Methods and apparatus for assembling solid oxide fuel cells

• US 20040110054A1
• Filed: 12/10/2002
• Published: 06/10/2004
• Est. Priority Date: 12/10/2002
• Status: Active Grant

• Current Assignee: Cummins Enterprise, LLC (Cummins Incorporated)
• Original Assignee: General Electric Company
• Inventors: Wei, Chang, Hart, Richard Louis, Hardwicke, Canan Uslu, Bourgeois, Richard Scott, Jackson, Melvin Robert, Gigliotti,, Michael Francis Xavier Jr.
• Granted Patent: US 7,329,471 B2
• Time in Patent Office: Days
• US Class Current: 429/38
• CPC Class Codes: H01M 8/1231 with both reactants being gaseous or vaporised
• CPC Class Codes: H01M 8/1253 the electrolyte containing zirconium oxide
• CPC Class Codes: H01M 8/2425 High-temperature cells with solid electrolytes
• CPC Class Codes: H01M 8/2432 Grouping of unit cells of planar configuration
• CPC Class Codes: H01M 8/2483 characterised by internal manifolds
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A solid oxide fuel cell comprises at least one hollow manifold, an anode, an electrolyte, and a cathode. The at least one hollow manifold comprises a wall that defines a chamber therein. A plurality of openings extending through, such that the plurality of openings are in flow communication with the chamber. The anode is formed on an exterior surface of the wall. The electrolyte is deposited on the anode, and the cathode is deposited on the electrolyte.

Claims

1. A solid oxide fuel cell comprising:

at least one hollow manifold comprising a wall extending between a first end and a second end, said wall defining a chamber therein, said wall comprising a plurality of openings extending therethrough in flow communication with said chamber;

an anode on an exterior surface of said manifold wall;

an electrolyte on said anode; and

a cathode on said electrolyte.

2. A solid oxide fuel cell in accordance with claim 1 wherein said at least one manifold wall comprises a top wall, a bottom wall, and a plurality of sidewalls, said plurality of sidewalls extending substantially perpendicularly between said top wall and said bottom wall, said plurality of manifold openings extending through said top wall.

3. A solid oxide fuel cell in accordance with claim 1 wherein said at least one hollow manifold further comprises an electrically conductive material.

4. A solid oxide fuel cell in accordance with claim 1 wherein said anode is bonded directly to said at least one manifold.

5. A solid oxide fuel cell in accordance with claim 1 wherein said electrolyte is at least coextensive with said anode, said electrolyte is bonded directly to said at least one manifold.

6. A solid oxide fuel cell in accordance with claim 1 wherein said electrolyte is substantially impermeable to a gas, and is configured to conduct oxygen ions between said cathode and said anode.

7. A fuel cell stack comprising:

a first solid oxide fuel cell and a second solid oxide fuel cell, said first solid oxide fuel cell and said second solid oxide fuel cell electrically coupled together in series in a stack configuration such that at least one sealed passage extends between said first and said second solid oxide fuel cells, said first and second fuel cell each comprising;

a hollow manifold comprising a continuous wall extending between a first end and a second end, said wall defining a chamber therein, said wall comprising a plurality of openings extending therethrough in flow communication with said chamber;

an anode on said manifold wall;

an electrolyte on said anode; and

a cathode on said electrolyte.

8. A fuel cell stack in accordance with claim 7 further comprising a cathode flow channel coupled to at least one of said first solid oxide fuel cell manifold and said second solid oxide fuel cell manifold, said cathode flow channel for directing a gas between said first and said second solid oxide fuel cells.

9. A fuel cell stack in accordance with claim 7 wherein at least one of said first solid oxide fuel cell manifold and said second solid oxide fuel cell manifold is substantially rectangular.

10. A fuel cell stack in accordance with claim 7 wherein at least one of said first solid oxide fuel cell manifold and said second solid oxide fuel cell manifold further comprises an electrically conductive material.

11. A fuel cell stack in accordance with claim 7 wherein each said electrolyte is at least coextensive with each said anode such that each said electrolyte is bonded to said manifold.

12. A fuel cell stack in accordance with claim 7 wherein each said manifold comprises a pair of end plates coupled to a first end and a second end of said manifold.

13. A fuel cell stack in accordance with claim 7 wherein said electrolyte is substantially impermeable to a gas, and is configured to conduct oxygen ions between said cathode and said anode.

14. A fuel cell stack in accordance with claim 7 wherein said at least one sealed passage comprises a pair of seal members positioned between said first and second solid oxide fuel cells, said plurality of seal members configured to electrically insulate said first solid oxide fuel cell from said second solid oxide fuel cell.

15. A fuel cell stack in accordance with claim 7 further comprising a substantially hollow cathode end plate and a substantially solid anode end plate.

16. A method for fabricating a fuel cell stack, said method comprising:

forming a first solid oxide fuel cell and a second solid oxide fuel cell, wherein the first and second solid oxide fuel cells each include a hollow manifold formed from a wall such that a chamber is defined therein,

forming a plurality of openings to extend through each manifold wall such that the plurality of openings extend into the chamber;

forming an anode on the wall, such that the anode extends over the wall openings;

depositing an electrolyte on said anode; and

depositing a cathode on said electrolyte.

17. A method in accordance with claim 16 further comprising:

positioning at least one seal between the first solid oxide fuel cell and the second solid oxide fuel cell; and

coupling a cathode flow channel to at least one of the manifolds for directing a fluid flow between the first solid oxide fuel cell and the second solid oxide fuel cell.

18. A method for fabricating a fuel cell stack in accordance with claim 16 wherein said forming a first solid oxide fuel cell and a second solid oxide fuel cell comprises forming at least one substantially rectangular manifold.

19. A method for fabricating a fuel cell stack in accordance with claim 16 wherein said forming a first solid oxide fuel cell and a second solid oxide fuel cell comprises forming a manifold from an electrically conductive material.

20. A method for fabricating a fuel cell stack in accordance with claim 16 wherein said depositing an electrolyte on said anode comprises depositing an electrolyte such that the electrolyte is at least coextensive with the anode, such that the electrolyte is bonded to the manifold.

21. A method for fabricating a fuel cell stack in accordance with claim 16 further comprising mechanically coupling a pair of end plates to a first end and a second end of the manifold.

22. A method for fabricating a fuel cell stack in accordance with claim 16 wherein said depositing an electrolyte on the anode comprises depositing an electrolyte on the anode that is substantially impermeable to a gas.

23. A method for fabricating a fuel cell stack in accordance with claim 16 wherein said depositing an electrolyte on the anode comprises depositing an electrolyte on the anode that is configured to conduct oxygen ions between the cathode and the anode.

24. A method for fabricating a fuel cell stack in accordance with claim 16 wherein said positioning at least one seal between the first solid oxide fuel cell and the second solid oxide fuel cell comprises positioning two seals between the first solid oxide fuel cell and the second solid oxide fuel cell, such that the seals electrically insulate the first solid oxide fuel cell from the second solid oxide fuel cell.

25. A method for fabricating a fuel cell stack in accordance with claim 16 said method further comprising electrically coupling a substantially hollow cathode end plate and a substantially solid anode end plate to the fuel cell stack.

26. A solid oxide fuel cell comprising:

at least one hollow manifold comprising at least one of an interconnect and an electrode, said manifold further comprising a wall extending between a first end and a second end, said wall defining a chamber therein; and

a cathode on said manifold.

27. A solid oxide fuel cell in accordance with claim 26 wherein said manifold further comprises said electrode, said interconnect comprising a substantially planar piece of material coupled to said manifold.

28. A solid oxide fuel cell in accordance with claim 27 wherein said electrode comprises an anode, said at least one manifold wall comprises a top wall, a bottom wall, and a pair of sidewalls, said pair of sidewalls extending substantially perpendicularly between said top wall and said bottom wall.

29. A solid oxide fuel cell in accordance with claim 27 wherein said electrode comprises a cathode, said at least one manifold wall comprises a top wall, a bottom wall, and a pair of sidewalls, said pair of sidewalls extending substantially perpendicularly between said top wall and said bottom wall.

30. A solid oxide fuel cell in accordance with claim 26 wherein said manifold further comprises said interconnect, an anode on an exterior surface of said manifold;

an electrolyte on said anode, and a cathode on said electrolyte.

31. A manifold for use with a solid oxide fuel cell, said manifold comprising a body defining a chamber therein, said body extending between a first end and a second end, said body comprising at least one of an interconnect and an electrode.