Novel designs of a cylindrical and a flat portable direct methanol fuel cell (DMFC) have been proposed in this research. Experimental cells have also been fabricated. Their maximum power output reached 12mWcm2 when operating at room temperature and with naturally breathed air. The weight and the volume of the experimental cylindrical cell are 27g and 30cm3, respectively, with 7.5cm3 of methanol inside. Its specific power and volumetric power density are 6.67mWg and 6.25mWcm3, respectively. The membrane electrode assembly was fabricated by hot pressing the electrodes purchased from E-Tek Co. The catalyst contents are 4.0mgcm2 of PtRu (80wt.% carbon supported) and 4.0mgcm2 of Pt (black) for anode and cathode, respectively. The new and compact design will make the portable DMFC lighter and cheaper, and bring it one step closer to be marketable.

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