Fuel processor for use in a fuel cell system

Abstract

A method for manufacturing a fuel processor may comprise coupling a plurality of micro-tubes in parallel to form a flow field tube array, each of the plurality of micro-tubes designed to receive a fluid flow, depositing a catalyst layer inside each of the plurality of micro-tubes, and attaching at least one burner to a first end of the flow field tube array.

1 . A method for manufacturing a fuel processor, comprising:
 coupling a plurality of micro-tubes in parallel to form a flow field tube array, each of the plurality of micro-tubes designed to receive a fluid flow;   depositing a catalyst layer inside each of the plurality of micro-tubes; and   attaching at least one burner to a first end of the flow field tube array.   
     
     
         2 . The method of  claim 1 , further comprising positioning at least one membrane electrode assembly (MEA) adjacent the flow field tube array. 
     
     
         3 . The method of  claim 1 , wherein the plurality of micro-tubes are thermally and electrically conductive. 
     
     
         4 . The method of  claim 1 , wherein the coupling further comprises welding the plurality of micro-tubes in parallel. 
     
     
         5 . The method of  claim 1 , further comprising attaching a reformer between the burner and the flow field tube array. 
     
     
         6 . The method of  claim 5 , further comprising depositing a catalyst layer in the reformer. 
     
     
         7 . The method of  claim 1 , further comprising depositing a catalyst layer in the at least one burner. 
     
     
         8 . The method of  claim 1 , wherein the catalyst layer is a reformer catalyst layer. 
     
     
         9 . The method of  claim 1 , wherein the depositing further comprising:
 trapping the catalyst layer in a macro cage of a zeolite; and   depositing the zeolite inside each of the plurality of micro-tubes.   
     
     
         10 . The method of  claim 1 , wherein the depositing further comprises mixing the catalyst layer with the fluid flow. 
     
     
         11 . The method of  claim 1 , wherein the depositing further comprises etching the catalyst layer inside each of the plurality of micro-tubes. 
     
     
         12 . The method of  claim 1 , further comprising depositing a second catalyst layer in the at least one burner. 
     
     
         13 . The method of  claim 12 , wherein the depositing the second catalyst layer further comprises:
 depositing an alumina layer on a thermally conductive substrate;   depositing a catalyst layer over the alumina layer; and   reducing the catalyst layer and the alumina layer.   
     
     
         14 . The method of  claim 13 , wherein the substrate is an aluminum porous metal or an aluminum metallic sponge. 
     
     
         15 . The method of  claim 13 , wherein the reducing further comprises depositing a reducing agent gas over the catalyst layer. 
     
     
         16 . The method of  claim 1 , further comprises wash coating a catalyst layer to at least one wall of the at least one burner. 
     
     
         17 . A method for manufacturing a fuel processor, comprising:
 forming at least one catalyst layer, comprising:
 depositing an alumina layer on a thermally conductive substrate; 
 depositing a catalyst layer over the alumina layer; and 
 reducing the catalyst layer and the alumina layer; 
   coupling a plurality of micro-tubes in parallel to form a flow field tube array, each of the plurality of micro-tubes designed to receive a fluid flow;   placing at least one of the catalyst layers inside each of the plurality of micro-tubes;   attaching at least one burner to a first end of the flow field tube array, and   placing at least one of the catalyst layers in the at least one burner.   
     
     
         18 . The method of  claim 17 , wherein the substrate is an aluminum porous metal or an aluminum metallic sponge. 
     
     
         19 . The method of  claim 17 , further comprising positioning at least one membrane electrode assembly (MEA) adjacent the flow field tube array. 
     
     
         20 . The method of  claim 17 , wherein the plurality of micro-tubes are thermally and electrically conductive.