Disclosed herein are fuel cell systems and, more specifically, fuel cell
electrode pair and stack assemblies and various methods relating thereto.
In one embodiment, the present invention is directed to a fuel cell
electrode pair assembly adapted for use with a fuel cell system, wherein
the electrode pair assembly comprises an anode structure derived from a
first silicon substrate and an opposing cathode structure derived from a
second silicon substrate, wherein at least (i) the anode structure
comprises one or more discrete anodic porous active regions disposed
across a top surface, or (ii) the cathode structure comprises one or more
discrete cathodic porous active regions disposed across a top surface,
and wherein the anode structure and the cathode structure each have at
least one adjoining support member made of silicon, one or more plastics,
or one or more glasses, and wherein the at least one adjoining support
member of the anode structure and the at least one adjoining support
member of the cathode structure have interfacing surfaces that are bonded
together with an optional interposing binding material and with at least
one selectively positioned bond to thereby form a hermetic seal, wherein
the at least one selectively positioned bond is selected from the group
consisting of a silicon-metal eutectic-silicon bond, a
silicon-frit-silicon bond, a silicon-metal-silicon microwave bond, a
silicon-polymer adhesive-silicon bond, a silicon-polymer adhesive-plastic
bond, a silicon-polymer adhesive-glass bond, or a silicon-glass anodic
bond.