There are several disadvantages in conventional unipolar/bipolar plates such as cost expensive, weight heavy and volume large. Therefore, it is difficult in making use conventional unipolar/bipolar plates to portable fuel cells. With a new heterogeneous carbon fiber bipolar plate, pumpless and air-breathing design and in cooperating with a special MEA, portable fuel cell stacks developed in our lab have made portable applications to be possible. The structure of the DMFC stack made with the new carbon fiber bipolar plate is much more simple and weight-light than the other designs. A two-layer 16-Cell DMFC Stack had been designed and made by using the heterogeneous carbon fiber monopolar plates developed in our fuel cell laboratory. With this design, the methanol solution can be directly stored in the anode chamber which can store fuel 17 ml and does not need any auxiliary equipment, so it easy to apply to the portable power source. Not including fuel, total weight of stack is only 50g and the volume is 75 cm3. The 16 cell stack includes two pieces of 117 membrane, 16 anode electrodes loading Pt/Ru 5 mg/cm2 and 16 cathode Pt loading 5 mg/cm2. Each single cell electrode area is about 3.5 cm², so the total electrode area of the 16-cell stack is 56cm2. With methanol concentration 3 M, pumpless, air-breathing, and room temperature, the largest output power density of the fuel cell can reach 10.3 mW/cm², and the total power can reach 578 mW in this stage. The performance of the stack will be further improved in the next stage.

The purpose of this paper is to identify the current status of fuel cell technology and to establish whether said technology is mature enough to be implemented into the Swedish Armed Forces. The question to be answered in this paper is as follows: Can hydrogen gas and fuel cells be used as an alternative source of energy within the Swedish Armed Forces? This paper is based on theoretical studies and reports from prior research done on fuel cells. By studying these facts a predictive answer has been obtained. The answer I have come to, is that the maturity of fuel cell technology is currently inadequate for the Swedish Armed Forces to implement, especially considering its harsh working conditions.

The effects of actively pulsing reactant flow rates into solid polymer electrolyte fuel cells were investigated in this thesis. First, work was conducted to determine the magnitude of voltage response to pulsed reactant flow on a direct hydrogen proton exchange membrane (PEM) cell. The effects of pulsed reactant flow into a direct methanol fuel cell (DMFC) were then considered. The PEM work showed substantially greater response to pulsed air flow than to pulsed fuel flow. It was found that several parameters affect the magnitude of cell response to active flow control (AFC). Increasing current load, increasing the magnitude of flow oscillation, decreasing the frequency of oscillation, and decreasing the average level of excess reactant supplied were found to maximize both the level of voltage oscillations and the decrease in cell power from steady state performance. Greater response to pulsed oxidant flow is believed to have been observed due to effects brought about by changes in membrane humidity. In contrast, pulsed fuel flow showed the greatest response in the study of DMFC technology. In this case, time averaged cell voltage was found to increase as the time averaged fuel flow rate was reduced. The increase in average cell power is the result of a reduction in methanol crossover; sustainable increases of up to 6% in power output were measured. The parameters found to effect the increase in cell power observed include the frequency of oscillation and the time-averaged NOSfuel. Pulsed air flow on the DMFC did not show any such rise in voltage, supporting the hypothesis that a reduction in methanol crossover is the phenomenon which brings about enhanced performance.

In this study, the flow plates of micro methanol fuel cells are designed and fabricated in-house through MEMS(Micro-Electro-Mechanical System) technology with deep UV lithography manufacturing processes (SU-8 photoresist) and micro electroforming manufacturing processes. The thesis investigates methanol and water crossover in a micro DMFC for serpentine flow field configuration. Experiments are conducted through various experiments with different operating conditions for the anode flow rate (2-10 sccm), cathode flow rate (100-500 sccm), methanol concentration (1, 2 and 3M), and temperature (25, 50 and 75¢J). Experimental results are presented in the form of polarization VI curves and PI curves under the above operating conditions. The experimental results show that the methanol and water crossover flux increases with increases in cell temperatures, methanol concentration and anode pressure drop. It is found that the fuel efficiency of the DMFC is closely related to the methanol crossover. Further examination of the relationship between the methanol crossover and cell performance reveals the possibility of reducing the methanol crossover by optimizing the anode flow rate.

The problem of the performance decay and the factors affecting on the DMFC performance for long-term operation are studied in this thesis. First, the influence of the initial treatments of MEA and the exposure of MEA in the atmosphere on the water content are measured. In addition, the effects of the pressure of the MEA hot press conditions, the treatments and preservation of MEA, and the operative conditions on the performance are also examined. Eventually, we expect that the best way to increase the DMFC performance and avoid the performance can be found. These can provide for references when a portable DMFC need to be designed and manufactured in future. In order to solve the problem of methanol crossover leading to the cathode poisoned, cells are operated only under the proper methanol concentration and discharged thoroughly before finishing the whole experiment. It is also necessary to maintain MEAs in proper wetness so that the performance of stack will not decay too quickly. In the initial treatment, firstly, a MEA is immersed in 3M MeOH and then boiled with 80oC DI water for an hour, respectively. The experimental conditions of this passive single-cell DMFC are pumpless in anode chamber, air-breathing, and room temperature. The power density of this DMFC with these test conditions can reach a value about 33mW/cm2. This value is about 106% higher than that of the untreated MEA. If MEA boiled with 0.5M H2SO4 for an hour and then boiled with 80oC DI water for an hour, its power density is about 75% higher than that of the untreated MEA.

In this thesis, a long-term operation direct methanol fuel cell (DMFC) stack with no performance decay is developed and improved. In a traditional passive portable DMFC, the Methanol solution is storage at anode Reaction chamber. The performance will drop after a short period due to the concentration of Methanol solution becoming lower (about 1.5M). Although High concentration of Methanol solution could increase the operation time, but it will couse crossover to poison the cathode Pt particle, and it is unable to keep long-term operation stably either. In order to achieve long-term operation stably, to maintain the concentration of methanol solution in the anode chamber will be very important. In our fuel supply stack, there are two chambers in the stack to storage methanol and water, and we could control the supplying rate by adjusting the diffusion area to control the diffusion rate of methanol and water. And the methanol solution deliver to anode reaction chamber by cotton tube. If the anode reaction chamber is filled with 1.3¢W, 2M methanol solution and without any fuel supply, operating on the 185mA constant current (82.2mA/cm2 ). The results shows that the performance begin decay about after 15minutes. If the appropriate amount of methanol and water is supplied, the performance can be steady in a long-term operation. But if supply too much methanol solution, the concentration in the anode reaction chamber will rise up, and the high concentration will cause crossover poised the cathode catalyst, and the performance will decay. If supply rate not enough, the concentration in the anode reaction chamber will become lower, and the performance will decay after long-term operation. In this study, based on operate current and the rate of evaporation of methanol solution, to supply appropriate supplying rate and concentration of methanol solution to anode reaction chamber, could keep the performance in a steady output.

Abstract The improvement of performance and the maintenance of stability of a portable air-breathing DMFC are studied in this thesis. The effect of the improvement of the internal structural of carbon fiber bunches on the cell performance is studied firstly. The small channels in the soft end of the carbon fiber bunches can be formed by changing the thickness of the copper plates burry within the gluing zone of the fiber bunches. Then one or two transverse grooves are form in proper location by cutting part of the carbon fibers at the soft end to shorten the airflow path to the area of electrode which is covered by the carbon fiber bunches so that the reaction area can obtained enough oxygen or fuel. Experimental results show that the maximum power density is about 20 mW/cm2 with no structure but it raised to about 24 mW/cm2 with the burry a 0.5mm thick copper plate and the two transverse grooves. It improves about 20% power density. The experiments prove that the improvement of the internal structure of the carbon fiber bunches is helpful in stack performance. In order to reduce the unneeded depletion of fuel, the bare nafion membrane pastes another special membrane to block methanol and water leakage. The strategy to block the leakage improved the rate of fuel utilization about 24%. In order to make the direct methanol fuel cell operating stably, a fuel supplying system by gravitation and diffusion forces is delivering the consumed fuel to maintain the concentration of methanol solution in anode reaction, by adjusting a sliding gate to control the diffusion area and utilizing three cotton threads and hoses to distribute the fuel to proper location. The multi-point type of fuel supplementary system allows the methanol solution to be distributed uniformly, so that the stack can maintain stable operation for a long period. In order to make the stack size to a minimization, the volume of the anode reaction chamber will be minimized as possible; however, the reduced chamber is still able to supply sufficient fuel maintaining operating stably in the high-current condition. The transient phenomena of output voltage under the various volume of the reaction chamber are also studied in this research. Finally, we hope to be able to identify the most appropriate space to meet demand. The above optimization results are able to provide a reference in the future design and production of portable DMFCs.

The experimental test and analysis of the direct methanol fuel cell (DMFC), which is made with a newly developed heterogeneous composite carbon fiber unipolar/bipolar plate, is performed in our lab. The work from the making of carbon fiber unipolar plate to the design of single-cell DMFC is also included in this study. The experimental work of various control parameters, such as methanol concentration, operating temperature, and the air flow rate, is also conducted in this thesis. The formation of carbon dioxide in anode is inspected during experiment. From a series of experimental test, we have understood the characteristics of DMFC better. The experimental result and experience can also provide the references of the application and development of DMFC in the future. According to our experiment, we find that the assembling of the new-type unipolar/bipolar plate doesn¡¦t need to use the large compressing force to reduce the contact resistance like those of the traditional unipolar/bipolar plates. The structure of the DMFC stack made with the new carbon fiber unipolar/bipolar plate is simple and weight light. However, the experimental results still show that the factors that affect the performance of the DMFC fuel cell are similar to those with the conventional unipolar/bipolar plates. For example, increasing the reactive temperature of fuel, proper methanol concentration, and proper content of catalyst all can effectively improve the power density of a DMFC. The structure of the methanol mixture directly stored in the flow channel of the anode is simple. However, the design exists the problems of the crossover of methanol, the stripping of the anode electrode, and the removal of the carbon dioxide. Special attention is needed to overcome and improve those problems in making DMFC stacks. Or the performance of the cell will decline after long period operation.

Several disadvantages in general unipolar/bipolar plates are that cost is expensive, weight is heavy and the volume is large. The high compressing pressure is also necessary to reduce the contact resistance in making up a fuel cell stack. Therefore, it is difficult in making use general unipolar/bipolar plates to portable fuel cells. With a new heterogeneous carbon fiber bipolar plate, pumpless and air-breathing design and in cooperating with a special MEA, a portable fuel cell stacks developed in our lab have made portable applications to be possible. The structure of the DMFC stack made with the new carbon fiber bipolar plate is much more simple and weight-light than the other designs. The three portable DMFC stacks flat type, cylinder type (I), and cylinder type (II) are developed in series in our lab. The methanol solution can be stored directly in the flow channel of the anode, and does not need the extra auxiliary equipment, so it easy to apply to the portable fuel cell. The developed portable DMFC of cylinder type (II), weight is only 20g, volume is 30cm3, and the fuel stored capacity is 7.5ml. In the flat type DMFC, In anode Pt-Ru loading 3 mg/cm2, and cathode Pt loading 1 mg/cm2, methanol concentration 3 M, pumpless, air-breathing, and room temperature, the largest of output power density of the fuel cell can reach 5.27 mW/cm2, and the total power can reach 71 mW. The weight of DMFC of cylinder type (II) is far lower than DMFC of flat type in addition, so its power density 1.33mW/g is about 1.68 times of flat type 0.79 mW/g.

In this thesis the experimental method is used to study the characteristics of a DMFC when a heterogeneous carbon fiber bipolar plate is applied to it. The first main study is about the effect of the different structures of the carbon fiber bunch on the fuel cell performance. Additionally, a high temperature hot-pressing process is performed to change the inner molecular structure so that the hydrogen ion can be blocked to avoid the lateral migration between two adjacent cells. Finally, the two techniques are applied to make our new portable DMFC stack. The bipolar plates with the sawtooth or non-sawtooth carbon fiber bunches have been used in making our DMFC stack. The experimental results display that the performances of the two structures both are better than the traditional graphite bipolar plate. However, the performance of DMFC with the sawtooth bipolar plate is much better than that without sawtooth, especially in high current density. When carbon fiber bunches with sawtooth use at anode and cathode of bipolar plates, the performance can be enhanced and its power density 27.6% higher than that without sawtooth. During our study we also found that part of hydrogen ions can laterally migrate to its adjacent cathode and do not directly cross to its opposite cathode, when the banded type MEA are used to multiple cell stack. Therefore, the performance cannot be performed well due to this type ion transfer. In order to block the lateral migration, the narrow area of the membrane between two adjacent electrodes is pressed with a high temperature hot-pressing device. After a short time hot-press between two adjacent electrodes, the hydrogenion migration phenomenon reduced, and the performance had been improved about 10% higher than that without hot-press. Finally, a double layer 2x6-cell flat type DMFC is made. This 12-cell stack is composed of each electrode area 0.5x5cm2, two sheets of membrane for 6-cell using Nafion 117, the anode catalyst Pt-Ru loading 4mg/cm2, and cathode catalyst Pt loading 4mg/cm2, the methanol concentration 3M, air-breathing, and operating in room temperature. The output power of the cell can reach an average power density 8.0mW/cm2 and total power 240mW with our handmade stack. If the performance of each fuel cell is more uniform, we expect that total power can reach 480 mW. The power level should be satisfied for any kind mobile phone.