Development and evaluation of portable and wearable fuel cells for soldier use

• Test and evaluation of systems developed for portable and wearable military applications.
• Laboratory results and soldier feedback from limited test events included.
• Portable FC systems require power density improvements for widespread use.
• Based on feedback, desirable wearable system attributes include thin form factor.
• Wearable systems based on Alane demonstrated high power density offering an attractive power source.

A number of fuel cell systems have been recently developed to meet the U.S. Army's soldier power requirements. The operation and performance of these systems are discussed based on laboratory results and limited soldier evaluation. The systems reviewed are primarily intended for soldier use in an austere environment with minimum access to resupply and vehicular transportation. These applications require high power and energy density sources that are portable (300 W) and wearable (20 W) to minimize the soldier's load burden. Based on soldier field evaluations of portable fuel cell systems, improvements in power density and compatibility with logistical fuels are required to be successfully deployed. For soldier worn applications, a novel chemical hydride system has shown significant advances in power and energy density while maintaining a small form factor. The use of a high energy dense fuel cartridge (800 Wh kg−1) based on AlH3 (Alane) thermolysis, allows a power density of (28 W kg−1) which offers promising weight savings compared to the standard military batteries.