Passive direct methanol fuel cells (DMFC) with neither liquid pumps nor gas blowers/compressors have been recognized as the most promising power source for portable electronic devices, such as cellular phone, PDA, notebook, etc., because this type of fuel cell not only offers the unique advantages of high-energy density, high-energy efficiency, simple and compact system, rapid recharge, but also eliminates parasitic power losses of the fuel cell system. However, since the supply of oxygen in the passive DMFC relies virtually on breathing oxygen naturally from ambient air without any external means of air movement, this type of fuel cell often suffers from oxygen-starving and water-flooding problems. Moreover, the typical design of the passive DMFC renders too much heat loss from the fue...[ Read more ]

Passive direct methanol fuel cells (DMFC) with neither liquid pumps nor gas blowers/compressors have been recognized as the most promising power source for portable electronic devices, such as cellular phone, PDA, notebook, etc., because this type of fuel cell not only offers the unique advantages of high-energy density, high-energy efficiency, simple and compact system, rapid recharge, but also eliminates parasitic power losses of the fuel cell system. However, since the supply of oxygen in the passive DMFC relies virtually on breathing oxygen naturally from ambient air without any external means of air movement, this type of fuel cell often suffers from oxygen-starving and water-flooding problems. Moreover, the typical design of the passive DMFC renders too much heat loss from the fuel cell to the ambient air, resulting in a lower operating cell temperature and thereby lower cell performance. Hence, a better understanding of coupled heat and mass transport as well as electrochemical characteristics is essential to achieve the optimal design and improve the cell performance of this type of passively operated fuel cell.

This thesis presents both experimental and theoretical investigations of coupled heat/mass transfer and electrochemical characteristics in the passive DMFC. Unlike active fuel cells, which can be operated under stabilized operating conditions, the discharging behavior of the passive DMFC usually varies with time, as the methanol concentration in the fuel reservoir decreases with time. This poses a difficulty in characterizing the performance of the passive DMFC under relatively stable operating conditions. In this work, we found that the performance of the passive DMFC became relatively stable as the cell operating temperature rose to a relatively stable value. This finding indicates that the performance of the passive DMFC can be characterized by collecting polarization data at the instance when the cell operating temperature under the open-circuit condition rises to a relatively stable value. With this proposed standard of passive DMFC performance characterization, the effects of two important parameters, including methanol concentration and cell orientation, on the passive DMFC performance were then investigated. It is found that the cell performance increased with methanol concentration. Unlike previous studies that attributed the improved performance as a result of increasing methanol concentration to the reduced anode mass transport polarization, our experimental results revealed that the improved cell performance was primarily due to the increased cell operating temperature as a result of the increased rate of methanol crossover with high methanol concentration operation. We also found that the performance was sensitive to the cell orientation. The vertical operation always yielded better performance than did the horizontal operation. This can be attributed to the increased operating temperature as a result of a higher rate of methanol crossover, which resulted from the stronger natural convection in the vertical orientation. These parametric studies indicated that the thermal management is a key factor for improving the performance of the passive DMFC.

To enhance oxygen transport on the air-breathing cathode and to reduce the heat loss from the cathode, a porous current collector for the passive DMFC was proposed to replace conventional perforated-plate current collectors. Because of its high specific area of transport and effectiveness in removing the liquid water as a result of the capillary action in the porous structure, the porous current collector enables a significant enhancement of oxygen supply to the fuel cell. In addition, because of the lower effective thermal conductivity of the porous structure, the heat loss from the fuel cell to ambient air can be reduced. The experimental results showed that the passive DMFC having the porous current collector yielded much higher and much more stable performance than did the cell having the conventional perforated-plate current collector with high methanol concentration operation. As a following up to oxygen transport enhancement, a new design of membrane electrode assembly (MEA) was proposed, in which the conventional cathode gas diffusion layer (CGDL) is eliminated while utilizing a porous metal structure for transporting oxygen and collecting current. We show theoretically that the new MEA enables a higher mass transfer rate of oxygen and thus better performance. Moreover, the measured polarization and constant-current discharging behavior showed that the passive DMFC with the new MEA yielded higher and much more stable performance than did the cell having the conventional MEA.

Besides the experimental investigations, to further theoretically study the thermal effect on the cell performance, a one-dimension single-phase model is developed by considering inherently coupled heat and mass transport along with the electrochemical reactions occurring in passive DMFCs. The analytical solutions predicting the performance of this type of fuel cell operating with different methanol concentrations are obtained. It was further revealed that the improved performance with higher methanol concentrations is due primarily to the increased operating temperature resulting from the exothermic reaction between the permeated methanol and oxygen on the cathode. In addition, to further reflect the effect of two-phase heat and mass transport on the performance of the passive DMFC, we then developed a two-phase two-dimensional thermal model. With this model, the effects of methanol concentration, open ratio and channel and rib width on cell performance were investigated. It was found that although the larger open ratio and smaller channel and rib width exhibit the lower cell operating temperature as a result of the lower heat generation rate, the cell performance is still higher as a result of the increased mass transfer rate on both the anode and cathode.

Keywords: Passive Direct Methanol Fuel Cell; Cell Performance; Thermal Effect; Open-circuit Condition; Methanol Concentration; Cell Orientation; Metal Foam, Effective Thermal Conductivity; Oxygen Transport; Mass Transfer Resistance; Two-phase Transport; Open Ratio; Channel and Rib Width.