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Electrochemical cells formed on pleated substratesRelated Patent Categories: Chemistry: Electrical Current Producing Apparatus, Product, And Process, Current Producing Cell, Elements, Subcombinations And Compositions For Use Therewith And AdjunctsElectrochemical cells formed on pleated substrates description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060105231, Electrochemical cells formed on pleated substrates. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] This is a divisional of U.S. patent application Ser. No. 11/047,557 filed on 2 Feb. 2005. The subject matter of this application is also related to that of a co-owned application entitled "ELECTROCHEMICAL CELLS HAVING CURRENT-CARRYING STRUCTURES UNDERLYING ELECTROCHEMICAL REACTION LAYERS" filed concurrently herewith and a co-owned application entitled "MEMBRANES AND ELECTROCHEMICAL CELLS INCORPORATING SUCH MEMBRANES" filed concurrently herewith, both of which are hereby incorporated by reference herein. This application claims the benefit of U.S. application No. 60/567,433 filed on 4 May 2004, which is hereby incorporated by reference herein. TECHNICAL FIELD [0002] This invention pertains to electrochemical cells. Some embodiments of the invention relate to fuel cells. Other embodiments of the invention relate to electrochemical reactors of other types such as chlor-alkali reactors, electrolysis reactors and the like. BACKGROUND [0003] A fuel cell is an electrochemical energy conversion device that facilitates combining a fuel, such as hydrogen gas or a hydrocarbon, with an oxidizing agent, for example air or oxygen, in one or more chemical reactions to produce electricity. [0004] A typical fuel cell includes an ion conducting membrane, such as a proton exchange membrane. The membrane separates a fuel on one side of the membrane from an oxidant on the other side of the membrane. The fuel is decomposed in a chemical reaction that liberates ions, typically protons, that travel through the membrane. After traveling through the membrane, the ions combine with the oxidant. The chemical reactions generate an electromotive force that can cause an electrical current to flow in an external circuit. A number of fuel cells are typically electrically connected in series to produce a desired output voltage. [0005] A significant problem with many fuel cell designs is that they require many seals. Making reliable seals between the components of fuel cells in fuel cell stacks presents numerous technical problems. Some fuel cells have a large number of parts. Assembling such fuel cells can be time consuming and expensive. [0006] Maintaining effective seals also presents problems in the design of other types of electrochemical reactor such as chlor-alkali cells or electrolysis cells. [0007] Some fuel cell systems include frames which support a number of membrane electrode assemblies ("MEAs") in parallel spaced apart relationship to one another. The frames include face seals which prevent fuel and oxidant from mixing with one another. FIGS. 1 and 2 schematically show prior art fuel cell systems 100 and 200. Fuel cell systems 100 and 200 include electrolyte membranes 104 supported by thin frames 102. Frames 102 are made of a suitable material, such as stainless steel. [0008] Each membrane 104 is located between two frames 102. First and second face seals 110, 112 seal each frame to adjacent membranes 104. First and second electrically conductive catalyst layers 106, 108 are disposed on either side of each membrane. First and second gas diffusion media 114, 116 are also present. [0009] Thin frame designs of the type illustrated in FIGS. 1 and 2 generally work well and have considerable design flexibility. Fuel cell systems 100 and 200 can provide multiple series-connected fuel cells in a structure that can be made thin. Such cells can offer satisfactory air-breathing fuel cell performance with diffusion being the major transport mechanism for both fuel and oxidant delivery. [0010] Fuel cell systems 100 and 200 suffer from the disadvantage that they include numerous face seals 110 and 112, between frames 102 and the electrolyte membranes 104. The surrounding structure must provide adequate support to make face seals 110 and 112 reliable. Design features intended to provide support for face seals 110 and 112 typically occupy volume within a fuel cell system without increasing the power output of the system. Such features tend to make the fuel cell systems volumetrically less efficient than would be ideal. Decreasing layer thickness increases the number of cells per layer but increases the number of face seals 110, 112. [0011] There exists a need for electrochemical reactors, such as fuel cells, chlor-alkali cells and electrolysis cells which are reliable and cost effective to manufacture. BRIEF DESCRIPTION OF THE DRAWINGS [0012] In drawings which illustrate non-limiting embodiments of the invention: [0013] FIG. 1 is a cross-sectional view of a prior art fuel cell array having a sealed thin frame structure; [0014] FIG. 2 is a perspective side view of a prior art fuel cell array having a sealed thin frame structure; [0015] FIG. 3 illustrates an electrochemical cell array formed on a continuous piece of gas barrier material; [0016] FIG. 4 is a schematic view of a pleated layer electrochemical cell; [0017] FIG. 4A is a cross-sectional schematic view of a pleated layer electrochemical cell with a fuel plenum; [0018] FIG. 4B is a cross-sectional schematic view of a pleated layer electrochemical cell with fuel and oxidant plenums; [0019] FIG. 5 is a cross-sectional schematic view of a pleated electrochemical cell; [0020] FIGS. 6A-6H illustrate a series of steps for fabricating electrochemical cells; Continue reading about Electrochemical cells formed on pleated substrates... 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