WO2002009218A2

WO2002009218A2 - Fuel cell array

Info

Publication number: WO2002009218A2
Application number: PCT/US2001/022344
Authority: WO
Inventors: Chowdary Ramesh Koripella; Joseph W. Bostaph
Original assignee: Motorola Inc
Current assignee: Motorola Solutions Inc
Priority date: 2000-07-18
Filing date: 2001-07-17
Publication date: 2002-01-31
Anticipated expiration: 2003-01-18
Also published as: KR100717985B1; EP1366533B1; CN1470084A; AU2001277897A1; EP1366533A2; ATE458280T1; JP2004525479A; WO2002009218A3; DE60141357D1; TW531931B; JP5116932B2; US6465119B1; KR20030024796A

Abstract

A fuel cell array apparatus (10) includes a base portion (14) formed of a singular body. At least two spaced apart membrane electrode assemblies (16) are formed on a major surface (26) of the base portion. A fluid supply channel (32) is defined in the base portion and equally communicates with each of the at least two spaced apart membrane electrode (18, 22) assemblies for supplying a fuel-bearing fluid thereto. An exhaust channel (38) is defined in the base portion and equally communicating with each of the membrane electrode assemblies. Each of membrane electrode assemblies and the cooperating fluid supply channel and cooperating exhaust channel forms a single fuel cell assembly.

Description

FUEL CELL ARRAY APPARATUS

Field of Invention

The present invention pertains to fuel cells, and

more particularly to an array of direct methanol fuel

cells and a method of fabricating the array of fuel

cells, in which electrical energy is produced through the

consumption of gaseous or liquid fuels.

Background of the Invention

Fuel cells in general, are ^{^}battery

replacements'¹, and like batteries, produce electricity

through an electrochemical process without combustion.

The electrochemical process utilized provides for the

combining of hydrogen with oxygen from the air. The

process is accomplished utilizing a proton exchange

membrane (PEM) sandwiched between two electrodes, namely

an anode and a cathode. Fuel cells, as known, can

provide perpetual electricity as long as fuel and oxygen

is supplied. Hydrogen is typically used as the fuel for

producing the electricity and can be processed from methanol, natural gas, petroleum, or stored as pure

hydrogen. Direct methanol fuel cells (DMFCs) utilize

methanol, in a gaseous or liquid form as fuel, thus

eliminating the need for expensive reforming operations.

DMFCs provide for a simpler PEM cell system, lower

weight, streamlined production, and thus lower costs.

In a standard DMFC, a dilute aqueous solution of

methanol is fed as the fuel on the anode side (first

electrode) and the cathode side (second electrode) is

exposed to forced or ambient air (or 02) . A nafion type

proton conducting membrane typically separates the anode and the cathode sides. The flow streams must be kept

separate in the design of the fuel cell. Several of

these fuel cells can be connected in series or parallel

depending on the power requirements.

Typically DMFCs designs are large stacks with forced airflow at elevated temperatures. Smaller air breathing

DMFC designs are more complicated. In conventional PEM

fuel cells, stack connections are made between the fuel

cell assemblies with conductive plates, machined with

channels or grooves for gas distribution. A typical

conventional fuel cell is comprised of an anode (H₂ or

methanol side) current collector, anode backing, membrane electrode assembly (MEA) (anode/ion conducting

membrane/cathode) , cathode backing, and cathode current

collector. Each fuel cell generates approximately 1.0 V,

although the typical operating voltage is lower. To

obtain higher voltages, fuel cells are typically stacked

in series (bi-polar manner - positive to negative) one on

top another. Conventional fuel cells can also be stacked

in parallel (positive to positive) to obtain higher

current, but typically, larger fuel cells are simply used. When stacking fuel cells, the fuel and oxidant

must remain separated. This requires creative management of the gas flows .

DMFCs typically operate between 0.2-0.8 volts. To power a device requiring greater potentials, multiple

fuel cells need to be connected in series for bipolar

voltage adding. However, a device capable of higher

voltages is sought in which a small single planar

surface, thus a smaller area, is utilized. In this

instance, multiple DMFCs are formed on a single planar

surface. Each fuel cell will include a fuel inlet and a

fuel outlet . There is a need to form the array of fuel

cells to share components, such as microfluidic channels

that feed the multiple fuel cells simultaneously. Accordingly, it is a purpose of the present

invention to provide for a planar array design in which

multiple direct methanol fuel cells can be ""stacked" ' in

a planar array, so that higher voltages can be obtained.

It is a purpose of the present invention to provide

for a planar stack design for a plurality of direct

methanol fuel cells in which a planar array of direct

methanol fuel cells is achieved on a single planar

surface.

It is a further purpose of the present invention to

provide for a planar stack design for direct methanol

fuel cells in which a plurality of microfluidic channels

are utilized to equivalently and simultaneously feed the

plurality of direct methanol fuel cells, remove the

exhaust, namely carbon dioxide, and recirculate the

methanol/water mixture.

It is yet a further purpose of the present invention

to provide for method of fabricating a planar stack of

direct methanol fuel cells in which a planar array of

direct methanol fuel cells is achieved on a single planar

surface including a plurality of microfluidic channels to

feed a fuel-bearing fluid, remove carbon dioxide exhaust,

and recirculate the methanol/water mixture. Summary of the Invention

The above problems and others are at least partially

solved and the above purposes and others are realized in

a fuel cell array apparatus and method of forming the

fuel cell array apparatus including a base portion,

formed of a singular body, and having a major surface.

At least two spaced apart membrane electrode assemblies

are formed on the major surface of the base portion. A

fluid supply channel is defined in the base portion and

communicating with each of the at least two spaced apart

membrane electrode assemblies for supplying a fuel-

bearing fluid to each of the at least two spaced apart

membrane electrode assemblies. An exhaust channel is

defined in the base portion and communicating with each

of the at least two spaced apart membrane electrode

assemblies. The exhaust channel is spaced apart from the

fluid supply channel for exhausting fluid from each of

the at least two spaced apart membrane electrode

assemblies . Each of the two spaced apart membrane

electrode assemblies and the cooperating fluid supply channel and cooperating exhaust channel forms a single

fuel cell assembly. There is additionally included a top

portion which includes a plurality of electrical

components for electrical integration of the plurality of

formed fuel cell assemblies.

Brief Description of the Drawings

Referring to the drawings :

FIG. 1 is a simplified sectional view of a plurality

of thin film fuel cell devices formed on a single base

portion including a plurality of microfluidic channels,

according to the present invention;

FIG. 2 is a simplified plan view of the fuel cell

array apparatus of FIG. 1, illustrating the plurality of

discrete fuel cells formed on the base portion; and

FIG. 3 is a simplified sectional view of an

alternative embodiment of a fuel cell planar array

including a plurality of direct methanol fuel cell

devices formed on a single base portion including a plurality of microfluidic channels, and a top portion,

according to the present invention.

Description of the Preferred Embodiments

Turning now to the drawings, FIG. 1 illustrates in

simplified sectional view a planar stack array of direct

methanol fuel cells fabricated according to the present

invention. More particularly, there is formed a planar

stack array 10, including at least two direct methanol

fuel cells, generally referenced 12. Fuel cells 12 are

formed on a base portion 14, each fuel cell 12 being

spaced at least 1mm apart from an adjacent fuel cell 12.

It should be understood that dependent upon the required

power output, any number of fuel cells 12 can be

fabricated to form a planar array of fuel cells. Base

portion 14 is formed from materials designed to be

impermeable to the mixture of fuel and oxidizer materials

that is utilized to power fuel cells 12. Typically a

hydrogen-containing fuel/oxidizer mixture is utilized to

power fuel cells 12. Suitable fuels that are consumed by

fuel cells 12 to produce electrical energy are hydrogen- containing materials such as hydrogen, methane and

methanol. In this particular example, methanol is used

to fuel cells 12. Base portion 14 is typically formed of

glass, plastic, silicon, ceramic, or any other suitable

material. Planar stack array 10 is composed of the at

least two direct methanol fuel cells 12 each defined by a

fuel cell membrane electrode assembly (MEA) 16,

accordingly, planar stack array 10 includes at least two

fuel cell membrane electrode assemblies. Fuel ' cell

membrane electrode assembly 16 is comprised of a first

electrode 18, including a carbon cloth backing, a film

20, such as a porous proton conducting electrolyte

membrane, and a second electrode 22, including a carbon

cloth backing. First and second electrodes 18 and 22 are

comprised of a material selected from the group

consisting of platinum, palladium, molybdenum, gold,

nickel, tungsten, carbide, ruthenium, and alloys of

platinum, palladium, molybdenum, gold, nickel, tungsten

carbide, and ruthenium. Film 20 is further described as

formed of a Nafion type material which is proton

conductive, but limits the permeation of the fuel from

the anode side to the cathode side. It should be

understood that film 20 can be formed as a single film membrane in which a plurality of fuel cell assemblies are

formed to include the single film membrane, or a film in

which each individual fuel cell assembly defines the

limits of the film.

Membrane electrode assembly 16 in this particular

example is positioned in a recess 24 formed in an

uppermost major surface 26 of base portion 12. It is

anticipated by this disclosure that membrane electrode

assembly 16 can be positioned on major surface 26 of base

portion 12 without the need for the formation of recess

24. In this instance, a spacer, such as a gasket, (not

shown) would be utilized to avoid complete compression of

membrane electrode assembly 16.

Planar stack array 10 further includes a top

portion, more specifically, in this particular

embodiment, a current collector 28 positioned to overlay

membrane electrode assembly 16. Current collector 28 is

disclosed in a preferred embodiment as being formed

discretely over each individually formed fuel cell

membrane electrode assembly 16. Current collector 28 is

further described in a preferred embodiment as comprised

of a perforated corrugated gold coated stainless steel .

It should be understood that in addition it is anticipated that current collector 28 can be formed of

any electrically conductive material.

Base portion 14 has formed within a plurality of

micro-fluidic channels as illustrated. More

particularly, base portion 14 has formed a fuel inlet, in

fluidic communication with a fluid supply channel 32. It

should be understood that while only one single fuel

inlet 32 is described, that it is anticipated by this

disclosure that any number of fuel inlets, more

particularly, water and methanol, inlets may be included

dependent upon design requirement. Fluid supply channel

32 is formed in base portion 14 utilizing standard

techniques, well known in the art, such as multi-layer

ceramic technology, micro-machining or injection molding.

Fluid supply channel 32 supplies a fuel-bearing fluid 34

to each of the at least two spaced apart fuel cell

membrane electrode assemblies 16. In this particular

example, fuel-bearing fluid 34 is comprised of methanol

and water. A mixing chamber 36 is formed in base portion

14 in micro-fluidic communication with fluid supply

channel 32 as illustrated. In a preferred embodiment,

fuel-bearing fluid 34 is 0.5%-4.0% methanol in water

(96%-99.5%) . The goal is to pump methanol into the overall assembly 10 at a rate of .0.002ml/min and pump the

water into the assembly 10 at a rate of 0.098ml/min (2%

to 98%) . The fuel cell assembly 10 would also be able

to use other fuels, such as hydrogen or ethanol.

Although, it should be understood that ethanol is not as

efficient, nor does it produce as much power as the use

of methanol. In this particular example separate

methanol and water tanks are utilized to supply the fuel-

bearing fluid. The methanol will be pumped in at a given

rate, and the water will be added as needed determined by

the methanol concentration sensor 37. They will be

homogeneously mixed in mixing chamber 36 before heading

to each individual fuel cells 12. In the alternative, as

previously disclosed, fuel-bearing fluid 34 can be pre-

mixed to the proper proportions which would eliminate ' the

need for mixing chamber 36 and methanol concentration

sensor 37. It should be understood that fluid supply

channel 32 provides for an equal and simultaneous

delivery of fuel-bearing fluid 34 to each individually

formed fuel cell 12.

In addition, there is formed in base portion 14, an

exhaust channel 38 communicating with each of the at

least two spaced apart fuel cells 12. Exhaust channel 38 serves to remove exhaust products 42 from fuel cells 12,

namely carbon dioxide, water, and methanol. During

operation, exhaust products are separated in a carbon

dioxide separation chamber 40 into a water and methanol

mixture 46 and a carbon dioxide gas 48. Next, water 46

is expelled through a fluid outlet 50 and gas 48 is

expelled through an exhaust outlet 52, such as a gas

permeable membrane .

Referring now to FIG. 2, illustrated in simplified

plan view is a typical fuel cell array 10 according to

the present invention. As illustrated, in this

particular embodiment fuel cell array 10 comprises four

individual fuel cells 12, formed on a major surface 26 of

base portion 14. As illustrated, fuel cell array 10 has

an overall base portion dimension of approximately 5.5cm

x 5.5cm x .5cm, and individual fuel cell areas of 4 x

1.5-2.0cm squares. Each individual fuel cell 12 is

capable of generating approximately 0.47V and 22.5mA/cm

of power.

During fabrication, individual fuel cell membrane

electrode assemblies 16 are formed using a direct

painting method or hot press method. More particularly,

the plurality of first electrodes 18 are formed in contact with surface 26 of base portion 14. Various

materials are suitable for the formation of electrodes

18. Suitable materials include platinum, palladium,

gold, nickel, tungsten carbide, ruthenium, molybdenum,

and various alloys of these materials.

In this specific embodiment, and for exemplary

purposes, each of the plurality of first electrodes 18

has a dimension of approximately 2.0cm x 2.0cm. There is

included a separation of approximately 0.5mm to 1mm

between adjacent fuel cells 12.

Film 20, formed of a proton conducting electrolyte,

also referred to as proton exchange membrane (PEM) , is

comprised of a Nafion type material. Film 20 limits the

permeation of fuel from the anode side of the fuel cell

20 to the cathode side.

Next, during fabrication of membrane electrode

assembly 16, a plurality of second electrodes 22 are

formed, correspondingly cooperating with the plurality of

first electrodes 18. Each second electrode 22 is formed

having approximately the same dimension as its

corresponding first electrode 18. It should be

understood, that as described, fuel cell membrane electrode assemblies 16 are each comprised of first

electrode 18, film 20 and second electrode 22.

Finally, current collector 28 is positioned relative

to second electrode 22. Current collector 28 is formed at

least 0.1mm thick and of a length dependent upon a point

of contact on each fuel cell 12. In the alternative, the

plurality of fuel cells 12 can be electrically interfaced

using silver conducting paint deposited by evaporation or

sputtering. Materials suitable for this are gold (Au) ,

silver (Au) , copper (Cu) , or any other low electrical

resistant material . The bulk resistivity of the

electrode material and area of the electrode will dictate

the type of current collection scheme to minimize ohmic

losses. In addition, anticipated by this disclosure to

achieve electrical interface between the plurality of

direct methanol fuel cells 12, are patterned conductive

epoxy and pressing, wire bonding, tab bonding, spring

contacts, flex tape, or alligator clips. It should be

understood, that it is anticipated that fuel cells 12 can

be electrically interfaced utilizing either a series

connection or a parallel connection, dependent upon the

desired resultant voltage. To achieve electrical

interfacing of the plurality of fuel cells 10, each of the second electrodes 22 is electrically connected to an

adjacent first electrode 18, thus connected in series

electrical interface, to increase the output voltage of

the fuel cell array apparatus 10; or each of the first

electrodes 18 is electrically connected to an adjacent

first electrode 18, and each of the second electrodes 22

is electrically connected to an adjacent second electrode

22, thus connected in parallel electrical interface, to

increase the output current of the fuel cell array

apparatus 10.

Referring now to FIG. 3, illustrated in simplified

sectional view is an alternative embodiment of the planar

array of fuel cells, generally referenced 10'. It should

be noted that all components of the first embodiment as

illustrated in FIGs. 1 and 2, that are similar to

components of the second embodiment as illustrated in

FIG. 3, are designated with similar numbers, having a

prime added to indicate the different embodiment .

Similar to the structure described with regard to FIGs . 1

and 2, this structure includes at least two direct

methanol fuel cells, generally referenced 12'. Fuel cells

12' are formed on a base portion 14', each fuel cell 12'

being spaced at least 1mm apart from an adjacent fuel cell 12'. Planar stack array 10', similar to planar stack

array 10 of FIGs. 1 and 2, is composed of the at least

two direct methanol fuel cells 12' each defined by a fuel

cell membrane electrode assembly (MEA) 16'. Fuel cell

membrane electrode assembly 16' is comprised of a first

electrode 18', including a carbon cloth backing, a film

20', comprised of a porous protonically conducting

electrolyte membrane, and a second electrode 22',

including a carbon cloth backing.

Planar stack array 10' further includes a current

collector 28' positioned to overlay membrane electrode

assembly 16'. In this particular embodiment, current

collector 28' is formed as part of a cap portion,

generally referenced 60. Cap portion 60, includes a gas

permeable water recovery system 62, and a water recovery

return channel 64. In addition, it should be understood

that cap portion 60 provides for the exposure of second

electrode 22' to ambient air. Water recovery system 62

serves to recapture water from the cathode sides of fuel

cells 12', and direct it toward water recovery return

channel 64 formed in cap portion 60 and continuing

through base portion 14', as illustrated. Water recovery return channel 64 is in micro-fluidic communication with

a separation chamber 40 ''and ultimately a fuel outlet 50',

discussed presently.

As illustrated, base portion 14' has formed within, a

plurality of micro-fluidic channels. More particularly,

base portion 14' has formed a fuel inlet 30', in fluidic

communication with a fluid supply channel 32'. Similar to

fluid supply channel 32 of FIGs. 1 and 2, fluid supply

channel 32' supplies a fuel-bearing fluid 34' to each of

at the at least two spaced apart fuel cell membrane

■electrode assemblies 16'. A mixing chamber 36' is formed

in base portion 14' in micro-fluidic communication with

fluid supply channel 32' as illustrated. Similar to FIG.

1, in this particular example, separate methanol and

water tanks are utilized to supply fuel-bearing fluid 34¹.

The methanol will be pumped in at a given rate, and the

water will be added as needed determined by a methanol

sensor 37'. They will be homogeneously mixed in mixing

chamber 36' before flowing to each individual fuel cells

12'. In the alternative, as previously disclosed, fuel-

bearing fluid 34' can be pre-mixed which would eliminate

the need for mixing chamber 36' and methanol sensor 37'. It should be understood that fluid supply channel 32'

provides for an equal and simultaneous delivery of fuel-

bearing fluid 34' to each individually formed fuel cell

12'.

In addition, there is formed in base portion 14', an

exhaust channel 38' communicating with each of the at

least two spaced apart fuel cells 12'. Exhaust channel

38'^' serves to remove exhaust products 42' from fuel cells

12', namely carbon dioxide and water/methanol . During

operation, exhaust products are separated in carbon

dioxide separation chamber 40' into a water and methanol

mixture 46' and^' a carbon dioxide gas 48'. Next, the water

and methanol mixture 46' is expelled through fluid' outlet

50' and gas 48' is expelled through an exhaust outlet 52',

such as a gas permeable membrane.

Accordingly, disclosed is a fuel cell array

apparatus and method of fabrication which provides for

the fabrication of multiple fuel cells to be deposited on

a planar surface, thus allowing higher voltages and

currents to be gained on a single planar surface. More

particularly, the design provides for high voltages on a

planar surface, in a very small area, and allows for the feeding of a fuel-bearing fluid and the exhausting of by¬

products, equivalently and simultaneously to the

plurality of fuel cells through a series of micro-fluidic

channels formed in a base portion.

While we have shown and described specific

embodiments of the present invention, further

modifications and improvements will occur to those

skilled in the art. We desire it to be understood,

therefore, that this invention is not limited to the

particular forms shown and we intend in the appended claims to cover all modifications that do not depart from

the spirit and scope of this invention. ^■

Claims

What is claimed is :

1. A fuel cell array apparatus comprising:

a base portion, formed of a singular body, and

having a major surface;

at least two spaced apart fuel cell membrane

electrode assemblies formed on the major surface of the

base portion;

a fluid supply channel defined in the base portion

and equally communicating with each of the at ^■ least two

spaced apart fuel cell membrane electrode assemblies for

equally supplying a fuel-bearing fluid to each of the at

least two spaced apart fuel cell membrane electrode

assemblies;

an exhaust channel defined in the base portion and

equally communicating with each of the at least two

spaced apart fuel cell membrane electrode assemblies, the

exhaust channel spaced apart from the fluid supply

channel for exhausting fluid from each of the at least

two spaced apart fuel cell membrane electrode assemblies,

each of the two spaced apart fuel cell membrane electrode

assemblies and the cooperating fluid supply channel and cooperating exhaust channel forming a single fuel cell

assembly; and

a top portion characterized as providing for the

exposure of a portion of each fuel cell assembly to

ambient air and further including a plurality of

electrical components for electrical integration of the

plurality of formed fuel cell assemblies.

2. A fuel cell array apparatus as claimed in claim 1

wherein the base portion comprises a material selected

from the group consisting of ceramic, plastic, glass, and

silicon.

3. A fuel cell array apparatus as claimed in claim

1 wherein each of the at least two spaced apart fuel cell

membrane electrode assemblies includes a first electrode,

a film formed adjacent the first electrode, formed of a

nafion type material, and a second electrode formed

adjacent the film.

4. A fuel cell array apparatus as claimed in claim

3 wherein the first and second electrodes comprise a

material selected from the group consisting of platinum, palladium, gold, nickel, tungsten carbide, ruthenium,

molybdenum, and alloys of platinum, palladium, gold,

nickel, tungsten carbide, molybdenum, and ruthenium.

5. A fuel cell array apparatus as claimed in claim

4 wherein the film overlying the first electrode

comprises a material characterized as a proton exchange

material .

6. A fuel cell array apparatus as claimed in claim

5 wherein the at least two spaced apart fuel cell

membrane electrode assemblies share the film formed of a

nafion type material.

7. A fuel cell array apparatus as claimed in claim 3

wherein each of the second electrodes is electrically

connected to an adjacent first electrode, thus connected

in series electrically, to increase the output voltage of

the fuel cell array apparatus.

8. A fuel cell array apparatus as claimed in claim 3

wherein each of the first electrodes is electrically

connected to an adjacent first electrode, and each of the second electrodes is electrically connected to an

adjacent second electrode, thus connected in parallel

electrically, to increase the output current of the fuel

cell array apparatus.

9. A fuel cell array apparatus as claimed in claim

1 wherein the fluid supply channel defined in the base

portion and equally communicating with each of the at

least two spaced apart fuel cell membrane electrode assemblies includes a mixing chamber.

10. A fuel cell array apparatus as claimed in claim 1 wherein the fluid supply channel defined in the base

portion and equally communicating with each of the at

least two spaced apart fuel cell membrane electrode

assemblies includes a methanol concentration sensor.

11. A fuel cell array apparatus as claimed in claim

1 wherein the exhaust channel defined in the base portion

and equally communicating with each of the at least two

spaced apart fuel cell membrane electrode assemblies

further includes a carbon dioxide separation chamber and

a carbon dioxide exhaust vent .

12. A fuel cell array apparatus as claimed in claim

1 wherein the fuel cell membrane electrode assemblies are

spaced at least 1mm from an adjacent fuel cell membrane

electrode assembly.

13. A fuel cell array apparatus comprising:

a base portion, formed of a singular body, and

having a major surface, the base portion formed of a

material selected from- the group consisting of ceramic,

plastic, glass, and silicon;

at least two spaced apart fuel cell membrane

electrode assemblies formed on the major surface of the

base portion, each of the at least two spaced apart fuel

cell membrane electrode assemblies including a first

electrode, a film in contact with the first electrode and

formed of a protonically conductive electrolyte, and a

second electrode in contact with the film;

a fluid supply channel defined in the base portion

and equally communicating with each of the at least two

spaced apart fuel cell membrane electrode assemblies for

equally supplying a fuel-bearing fluid to each of the at least two spaced apart fuel cell membrane electrode

assemblies;

an exhaust channel defined in the base portion and

equally communicating with each of the at least two

spaced apart fuel cell membrane electrode assemblies, the

exhaust channel spaced apart from the fluid supply

channel for exhausting fluid from each of the at least

two spaced apart fuel cell membrane electrode assemblies,

each of the two spaced apart fuel cell membrane electrode

assemblies and the cooperating fluid supply channel and

cooperating exhaust channel forming a single fuel cell

assembly; and

a top portion characterized as providing for the

exposure of a portion of each fuel cell assembly to

ambient air and including a plurality of electrical

components for electrical integration of the plurality of

formed fuel cell assemblies.

14. A method of fabricating a fuel cell array

apparatus comprising the steps of:

providing a base portion formed of a material

selected from the group consisting of ceramic, plastic,

glass, and silicon; forming a fluid supply channel in the base portion

for equally supplying a fuel-bearing fluid to each of at

least two spaced apart fuel cell membrane electrode

assemblies ;

forming an exhaust channel in the base portion, the

exhaust channel spaced apart from the fluid supply

channel for exhausting fluid from each of the at least

two spaced apart fuel cell membrane electrode assemblies;

forming the at least two spaced apart fuel cell

membrane electrode assemblies on the major surface of the

base portion, the step of forming each of the at least

two spaced apart fuel cell membrane electrode assemblies

including the steps of bringing into contact a first

electrode and a major surface of the base portion,

bringing into contact a film and the first electrode, and

bringing into contact a second electrode and the film,

each of the two spaced apart fuel cell membrane electrode

assemblies and the cooperating fluid supply channel and

cooperating exhaust channel forming a single fuel cell

assembly; and

forming a top portion characterized as providing for

the exposure of a portion of each, fuel cell assembly to

ambient air and including a plurality of electrical components for electrical integration of the plurality of

formed fuel cell assemblies.