Micro-scale fuel cell fibers and textile structures therefrom

Abstract

A proton exchange membrane fuel cell fiber has an inner and outer electrode that is either an anode or cathode, a first and second layer that include either a fuel catalyst layer or oxidant catalyst layer, and a proton exchange membrane. These components are combined into a fiber having a diameter of about 5 mm or less and the length of about 1 cm or more.

1 . A proton exchange membrane fuel cell fiber, comprising: 
 an inner electrode;    a first layer selected from the group consisting of a fuel catalyst layer and oxidant catalyst layer intimately adjoined to the inner electrode;    an outer electrode;    a second layer selected from the group consisting of a fuel catalyst layer and oxidant catalyst layer intimately adjoined to the outer electrode; and,    a proton exchange membrane between the first and second layers,    wherein each of the inner and outer electrodes are exclusively one of either an anode or cathode, and,    wherein the diameter of the fiber ranges from about 5 mm or less and the length ranges from about 1 cm or more.    
     
     
         2 . The fiber of  claim 1 , wherein the inner electrode comprises a conductive structure effective for liquid or gas transfer therethrough selected from the group consisting of porous, hollow, open tubular and combination thereof.  
     
     
         3 . The fiber of  claim 1 , wherein the inner electrode comprises an anode and the outer electrode comprises a cathode.  
     
     
         4 . The fiber of  claim 1 , wherein the inner electrode comprises a cathode and the outer electrode comprises an anode.  
     
     
         5 . The fiber of  claim 1 , wherein the inner and outer electrodes independently comprise a composition selected from the group consisting of pressed carbon black, pressed graphite, continuous carbon fiber, nanostructured conductive oxide, ceramic or polymer fiber-based thin conductive films, ceramic or polymer fiber-based thin metallic films, porous metal wire, porous conductive polymers, or combinations thereof.  
     
     
         6 . The fiber of  claim 1 , wherein the fuel catalyst layer comprises a catalyst material selected from the group consisting of finely structured transition metals, polypeptide enzyme, metal-centered macromolecule and combinations thereof.  
     
     
         7 . The fiber of  claim 6 , wherein the fuel catalyst layer comprises finely structured transition metals.  
     
     
         8 . The fiber of  claim 1 , wherein the proton exchange membrane comprises a proton conductive polymer or continuous inorganic film.  
     
     
         9 . The fiber of  claim 8 , wherein the proton exchange membrane comprises a chemical structure of —(CF 2 CF 2 ) n —CF 2 C(F—)—(OCF 2 CF(CF 3 )—)OCF 2 SO 3 H.  
     
     
         10 . The fiber of  claim 1 , wherein the oxidant catalyst layer comprises a catalyst material selected from the group consisting of finely structured transition metals, polypeptide enzyme, metal-centered macromolecule and combinations thereof.  
     
     
         11 . The fiber of  claim 10 , wherein the oxidant catalyst layer comprises a finely structured transition metals.  
     
     
         12 . The fiber of  claim 1 , wherein the outer electrode is a material selected from the group consisting of vapor deposited carbon, conductive adhesive, vapor deposited metal film, conductive polymeric coating, liquid deposited carbon black, liquid deposited graphite, liquid deposited metal particles and combinations thereof.  
     
     
         13 . A textile comprising the fiber of  claim 1 .  
     
     
         14 . The textile of  claim 13 , wherein the textile is substantially comprised of the fiber of  claim 1 .  
     
     
         15 . A garment comprising the textile of  claim 13 .  
     
     
         16 . A method for producing power from electrochemical oxidation, comprising the steps of: 
 providing a proton exchange membrane fuel cell fiber having an inner electrode, a first layer selected from the group consisting of a fuel catalyst layer and oxidant catalyst layer intimately adjoined to the inner electrode, an outer electrode, a second layer selected from the group consisting of a fuel catalyst layer and oxidant catalyst layer intimately adjoined to the outer electrode and a proton exchange membrane between the first and second layers, wherein each of the inner and outer electrodes are exclusively one of either an anode or cathode and wherein the diameter of the fiber ranges from about 5 mm or less and the length ranges from about 1 cm or more; and,    conducting an oxidative process therein effective to produce energy.    
     
     
         17 . The method of  claim 16 , further comprising the step of channeling a fuel source to the fiber.  
     
     
         18 . The method of  claim 16 , wherein the inner electrode comprises an anode.  
     
     
         19 . The method of  claim 16 , wherein the inner electrode comprises a cathode.  
     
     
         20 . The method of  claim 18 , wherein the step of adjoining the cathode comprises a method selected from the group consisting of dip coating, vapor phase, spin coating, film casting, press forming, doctor blading, and combinations thereof.