Build Your Own Fuel Cells

by Phillip Hurley Table of Contents with sections, chapters and text subheads

Introduction
A short history of the fuel cell
ro!e"s #$as battery# Fuel cells today

%hat exactly is a fuel cell& Fuels for fuel cells

Many sources of hydrogen Fuel delivery packages Hydrogen from fossil fuels Hydrogen from water Technology of the future Global impact Storing hydrogen What is a fuel? Water is a fuel Who bears the real costs? Skeletons in the closet The hydrogen water economy is coming! Water based hydrogen production "lectroly#ers Solar$ wind and hydro power for electroly#ers %hoto electrolysis %hoto biological

Types of Fuel Cells

Operatin$ te'peratures (e$enerati!e fuel cells

)yste's * Co'ponents O!er!iew

Photo!oltaic fuel cell syste's
Fuel cells vs& batteries 'omponents of a %( fuel cell system Wind or small hydro power )dd ins for the system Fuel cell configurations Matching the %( panels to your needs %owering the electroly#er *uilding an electroly#er 'ompressing the hydrogen More resources *uilding a %( panel for your electroly#er Figuring %( panel costs Wiring the system Support and use components Housing the system 'ontrol valve

P+, fuel cell co'ponents

,+A basics Purchasin$ ,+As and co'ponents )urplus fuel cells

Buildin$ the -./ Hard raphite Con!ection )in$le )lice Fuel Cell
+,- Fuel 'ell Tool list +,- Fuel 'ell Materials list

)bout the materials

*uying membrane electrode assemblies and components Mounting the membrane electrode assembly .ubber gaskets and spacers +eep the components clean Working with graphite /btaining graphite "nd plates Miscellaneous parts Fuel cell 0a##

Simple tools do the 0ob

Wet and dry bandsaw 1rill press Setting up for fuel cells

%reparing the graphite

*uy graphite pieces that fit your saw Setting the water flow Slabbing the graphite *egin to cut Fences .ipping gauges %lan the cuts carefully 'ut e2tra pieces "rr on the thicker side 'ut the plate to si#e Sanding Sanding surface and techni3ue 'leaning the bandsaw 4sing the templates 1rilling the holes .outing the vertical flow fields .outing the serpentine flow fields .outing the serpentine flow fields

%reparing the other parts

"nd plates Gas gaskets and spacers Mylar surrounds for the M") 5membrane electrode assembly6 Handling the M") 5membrane electrode assembly6 )ssemble the M") in the Mylar surround "lectrode plate materials 'utting the electrodes Gas entry ports Fasteners

)ssembling the +,- fuel cell Testing fuel cells

*uilding an electroly#er *uying an electroly#er Hook up the hydrogen %recautions Turn on the hydrogen Meter readings Test for continuity within the cell Troubleshooting 7 no reading 'onvection process

"lectroly#ers
How electroly#ers work
"lectrolytes )pplying electricity Types of electroly#ers The tank electroly#er Home built electroly#ers The electrolyte %reparing the electrolyte Safety precautions

*uilding the %8- electroly#er

Tools needed Materials needed %urpose of the %84se at your own risk "lectrode separators ) transparent electroly#er 9ickel electrodes %reparing the parts for assembly *ottom cap Height gauge Maintaining the electrolyte level :ncreasing amperage to the electroly#er Sealing the electroly#er Silicone cement vs& epo2y %reparing screws and nuts "po2y the pipe to the bottom cap 1ry the seals and test )ligning the top and bottom caps Wiring it up Filling the electroly#er 'onnecting to power

)crubber
(inegar *uilding a scrubber :nside tube length Transparent scrubbers

Making an electrolyte
Tools needed The filter bucket The drip bucket )dd ashes and water Wait 8 days to a week 'ollect the +/H solution

Buildin$ the 01/ )oft raphite Con!ection )in$le )lice Fuel Cell
Tool and materials list
Tools Materials needed

.eally simple tools do the 0ob

Stick technology Make it on your kitchen table %rint out the templates "ndplate;current collectors Mark the end plates 'ut and drill the end plates Soft graphite %ractice with the material 'utting the soft graphite Working with soft graphite 1rilling holes in soft graphite Mark the flow fields Making the flow field grooves Soft graphite is forgiving "asy construction and high performance )ligning the holes The hose connectors %repare the fasteners %repare the M") )ssemble the fuel cell

2esi$nin$ Fuel Cells

:deas for designing fuel cells
Fuel cell geometry *uckyballs 'eramics in fuel cells Wooden fuel cells

'arboni#ing other materials /ther natural materials for inspiration <*iomimicry< for fuel cells 'ollect supplier catalogs =earn from the materials Thinner and lighter designs 4se easy to obtain materials and tools "nd plate materials %lastics in fuel cells General materials considerations 'onvection vs& o2ygen hydrogen %lanning for maintenance *anded fuel cells Gas port plate Stack design considerations hardware =ongevity /perating environment :n summary

*uilding stacks
*ipolar plates %late thickness and groove depth Gas feed in the gasket Stack templates 'onvection stack configuration /2ygen hydrogen stack configuration %lan for easy disassembly =arger stacks need gas pressure Gas flow regulator )dditions to optimi#e performance Gasket thickness affects performance

+xperi'ental ,ethods for ,a3in$ ,+As 4,e'brane +lectrode Asse'blies5

)bout membrane electrode assemblies

M") components )pplying the catalyst to the substrate ,& Sputter diffusion >& ) *en0amin Franklin techni3ue .esources for the e2perimenter 8& "lectrochemical deposition ?& "lectroless deposition @& Mechanical 1eposition %owdering platinum 'arbon nano tubes 'arbon and platinum mi2tures A& "lectrostatic dispersion B& Simple mi2ing -& %hotochemical %latinum black )pplication techni3ues *rewsterCs reaction /ther methods to get platinum black

M") Tool list M") Materials list =oading the catalyst an e2perimental method
Making percent solutions M") components The substrate and catalyst 'onstruction overview %lanning to load the catalyst 'arbon cloth substrate 'utting the cloth Weighing the chemicals Safety precautions The work area Safelight conditions Timing and storage Making the solution Handling )F/ %rocedure summary %reparing the platinum solution

Water bath Making the platinum solution 4se a brush with no metal 'oating the carbon cloth Make a test paper 1ry the fabric pieces "2pose to 4( Washing out the ferrous salts /ther washing methods

%reparing the proton e2change membrane 5%"M6

Membrane thickness Handling the membrane Membrane preparation *athing the membrane +eep a steady temperature Safety precautions +eeping the membrane immersed The first two baths Fishing for the invisible membrane The third bath =ast three baths %ressing plates 'oat plate with powdered graphite =ay out the M") layers )dd the top plate carefully 'lamp the sandwich 'ook the sandwich :ncrease the pressure

Further e2periments
=ower the loading :ncrease the loading Matching gaskets to M")s What to e2pect from your M") Testing fuel cells *asic test e3uipment

.esources
=inks *ooks Supplier contact information MS1S

Templates
How to use the templates
+,- single slice convection %8- "lectroly#er =B- single slice convection +,- single slice o2ygen hydrogen =B- single slice o2ygen hydrogen +,- convection stack +,- o2ygen hydrogen stack Surround gasket with feed tunnels