. A manifold comprising: two or more featured layers including a
conduit layer; and the conduit layer having a plurality of conduit
channels therein, the plurality of conduit channels disposed
adjacent to one another within a single featured layer.
2. The manifold as recited in claim 1, wherein the featured layers
have a bend radius of no less than about twice a thickness of a
single featured layer.
3. The manifold as recited in claim 2, wherein the thickness is
less than 1 mm to 200 microns.
4. The manifold as recited in claim 1, further comprising at least
one barrier layer, the at least one barrier layer defining a
portion of the conduit channels.
5. The manifold as recited in claim 1, wherein one or more of the
featured layers define a port fluidly coupled with at least one of
the conduit channels.
6. The manifold as recited in claim 1, wherein the featured layers
form a thin flexible layer, and have a bend radius of about 1-5
mm.
7. The manifold as recited in claim 1, wherein at least one of the
conduit channels extends only partially within one of the featured
layers.
8. The manifold as recited in claim 1, wherein a first side of one
of the featured layers has at least one first partial recess
therein, and an opposite second side of the featured layer has at
least one second partial recess therein.
9. The manifold as recited in claim 8, wherein the at least one
first partial recess is fluidly coupled with the at least one
second partial recess.
10. The manifold as recited in claim 1, wherein the featured layers
are stacked and bonded together.
11. The manifold as recited in claim 1, wherein the featured layers
have a gas-tight seal with one another.
12. The manifold as recited in claim 1, wherein one or more of the
conduit channels includes a porous substrate therein.
13. The manifold as recited in claim 1, wherein the conduit
channels have a channel dimension, and the manifold has a manifold
width, where the manifold width is about 20 to 30 times the channel
dimension.
14. An electrochemical cell system comprising: at least one fuel
cell; at least one fluid manifold fluidly coupled with the at least
one fuel cell; and the at least one fluid manifold including two or
more featured layers including at least one conduit layer, each
conduit layer having one or more conduit channel.
15. The electrochemical cell system as recited in claim 14, further
comprising a fluid enclosure communicatively coupled with the at
least one fuel cell.
16. The electrochemical cell system as recited in claim 14, further
comprising one or more strain absorbing interfaces between and in
contact with at least one fluid enclosure and at least one of the
featured layers.
17. The electrochemical cell system as recited in claim 14, wherein
the at least one fluid manifold is a fuel manifold.
18. The electrochemical cell system as recited in claim 14, wherein
the at least one fluid manifold includes one or more of a heat
transfer manifold, an oxidant manifold, or a water removal
manifold.
19. The electrochemical cell system as recited in claim 14, further
comprising at least one barrier layer, the at least one barrier
layer coupled with the conduit layer, the at least one barrier
layer defining a portion of the conduit.
20. The electrochemical cell system as recited in claim 14, wherein
any one of the featured layers includes a feedback channel fluidly
coupled to a fluid plenum of the fuel cell.
21. The electrochemical cell system as recited in claim 14, wherein
the at least one fluid manifold interfaces with and has an adhesive
bond with one or more components of the electrochemical cell
system.
22. The electrochemical cell system as recited in claim 21, wherein
a bond strength of the adhesive bond is lower than an internal
pressure of the at least one fluid manifold.
23. The electrochemical cell system as recited in claim 14, wherein
the at least one fluid manifold interfaces with one or more of a
charge port, or a fluidic control system.
24. A method comprising: introducing fluid into a fluid manifold,
the manifold including two or more featured layers each having a
plurality of conduit channels; and flowing fluid through the
conduit channels.
25. The method as recited in claim 24, further comprising providing
fuel to a fuel cell, where the fluid manifold is fluidly coupled
with the fuel cell.
26. The method as recited in claim 24, wherein flowing fluid
includes flowing fluid from a first layer recess of a first conduit
layer to a second layer recess of a second conduit layer.
27. The method as recited in claim 24, wherein flowing fluid
through the conduit channels includes flowing fluid through a
porous substrate within at least one of the one or more conduit
channels.
28. The method as recited in claim 24, wherein flowing fluid
through the conduit channels includes providing a heat transfer
fluid to a electrochemical cell system through the conduit
channels.
29. The method as recited in claim 24, wherein flowing fluid
through the conduit channels includes providing oxidant to a
electrochemical cell system through the conduit channels or
removing water from the electrochemical cell system through the
conduit channels.
30. The method as recited in claim 24, wherein flowing fluid
through one or more conduit channels includes flowing fluid along a
partially recessed channel in the conduit layer.
31. The method as recited in claim 24, wherein flowing fluid
through one or more conduit channels includes directing material
along a first partial channel in the first side and along a second
partial channel in the second side.
32. The method as recited in claim 24, further comprising fluidly
coupling the fluid manifold with a charge port.
33. The method as recited in claim 24, further comprising fluidly
coupling the fluid manifold with a fluid enclosure.
34. The method as recited in claim 24, further comprising
distributing fluid on two or more layers via at least a first
flowpath, the first flowpath extending from a first featured layer
to a second featured layer, and returning from the second featured
layer to the first featured layer.
35. The method as recited in claim 24, wherein flowing includes
flowing a gas through the conduit channels.
36. The method as recited in claim 24, further comprising forming a
fluidic connection between components, the method including a use
of adhesive couplings of primarily planar faces.
37. A manifold comprising: two or more featured layers including
two or more non-restrictive conduit layers including a first
conduit layer and a second conduit layer; the first and second
conduit layers each having at least one conduit channel; and the
first conduit layer stacked with the second conduit layer.
38. The manifold as recited in claim 37, wherein the at least one
conduit channel is a gas conduit channel.
39 The manifold as recited in claim 37, further comprising a first
flowpath distributing fluid on two or more layers, the first flow
path extending from a first featured layer to a second featured
layer.
40. The manifold as recited in claim 37, wherein the flow path
returns from the second featured layer to the first featured
layer.
41. The manifold as recited in claim 37, wherein the first flow
path circumnavigates a second flow path.
42 The manifold as recited in claim 37, wherein the at least one
conduit channel is a delivery channel.
43. The manifold as recited in claim 37, wherein the at least one
conduit channel is a feedback channel.
Description
TECHNICAL FIELD
[0001] The present document relates to fluid management technology.
More specifically, it relates to a fluid manifold.
BACKGROUND
[0002] Trends in technology are progressing towards smaller scales
for systems in a variety of applications. Fluidic systems can be
integrated within restrictive form factors imposed by the system to
manipulate the transport of fluid. For example, flow-modulating
components can be arranged for functions such as reactant delivery,
heat transfer, and dosing of fluids.
[0003] Electronic components, such as personal electronic devices,
are trending to become smaller in size. As electronic components
are designed in smaller in size and incorporate sophisticated and
complex technology, the demands on the power supply become greater.
For instance, the power supply may need to occupy less volume or a
smaller footprint to accommodate the addition of the technology to
the device. The additional technology may also require that the
power supply last for longer periods of time. In addition, portable
electronic device may need to have energy storage maintained while
the power supply shrinks.
[0004] An example of a power supply for the electronic components
is a electrochemical cell system. In order to make a smaller
electrochemical cell system, many individual components of the
system, such as a fluid delivery component can be made smaller, but
need to meet the technical requirements of the electrochemical cell
system. For instance, the fluid delivery component may need to
maintain a certain pressure, without occupying an overall
significant volume of the electrochemical cell system, and without
interfering with the assembly of the electrochemical cell system.
Furthermore, the functionality of the electrochemical cell system
must not be compromised.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1A illustrates an exploded view of a electrochemical
cell system as constructed in accordance with at least one
embodiment.
[0006] FIG. 1B illustrates a block diagram of a electrochemical
cell system in accordance with at least one embodiment.
[0007] FIG. 2 illustrates an exploded perspective view of a fluid
manifold as constructed in accordance with at least one
embodiment.
[0008] FIG. 3A illustrates a cross-sectional view of a conduit
layer as constructed in accordance with at least one
embodiment.
[0009] FIG. 3B illustrates a cross-sectional view of a conduit
layer as constructed in accordance with at least one
embodiment.
[0010] FIG. 3C illustrates a cross-sectional view of a conduit
layer as constructed in accordance with at least one
embodiment.
[0011] FIG. 4 illustrates an exploded perspective view of a fluid
manifold as constructed in accordance with at least one
embodiment.
[0012] FIG. 5 illustrates an exploded perspective view of a fluid
manifold as constructed in accordance with at least one
embodiment.
[0013] FIG. 6 illustrates a view of an enclosure with an interface
as constructed in accordance with at least one embodiment.
[0014] FIG. 7 illustrates a side view of an enclosure with an
interface as constructed in accordance with at least one
embodiment.
DETAILED DESCRIPTION
[0015] The following detailed description includes references to
the accompanying drawings, which form a part of the detailed
description. The drawings show, by way of illustration, specific
embodiments in which the fluid manifold and fuel cell fuel systems
and methods may be practiced. These embodiments, which are also
referred to herein as "examples" or "options," are described in
enough detail to enable those skilled in the art to practice the
present invention. The embodiments may be combined, other
embodiments may be utilized or structural or logical changes may be
made without departing from the scope of the invention. The
following detailed description is, therefore, not to be taken in a
limiting sense and the scope of the invention is defined by the
appended claims and their legal equivalents.
[0016] In this document, the terms "a" or "an" are used to include
one or more than one, and the term "or" is used to refer to a
nonexclusive "or" unless otherwise indicated. In addition, it is to
be understood that the phraseology or terminology employed herein,
and not otherwise defined, is for the purpose of description only
and not of limitation.
[0017] A fluid manifold is provided herein. In the following
examples, a fuel manifold for a electrochemical cell system is
discussed. However, the fluid manifold is not necessarily so
limited and can be used in other types of fluidic control systems
or other types of systems in need of fluid management. For
instance, the fluid manifold can be used to deliver or remove other
types of fluids, including, but not limited to water, oxidant, or a
heat transfer fluid. For instance, the fluid manifold includes, but
is not limited to, a fuel manifold, a heat transfer manifold, an
oxidant manifold, or a water removal manifold.
Definitions
[0018] As used herein, "fluid" refers to a continuous, amorphous
substance whose molecules move freely past one another and that has
the tendency to assume the shape of its container. A fluid may be a
gas, liquefied gas, liquid or liquid under pressure. Examples of
fluids may include fluid reactants, fuels, oxidants, and heat
transfer fluids. Fluid fuels used in fuel cells may include
hydrogen gas or liquid and hydrogen carriers in any suitable fluid
form. Examples of fluids include air, oxygen, water, hydrogen,
alcohols such as methanol and ethanol, ammonia and ammonia
derivatives such as amines and hydrazine, silanes such as disilane,
trisilane, disilabutane, complex metal hydride compounds such as
aluminum borohydride, boranes such as diborane, hydrocarbons such
as cyclohexane, carbazoles such as dodecahydro-n-ethyl carbazole,
and other saturated cyclic, polycyclic hydrocarbons, saturated
amino boranes such as cyclotriborazane, butane, borohydride
compounds such as sodium and potassium borohydrides, and formic
acid.
[0019] As used herein, "fluid enclosure" may refer to a device for
storing a fluid. The fluid enclosure may store a fluid physically
or chemically. For example, the fluid enclosure may chemically
store a fluid in active material particles.
[0020] As used herein, "active material particles" refer to
material particles capable of storing hydrogen or other fluids or
to material particles that may occlude and desorb hydrogen or
another fluid. Active material particles may include fluid-storing
materials that occlude fluid, such as hydrogen, by chemisorption,
physisorption or a combination thereof. Some hydrogen-storing
materials desorb hydrogen in response to stimuli, such as change in
temperature, change in heat or a change in pressure. Examples of
hydrogen-storing materials that release hydrogen in response to
stimuli, include metal hydrides, chemical hydrides, suitable
micro-ceramics, nano-ceramics, boron nitride nanotubes, metal
organic frameworks, palladium-containing materials, zeolites,
silicas, aluminas, graphite, and carbon-based reversible
fluid-storing materials such as suitable carbon nanotubes, carbon
fibers, carbon aerogels, and activated carbon, nano-structured
carbons or any combination thereof. The particles may also include
a metal, a metal alloy, a metal compound capable of forming a metal
hydride when in contact with hydrogen, alloys thereof or
combinations thereof. The active material particles may include
magnesium, lithium, aluminum, calcium, boron, carbon, silicon,
transition metals, lanthanides, intermetallic compounds, solid
solutions thereof, or combinations thereof.
[0021] As used herein, "metal hydrides" may include a metal, metal
alloy or metal compound capable of forming a metal hydride when in
contact with hydrogen. Metal hydride compounds can be generally
represented as follows: AB, AB.sub.2, A.sub.2B, AB.sub.5 and BCC,
respectively. When bound with hydrogen, these compounds form metal
hydride complexes.
[0022] As used herein, "occlude" or "occluding" or "occlusion"
refers to absorbing or adsorbing and retaining a substance, such as
a fluid. Hydrogen may be a fluid occluded, for example. The fluid
may be occluded chemically or physically, such as by chemisorption
or physisorption, for example.
[0023] As used herein, "desorb" or "desorbing" or "desorption"
refers to the removal of an absorbed or adsorbed substance.
Hydrogen may be removed from active material particles, for
example. The hydrogen or other fluid may be bound physically or
chemically, for example. As used herein, "contacting" refers to
physically, chemically, electrically touching or within
sufficiently close proximity. A fluid may contact an enclosure, in
which the fluid is physically forced inside the enclosure, for
example.
[0024] As used herein, "composite fluid storage material" refers to
active material particles mixed with a binder, wherein the binder
immobilizes the active material particles sufficient to maintain
relative spatial relationships between the active material
particles. Examples of composite fluid storage materials are found
in commonly-owned U.S. patent application Ser. No. 11/379,970,
filed Apr. 24, 2006, whose disclosure is incorporated by reference
herein in its entirety. An example of a composite fluid storage
material is a composite hydrogen storage material.
[0025] Referring to FIG. 1, an example of an electrochemical cell
system, such as a electrochemical cell system 100 is shown.
Although the term electrochemical cell system is used herein, it
should be noted that the system can be used for any electrochemical
cell system. The electrochemical cell system 100 includes one or
more of a fuel cell 102, a fuel cell fuel system 104, a charge port
106, and fuel storage 108. The fuel cell fuel system 104 includes a
layered structure including, but not limited to, at least one
pressure regulator, at least one check valve, at least one flow
valve. In an option, the at least one pressure regulator, the at
least one check valve, at least one flow valve 106 include featured
layers that are stacked together and operatively interact together,
for example as discussed in co-pending application entitled
"FLUIDIC CONTROL SYSTEM AND METHOD OF MANUFACTURE", filed even date
herewith, having attorney docket number 2269.061US1, and is
incorporated herein by reference in its entirety. The
electrochemical cell system 100 further includes a manifold 118,
such as a fuel manifold 120 fluidly coupled with a fluid enclosure
114, such as the fuel storage 108. The manifold 118 is also fluidly
coupled with the fuel cell 102. The fluid coupling for the fuel
manifold and the fuel storage can include, but is not limited to
compression seals, adhesive bonds, or solder connections. Although
a fuel manifold is discussed as an example, the manifold can also
be used to distribute, deliver, or remove other types of fluids,
such as, but not limited to water, oxidant, or a cooling fluid.
[0026] Devices for detachably coupling the fluid coupling, such as
a pressure activated valve, can be used. For example, pressure
activated one-way valve allows a flow of fluid, for example, fluid
fuel, into a fluid enclosure for a fuel storage system. The flow of
fuel is allowed into a fluid reservoir during refueling, but does
not allow fuel to flow back out of the fuel reservoir. In an
option, flow of fuel is permitted to flow back out of the fluid
reservoir if the fluid reservoir is over pressurized with fuel.
[0027] An external refueling device can form a seal against a
portion of the sealing surface, for example, around the inlet port
with a seal, such as an o-ring or gasket. Fuel is introduced into
the fluid control system, and the fluidic pressure of the fuel
compresses the compressible member and breaks the seal between the
compressible member and the outside cover. In another option, an
environment surrounding the exterior of the outside cover may be
pressurized with fuel to force fuel through the refueling valve
assembly and into the fuel reservoir.
[0028] When the fueling process is complete, the refueling fixture
is removed from the valve assembly, and the valve becomes closed.
For example, the compressible member decompresses, and fluidic
pressure from the fuel reservoir through the fuel outlet port
exerts pressure on to the compressible member and presses the
compressible member against the outside cover. The decompression of
the compressible member and/or the fluid pressure from the
reservoir creates a seal between the compressible member and the
outside cover such that fuel does not flow past the compressible
member and into the fuel inlet port. In another option, the
compressible member and/or the fluid diffusion member can be
designed to intentionally fail if the pressure in the fuel
reservoir becomes too great, or greater than a predetermine amount.
Additional examples and details of valves can be found in commonly
owned co-pending patent application entitled REFUELING VALVE FOR A
FUEL STORAGE SYSTEM AND METHOD THEREFOR, filed on Jan. 9, 2007,
having Ser. No. 11/621,542, and attorney docket no. 2269.003US1,
which is incorporated by reference in its entirety.
[0029] In another option, a fluid coupling assembly can be used to
couple the system with another component. The coupling assembly
includes a first coupling member, a second coupling member, and a
seal member therebetween. The first coupling member and the second
coupling member are magnetically engagable, such as by way of a
first magnetic member and a second magnetic member having attracted
polarities. The engagement of the first coupling member and the
second coupling member opens a fluid flow path therebetween. When
the coupling members are disengaged, this fluid flow path is
sealed. Additional examples and details can be found in commonly
owned co-pending entitled MAGNETIC FLUID COUPLING ASSEMBLIES AND
METHODS, filed Nov. 7, 2007, having Ser. No. 11/936,662, and having
attorney docket no. 2269.056US1, which is incorporated herein by
reference in its entirety.
[0030] In a further option, the system includes a strain absorbing
interface 404 for contacting the fluid enclosure. For instance, the
interface is used for a rigid or semi-rigid component and a
flexible fluid enclosure. The interface absorbs any strain due to
dimensional changes in the fluid enclosure as it charges with
hydrogen. Rigid components, such as mounts or fluidic devices for
fuel cell communication, can be coupled to the fluid enclosure
through the flexible interface and not risk sheering due to
mechanical stress. The flexible interface allows for more component
configurations and applications for use with a flexible fluid
enclosure. The flexible interface absorbs strain and supports the
connection between component and enclosure. Additional examples and
details can be found in commonly owned co-pending patent
application entitled INTERFACE FOR FLEXIBLE FLUID ENCLOSURES, filed
even date herewith, having Ser. No. ______, and having attorney
docket no. 2269.063US1, which is incorporated herein by reference
in its entirety.
[0031] Referring to FIG. 6, a cross-sectional view of a flexible
fluid enclosure interface system 400 is shown, according to some
embodiments. The system 400 includes a flexible fluid enclosure 406
in contact with a strain absorbing interface 404 on a first side.
On a second side, the interface 404 may be in contact with a
featured layer 402. The featured layer may include a plurality of
featured layers, or one or more featured layers that collectively
form a functional control system component. An optional fluidic
connection 408 may be positioned in the interface 404, connecting
the enclosure 406 and featured layer 402.
[0032] The fluid enclosure may be flexible. For example, a flexible
fluid enclosure may include a flexible liner for storing a fluid.
The fluid enclosure can include fuel cartridges, such as
replaceable fuel cartridges, dispenser cartridges, disposable fuel
ampoules, refillable fuel tanks or fuel cell cartridges, for
example. The fuel cartridge may include a flexible liner that is
connectable to a fuel cell or fuel cell layer. The fuel cartridge
may also include a connecting valve for connecting the cartridge to
a fuel cell, fuel cell layer or refilling device. The fluid
enclosure 406 may be an enclosure formed by conformably coupling an
outer wall to a composite hydrogen storage material, for
example.
[0033] Conformably coupled refers to forming a bond that is
substantially uniform between two components and are attached in
such as way as to chemically or physically bind in a corresponding
shape or form. A structural filler or composite hydrogen storage
material may be conformably coupled to an outer enclosure wall, for
example, in which the outer enclosure wall chemically or physically
binds to the structural filler or composite hydrogen storage
material and takes its shape. The outer enclosure wall is the
outermost layer within a fluid enclosure that serves to at least
partially slow the diffusion of a fluid from the enclosure. The
outer enclosure wall may include multiple layers of the same or
differing materials. The outer enclosure wall may include a polymer
or a metal, for example. The fluid may be hydrogen, for example.
Examples of such enclosures may be found in commonly owned U.S.
patent application Ser. No. 11/473,591, filed Jun. 23, 2006.
[0034] The strain absorbing interface 404 may be manufactured of
any suitable material that allows it to be flexible, absorb strain
and bond to the enclosure 406 and featured layer 402. The material
chosen should provide a suitable bond, physical or chemical,
between the featured layer 402 and enclosure 406 and also allow for
the differential in strain between the strain of the enclosure wall
and the rigidity of the featured layer 402, so that the sheer
stress on any bonds does not exceed the strength of such bonds. The
interface 404 may be manufactured of an elastomeric material or
silicon material, for example. Elastomeric materials may include
thermoplastic elastomers, polyurethane thermoplastic elastomers,
polyamides, melt processable rubber, thermoplastic vulcanizate,
synthetic rubber and natural rubber, for example. Examples of
synthetic rubber materials may include nitrile rubber,
fluoroelastomers such as Viton.RTM. rubber (available from E.I.
DuPont de Nemours, a Delaware corporation), ethylene propylene
diene monomer rubber (EPDM rubber), styrene butadiene rubber (SBR),
and Fluorocarbon rubber (FKM).
[0035] As the fluid enclosure 406 is filled with fluid, or charged,
the dimensions of the enclosure 406 increase (see FIG. 7). The
strain absorbing interface 406 may deform or change in dimension,
such as in thickness 412. The strained interface 414 then maintains
a consistent, less stressful contact between the enclosure 406 and
featured layer 402. The featured layer 402 would then undergo
little to no strain, as the interface 414 absorbs strain caused by
the enclosure 406 movements. The interface 414 may absorb all or at
least part of the strain caused by changes in dimension of
enclosure 406.
[0036] The featured layer 402 may be any fitting, mount, connector,
valve, regulator, pressure relief device, planar microfluidic
device, a plate, or any device that might control the flow of a
fluid from the fluid enclosure into or out of the enclosure or
combinations thereof, for example. Examples of fluids include, but
are not limited to, gas, liquefied gas, liquid or liquid under
pressure. Examples of fluids may include fluid reactants, fuels,
oxidants, and heat transfer fluids. Fluid fuels used in fuel cells
may include hydrogen gas or liquid and hydrogen carriers in any
suitable fluid form. Multiple interfaces 404 and multiple featured
layers 402 may be utilized in conjunction with one or more fluid
enclosures 406, where the featured layers form functional
components such as, but not limited to, the fluidic control system,
the manifold, the pressure regulator, the check valve. In another
option, the interfaces 404 can be coupled with an inlet of the
fluidic control system, the fuel cell, or the fluidic
enclosure.
[0037] FIG. 1B illustrates additional examples for the manifold
118. A fuel cell assembly 100 includes a fluid enclosure 114
fluidly coupled with a fluidic controller, such as a pressure
regulator component 116 by a manifold 118. The one or more fluid
control components can include, but are not limited to a fluidic
control system, inlets, outlets, a check valve component, a flow
valve component, a charge valve component, a pressure relief
component, a conduit, an on/off valve, a manual on/off valve, or a
thermal relief component.
[0038] The pressure regulator 116 is fluidly coupled with a fuel
cell 102 via a manifold 118. The manifold 118 includes one or more
conduit channels 130 therein. In a further option, the manifold 118
fluidly coupled with the pressure regulator component 116 and the
fuel cell 102 can further include at least one feedback channel 129
and a delivery channel 133. The delivery channel 133 delivers fluid
such as a fuel to the fuel cell 102. The feedback channel 129
allows for the regulator to be piloted based on the feedback to the
pressure regulator component 116 from pressure in the fuel plenum,
and is fluidly coupled to a fluid plenum of the electrochemical
cell system. Additional examples and details can be found in
commonly owned co-pending patent application entitled FLUIDIC
DISTRIBUTION SYSTEM AND RELATED METHODS, filed even date herewith,
having Ser. No. ______, and having attorney docket no. 2269.067US1,
which is incorporated by reference in its entirety.
[0039] Each of the components of the electrochemical cell system
100 can be formed by the flexible layered structured as discussed
above and below. In a further option, the one or more conduit
channels 130 include a gas conduit channel. Multiple ports,
channels, including conduit channels or delivery channels are
possible, such as shown in FIGS. 5 and 6.
[0040] Referring to FIG. 2, the manifold 118, such as the fuel
manifold 120, includes a layered structure formed of multiple,
thin, flexible featured layers. The layered structure is made
small, nano-fabrication technologies, and/or micro fabrication
technologies can be employed to produce and assemble the layers.
For instance, processes for producing and/or assembling the layers
include, but are not limited to, microfluics application processes,
or chemical vapor deposition for forming a mask, and followed by a
process such as etching. In addition, materials for use in
fabricating the thin layered structure includes, but is not limited
to, silicon, polydimethylsiloxiane, parylene, or combinations
thereof.
[0041] The featured layers include one or more features. In an
option, the featured layers of the layered structure provides a
gas-tight seal such that the featured layers are gas-tight. For
example, a bond is provided with the layers that is impermeable to
a fluid. In another example, the bond may be substantially
impermeable to hydrogen or any other fluid at or below 350 psi or
2.5 MPa. Examples of fluids include, but are not limited to,
hydrogen, methanol, formic acid, butane, borohydrides, water, air,
or combinations thereof. In another option, the bond is
substantially impermeable to fluid at or below 150 psi or 1.03 MPa.
In yet another option, the bond is substantially impermeable to
fluid at or below 15-30 psi or 0.10-0.21 MPa. The layered structure
allows for the manifold to be of a size that does not take up
unnecessary volume, nor an unnecessarily large footprint, yet
allows for the pressure, volume, and temperature requirements for
fuel cell fuel supply systems to be met. The multiple layers can be
coupled together by thermal bonding, adhesives, soldering,
ultrasonic welding, etc.
[0042] The manifold 118 can be made of relatively thin layers of
material, allowing for the manifold 118 to be flexible. In an
option, the manifold 118, and/or the featured layers that make up
the manifold 118, such as, but not limited to the conduit layer 122
and/or the barrier layer, are flexible enough to have a bend radius
of about 1-5 mm. In a further option, the manifold 180, and/or the
featured layers, and/or the conduit layer 122, and/or the barrier
layer have a bend radius of no less than about twice a thickness of
a single featured layer, where the thickness is optionally less
than 1 mm to 200 microns. The flexible manifold can be bent around
components, or wrapped around components, providing greater number
of assembly options for the electrochemical cell system.
[0043] The fluid manifold 118 includes at least one featured layer,
such as a conduit layer 122 defined in part by a first side 124 and
a second side 126. In an option, the at least one conduit layer 122
is relatively thin, for example, compared with the length and
width. In an example, the thickness of the at least one conduit
layer 122 is generally less than about 1 mm. In another example,
the thickness of the at least one conduit layer 122 is about 5
.mu.m-1 mm. In an example, the width and length of the layer 122 is
about 1 mm and 100 mm, respectively. In another example, the
thickness of the at least one conduit layer 122 is about 100 .mu.m,
and the width and length of the layer 122 is about 1 mm and 1.5 mm,
respectively. The width and/or the length can be altered for
geometry of the system in which the manifold 118 is installed.
[0044] In a further option, the thickness of the layer is about
10-500 micron, and a dimension of the conduit channel, such as a
height or a width or a channel depth, is about 50 micron to 1 mm.
The layer is highly planar such that a width of the manifold is
greater than about thirty times the dimension of the conduit
channel. In another option, the width of the planar portion of the
manifold is greater than three times the dimension of the conduit
channel.
[0045] The at least one conduit layer 122 includes at least one
conduit channel 130 therein. In an option, the conduit layer 122
includes a plurality of conduit channels 130 in the conduit layer
122, and in a further option, in each of the conduit layers 122.
The plurality of conduit channels 130 are disposed adjacent one
another in a single layer. The at least one conduit channel 130 can
also be a recess or a partial recess or channel, and is a conduit
channel that allows for material such as a fluid to flows
therethrough. The at least one conduit channel 130, in an option,
extends through the conduit layer 122, from the first side 124 to
the second side 126, as shown in FIG. 2 and FIG. 3A. In another
option, the at least one conduit channel 130 extends only partially
within a side of the conduit layer 122, as shown in FIG. 3B. In yet
another option, the conduit layer 122 includes two or more conduit
channels 130, within a single conduit layer. For example, two or
more conduit channels 130 which extend from the first side 124 to
the second side 126 can be disposed within the conduit layer 122,
as shown in FIG. 4. The two or more conduit channels 130 can
include recesses that extend partially within a side of the conduit
layer 122 (FIG. 3B) and/or the conduit channels 130 can extend
through the layer 122 (i.e. from the first side 124 and through the
second side 126). The conduit channels 130 that extend partially
within the featured layer, optionally can be fluidly coupled with
one another.
[0046] The two or more conduit channels 130 can be formed within
the featured layer such as the conduit layer 122 such that they do
not intersect with one another in the conduit layer 122.
Alternatively, the two of more conduit channels 130 can be formed
within featured layer such as the conduit layer 122 such that they
do intersect with one another or are fluidly coupled in the conduit
layer 122. The conduit channel 130 extends along the conduit layer
122, and allows for material such as fluid or fuel to flow
therethrough. In an option, the conduit channels 130 and/or ports
are sized and positioned so that flow therethrough is
non-restrictive, which can be combined with any of the embodiments
discussed above or below. For example, the conduit channels 130
and/or ports are sized similarly throughout the manifold so that
flow therethrough is not restricted by changing the cross-sectional
size of the channels or ports. In a further option, the conduit
channels are delivery channels, where the channels deliver fluid
such as a fuel. In a further option, the conduit channels include a
feedback channel, for example for varying actuation of a regulator
based on the pressure in a fuel cell fuel plenum. In yet another
option, the conduit channel is a gas conduit channel.
[0047] In a further option, the conduit channel includes a channel
having a surface allowing for non-restrictive flow. For example,
the conduit channel has a surface roughness that is 1/50.sup.th of
the hydraulic diameter of the channel. In a further option, the
fluid for the conduit channel includes a gas, such as a low
viscosity fluid that reduces inhibitive capabilities of the
channels, including, but not limited to, hydrogen.
[0048] In another option, a conduit channel such as a first recess
132 can be formed on the first side 124 of the conduit layer 122,
and a second recess 134 can be formed on the second side 126 of the
conduit layer 122, where the first recess 132 and the second recess
134 do not necessarily extend from the first side 124 through to
the second side 126. In an example shown in FIG. 3C, the partial
conduit channels or recesses 136 are disposed on opposite sides of
the conduit layer 122, allowing for material to travel therethrough
via the recesses on the first side 124 and the second side 126.
[0049] The conduit layer 122, in another option, is formed of
metals, plastics, elastomers, or composites, or a combination
thereof. The at least one conduit channel 130 is formed within
and/or through the layer 122, in an option. For example, the at
least one conduit channel 130 can be etched or stamped on, within
and/or through the layer 122. In another option, the at least one
conduit channel 130 can be drilled within and/or through the layer,
formed with a laser, molded in the layer 122, die cutting the layer
122, or machined within and/or through the layer 122. In an option,
the at least one conduit channel 130 has a width of about 5 to 50
times the depth of the recess. In another option, the at least one
conduit channel 130 has a width of about 1 mm-2 mm. In yet another
option, the at least one recess has a width of about 50-100
.mu.m.
[0050] One of the featured layers of the manifold 118 further
optionally includes at least one barrier layer 140, as shown in
FIG. 2. The barrier layer defines a portion of the conduit channels
130, for instance a wall portion of the conduit channel 130. In a
further option, the manifold 118 includes a first barrier layer 142
and a second barrier layer 144 disposed on opposite sides of the
conduit layer 122. For example, the first barrier layer 142 abuts
and seals against the first side 124 of the conduit layer 122, and
the second barrier layer 144 abuts and seals against the second
side 126 of the conduit layer 122. This allows for the conduit
channel 130 to be enclosed and form a conduit through which
material travels. The barrier layers 142, 144 can be coupled with
the conduit layer 122, for example, but not limited to, using
adhesives, bonding techniques, or laser welding. In a further
option, the barrier layers 142, 144 and a featured layer such as
the conduit layer 122 are stacked together, and further optionally
sealed together. For example, the layers 122, 142, 144 are stacked
and optionally coupled together through thermal bonding, adhesive
bonding, gluing, soldering, ultrasonic welding, diffusion bonding,
heat sealing, etc. In a further option, layers 122, 142, 144 are
joined by gluing with cyano acrylate adhesive. In yet another
option, layers 122, 142, 144 could be built up and selectively
etched as is done for MEMS and/or integrated circuits.
[0051] The layers 122, 142, 144, in an option, include one or more
bonding regions 369 allowing for flowing adhesives or other bonding
agents so that layers can be bonded without the functional
components, the conduit channels, or ports also being bonded. In a
further option, the one or more featured layers include barrier
features, such as, but not limited to, physical barriers such as
ridges, or recesses and/or chemical barriers that separate bonding
regions from functional regions and/or prevent bonding material
from entering function regions.
[0052] In a further option, the featured layers can form one or
more of the barrier layers 142, 144 including one or more ports 150
therein. For example, the one or more ports 150 can include an
inlet 152 and an outlet 154. The inlet and outlet 152, 154 are
positioned within the barrier layer 144 such that they are fluidly
coupled with the conduit channel 130. For example, the inlet and/or
outlet 152, 154 are positioned adjacent to at least one conduit
channel of another featured layer, for example as shown in FIGS. 2
and 4. Material such as fluid fuel can travel in through the inlet
152, through the conduit channel 130, and out of the outlet 154.
The one or more ports 150 provide fluid communication between the
manifold 118 and components to which the manifold 120 is coupled,
such as, but not limited to, a fluid enclosure such as the fuel
storage 108 (FIG. 1) or the fuel cell 102 (FIG. 1). The one or more
ports 150 can further provide fluid communication within the
manifold 118, for example, between various featured layers. It
should be noted that it is possible to use the manifold 118 as a
fluid distribution system where there is a single inlet and
multiple outlets so that the manifold 118 feeds multiple locations,
for example on a fuel cell layer. The fluids usable with the
manifold 118 include, but are not limited to: fuel, water, coolant,
or oxidant. Examples of fluids which may be used could include, but
are not limited to: hydrogen, methanol, ethanol, butane, formic
acid, borohydride compounds, such as sodium and potassium
borohydride, and aqueous solutions thereof, ammonia, hydrazine,
silanes, or combinations thereof.
[0053] In a further option, a filter element 131 can be
incorporated into a part of the flow path. For example, the filter
element 131 can be disposed within the conduit channel 130, as
shown in FIG. 3A. In another option, the filter element 131 can be
disposed within the ports 150, such as the inlet 152. The filter
element 131 can include a porous substrate or a flow constricting
element. In another option, the filter element 131 can define the
conduit channel 130. The filter element 131 disposed within the
conduit channel 130 and/or the ports 150 assists in preventing
collapsing of the conduit channel 130 and/or port 150 for instance,
when the fuel manifold 120 is bent around itself or other
components within the fuel cell assembly. In a further option, the
conduit channel 130 extends along the conduit layer 122, and the
conduit channel 130 is defined by a length. The filter element 131,
in an option, extends along a portion, or the entire length of the
conduit channel 130. In an option, the filter element 131 is a
porous substrate.
[0054] FIGS. 4 and 5 illustrate additional options for the manifold
118, where the fluid manifold includes multiple featured layers.
Referring to FIG. 4, the fuel manifold 120 includes the at least
one conduit layer 122, a first barrier layer 142, and a second
barrier layer 144. The first barrier layer 142 and the second
barrier layer 144 include one or more ports 150 therein. The at
least one conduit layer 122 includes conduit channels such as a
first recess 132, a second recess 134, and a third recess 136. The
first, second, and third recesses 132, 134, 136 extend in a pattern
within the conduit layer 122, and line up with their respective
ports when the layers are stacked together, such that there is
fluid communication. The barrier layers 142, 144 can be coupled
with the conduit layer 122 using, for example, but not limited to,
adhesives, bonding techniques, or laser welding. in a further
option, the barrier layers 142, 144 and the conduit layer 122 are
sealed together.
[0055] FIG. 5 illustrates another example of a manifold 118, which
also includes multiple featured layers. For instance, the manifold
118 includes multiple featured layers including at least two
conduit layers 122, a first barrier layer 142, a second barrier
layer 144, and a third barrier layer 146. The conduit layers 122
for the various embodiments herein can serve as a barrier layer and
conduit layer, and various features such as ports or conduit
channels, or partially recessed channels can be formed in one or
more of the featured layers, alone or in combination. The layers
include at least one conduit channel. The conduit channel includes,
but is not limited to a delivery channel, or a feedback
channel.
[0056] A first conduit layer is disposed between the first barrier
layer 142 and the second barrier layer, and a second conduit layer
is disposed between the second barrier layer 144 and the third
barrier layer 146. It should be noted that additional layers,
including conduit layers and barrier layers could be incorporated
into the manifold 118 for additional material flow options.
[0057] The first barrier layer 142 and/or the second barrier layer
144 include one or more ports 150 therein. It is possible for the
third barrier layer 146 to further include one or more ports 150
therein. The ports 150 allow for material to flow in to and out of
the manifold 120, and further to flow between the multiple conduit
layers 122. The at least one conduit layer 122 includes one or more
recesses therein 130. The multiple recesses align with their
respective ports when the layers are brought together, for example,
by stacking the layers together and optionally sealing the
layers.
[0058] The barrier layers 142, 144, 146 can be coupled with the
conduit layers 122, for example, but not limited to, adhesives,
bonding techniques, or laser welding. In a further option, the
barrier layers 142, 144, 146 and the conduit layers 122 are sealed
together. The various layers, including the featured layers and/or
the barrier layers and/or the conduit layers allow for a flow path.
In an option, a first flow path allows for fluid, such as gas, to
be distributed on two more layers, where the first flow path
extends from a first featured layer to a second featured layer. In
yet another option, the flow path returns from the second featured
layer to the first featured layer. In still another option, the
first flow path circumnavigates a second flow path.
[0059] The fluid manifold provides a layered structure allowing for
fuel distribution in a relatively small amount of space. For
example, the fuel system can be made with an overall thickness of
about 50-100 .mu.m, or in another example the overall thickness is
about 20-100 .mu.m. The fuel cell fuel manifold further allows for
the transport of fuel, such as gas, while maintaining certain
levels of pressure. For instance, hydrogen gas can be distributed
through the layered structure of the fuel manifold while pressure
in the range of 2-10 psig.
[0060] The fluid manifold interacts with or can be coupled to the
fuel cell or other system components using adhesives working over
comparatively large surface areas to that the force due to internal
fluidic pressures that is forcing the components apart is easily
overcome by the strength of the adhesive bond. A high internal
pressure can be counteracted with a bond that has a relatively low
tensile strength.
[0061] A method includes introducing fluid, such as a fuel, into a
fluid manifold, the manifold including two or more featured layers
each having a plurality of conduit channels. In an example, the
fuel includes a gas or a liquid such as, but not limited to,
hydrogen, hydrogen, methanol, ammonia, silanes, formic acid butane,
or borohydrides. The method further includes flowing fluid through
the conduit channels. The conduit channels include, but are not
limited to, fuel channels, feedback channels, or delivery
channels.
[0062] Several options for the method are as follows. For instance,
the method optionally includes providing fuel to a fuel cell
assembly, where the fluid manifold is fluidly coupled with the fuel
cell. The method optionally includes flowing material from a first
layer recess of a first conduit layer to a second layer recess of a
second conduit layer, and/or flowing material through a porous
substrate within at least one of the one or more conduit channels,
and/or providing a heat transfer fluid to a electrochemical cell
system through the conduit channels. The method further optionally
includes providing oxidant to a electrochemical cell system through
the conduit channels or removing water from the electrochemical
cell system through the conduit channels.
[0063] Further options for the method are as follows. For instance,
flowing fluid through one or more conduit channels includes flowing
fluid along a partially recessed channel in the conduit layer,
and/or flowing fluid through one or more conduit channels includes
directing material along a first partial channel in the first side
and along a second partial channel in the second side. In another
option, the method further includes coupling with a charge port,
and/or coupling with fuel storage. In still another option, the
method further includes distributing fluid on two or more layers
via at least a first flowpath, the first flowpath extending from a
first featured layer to a second featured layer, and returning from
the second featured layer to the first featured layer.
[0064] In the description of some embodiments of the invention,
reference has been made to the accompanying drawings that form a
part hereof, and in which are shown, by way of illustration,
specific embodiments of the invention that may be practiced. In the
drawings, like numerals describe substantially similar components
throughout the several views. These embodiments are described in
sufficient detail to enable those skilled in the art to practice
the invention. Other embodiments may be utilized and structural,
logical, and electrical changes may be made without departing from
the scope of the invention. The following detailed description is
not to be taken in a limiting sense, and the scope of the invention
is defined only by the appended claims, along with the full scope
of equivalents to which such claims are entitled.
* * * * *