U.S. patent application number 10/997787 was filed with the patent office on 2006-06-15 for solid oxide fuel cell system.
Invention is credited to Lorne Johanson, Hongsang Rho, Partho Sarkar.
Application Number | 20060127725 10/997787 |
Document ID | / |
Family ID | 29582331 |
Filed Date | 2006-06-15 |
United States Patent
Application |
20060127725 |
Kind Code |
A9 |
Sarkar; Partho ; et
al. |
June 15, 2006 |
Solid oxide fuel cell system
Abstract
This invention relates to a fuel cell system comprising an outer
tubular solid oxide fuel cell, a solid phase porous matrix located
inside the outer fuel cell and attached to its inner electrode
layer, and at least one inner tubular solid oxide fuel cell
embedded in the matrix. The outer fuel cell has an inner electrode
layer configured to receive a first reactant fluid, an outer
electrode layer configured to receive a second reactant fluid, and
an electrolyte layer sandwiched between the electrode layers. The
inner fuel cell has an outer electrode layer configured to receive
the first reactant fluid, an inner electrode layer configured to
receive the second reactant fluid, and an electrolyte layer
sandwiched between the inner and outer electrode layers. The matrix
has sufficient mechanical strength to support the inner fuel cell
and sufficient porosity to enable the first reactant fluid to flow
through the matrix to the inner and outer fuel cell
respectively.
Inventors: |
Sarkar; Partho; (Edmonton,
CA) ; Rho; Hongsang; (Edmonton, CA) ;
Johanson; Lorne; (Edmonton, CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20050196657 A1 |
September 8, 2005 |
|
|
Family ID: |
29582331 |
Appl. No.: |
10/997787 |
Filed: |
November 23, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/CA03/00761 |
May 23, 2003 |
|
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10997787 |
Nov 23, 2004 |
|
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10156755 |
May 23, 2002 |
6936367 |
|
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PCT/CA03/00761 |
May 23, 2003 |
|
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Current U.S.
Class: |
429/423 ;
429/466 |
Current CPC
Class: |
Y02E 60/50 20130101;
H01M 8/0252 20130101; C25D 1/14 20130101; H01M 8/12 20130101; H01M
8/004 20130101; H01M 8/0232 20130101; H01M 8/2475 20130101; H01M
8/0612 20130101; H01M 8/1226 20130101; H01M 8/243 20130101; C04B
38/06 20130101; H01M 8/2485 20130101; H01M 8/1286 20130101; C25D
13/14 20130101; H01M 8/06 20130101; H01M 8/02 20130101; H01M 8/0236
20130101; H01M 8/1213 20130101; C25D 13/02 20130101 |
Class at
Publication: |
429/031 ;
429/038; 429/020 |
International
Class: |
H01M 8/12 20060101
H01M008/12; H01M 8/02 20060101 H01M008/02; H01M 8/06 20060101
H01M008/06 |
Claims
1. A fuel cell system comprising: (a) an outer tubular solid oxide
fuel cell comprising an inner electrode layer configured to receive
a first reactant fluid, an outer electrode layer configured to
receive a second reactant fluid, and an electrolyte layer
sandwiched between the electrode layers; (b) a solid phase porous
matrix located inside the outer fuel cell and attached to its inner
electrode layer; and (c) at least one inner tubular solid oxide
fuel cell embedded in the matrix substantially inside the outer
fuel cell, the inner fuel cell having an outer electrode layer
configured to receive the first reactant fluid, an inner electrode
layer configured to receive the second reactant fluid, and an
electrolyte layer sandwiched between the inner and outer electrode
layers; the matrix having sufficient mechanical strength to support
the inner fuel cell within the outer fuel cell and sufficient
porosity to enable the first reactant fluid to flow through the
matrix to the inner electrode layer of the outer fuel cell and to
the outer electrode layer of the inner fuel cell.
2. The fuel cell system of claim 1 wherein the matrix is a solid
state porous foam.
3. The fuel cell system of claim 2 wherein the foam is an
electronic or mixed (electronic and ionic) conductive material and
is electrically coupled to the cathode of the inner and outer fuel
cells.
4. The fuel cell system of claim 3 wherein the foam composition
includes one or more materials selected from the group consisting
of: lanthanum strontium manganate, La.sub.1-xSr.sub.xCrO.sub.3,
La.sub.1-xCa.sub.xCrO.sub.3, La.sub.1-xMg.sub.xCrO.sub.3,
LaCr(Mg)O.sub.3, LaCa.sub.1-xCr.sub.yO.sub.3,
La.sub.1-xSr.sub.xFeO.sub.3,
(La.sub.1-xSr.sub.x)(Fe.sub.1-4Co.sub.y)O.sub.3, stainless steel
316 and 316L, Ni-Yittria stabilized zirconia--Ni and doped zirconia
cermet, Ni doped --CeO.sub.2 cermet, Cu doped-ceria cermet,
silver-(Bi--Sr--Ca--Cu--O)-oxide cermet,
silver-(Y--Ba--Cu--O)-oxide cermet;
silver-alloy-(Bi--Sr--Ca--Cu--O)-oxide cermet;
silver-alloy-(Y--Ba--Cu--O)-oxide cermet; silver and its alloys,
Inconel steel and any super alloy, ferritic steel, SiC, and
MoSi.sub.2.
5. The fuel cell system of claim 1 wherein the matrix is a material
selected form the group consisting of a metal mesh, a metal,
ceramic or cermet wool bundle, and metal, ceramic or cermet
entangled fibrous bundle.
6. The fuel cell system of claim 2 wherein the inner fuel cell's
inner electrode layer is an anode, the inner fuel cell's outer
electrode layer is a cathode, the outer fuel cell's inner electrode
layer is a cathode, the outer fuel cell's outer electrode is an
anode, the first reactant is fuel, and the second reactant is
oxidant.
7. The fuel cell system of claim 6 wherein the inner fuel cell has
a diameter between 10 .mu.m and 10,000 .mu.m.
8. The fuel cell system of claim 7 wherein the inner fuel cell has
a diameter between 10 .mu.m and 5,000 .mu.m.
9. The fuel cell system of claim 6 wherein the matrix includes at
least one elongate void for enhancing the delivery of oxidant to
the cathode of the inner and outer fuel cells.
10. The fuel cell system of claim 6 further comprising an oxidant
diffuser that has an inlet fluidly connectable to an oxidant
source, and a plurality of outlets fluidly coupled to the
matrix.
11. The fuel cell system of claim 1 further comprising a plurality
of tab openings through the outer electrode and electrolyte layers
of the inner fuel cell, the tab openings being spaced along the
length of the inner fuel cell; and a gas-impermeable, electrically
conductive tab located in and sealing each opening, each tab being
electrically connected to the inner electrode layer of the inner
fuel cell and electrically connectable to an external circuit.
12. The fuel cell stack of claim 11 wherein each tab is an inert
metal coating that is suitable for use under SOFC operating
conditions.
13. The fuel cell system of claim 11 further comprising at least
one current collector rod embedded in the matrix, and electrically
connected to at least one of the tabs and electrically connectable
to an external circuit.
14. The fuel cell system of claim 11 further comprising at least
one current collector plate transversely embedded in the matrix
inside the outer fuel cell, the plate being electrically insulated
or isolated from the matrix by a high temperature insulating
material between the plate and the matrix or by a gap between the
plate and the matrix, the plate having an opening for receiving the
inner fuel cell, and perforations that enable the flow through of a
reactant fluid to the outer electrode layer of the inner fuel cell
and the inner electrode layer of the outer fuel cell, the current
collector plate being electrically connected to at least one of the
tabs and electrically connectable to an external circuit.
15. The fuel cell system of claim 1 further comprising a fuel
reformer comprising a reformer chamber with a fuel inlet for
fluidly coupling to an unreformed fuel source and a fuel outlet
fluidly coupled to the anode of the inner and outer fuel cells, the
reformer chamber being thermally coupled with at least one of the
fuel cells so that the heat produced by the fuel cell reaction is
used to reform unreformed fuel.
16. The fuel cell system of claim 15 wherein the reformer chamber
is a double-walled cup and the fuel cell is located inside the
cavity of the cup.
17. The fuel cell system of claim 15 further comprising a
catalyst-coated solid state porous matrix inside the reformer
chamber.
18. The fuel cell system of claim 15 wherein the reformer chamber
is a reformer tube coiled around the outer fuel cell, the fuel
inlet and outlet being at opposite ends of the tube.
19. The fuel cell system of claim 18 wherein the reformer tube
includes catalytic material dispersed along the inside of the
reformer tube.
20. The fuel cell system of claim 1 wherein the inner fuel cell
further comprises a porous electrically conductive current
collector located inside the inner fuel cell, electrically coupled
to its inner electrode layer, and having sufficient porosity to
enable the flow of the second reactant fluid through the current
collector and to the inner fuel cell's inner electrode layer.
21. A fuel cell system comprising: (a) at least one tubular solid
oxide fuel cell, the fuel cell comprising an outer electrode layer
configured to receive a first reactant fluid, an inner electrode
layer configured to receive a second reactant fluid, and an
electrolyte layer sandwiched between the electrode layers; (b) a
porous electrically conductive current collector located inside the
fuel cell, electrically coupled to the inner electrode layer, and
having sufficient porosity to enable the second reactant fluid to
flow through the current collector and to the inner electrode
layer, the current collector composition including one or more
materials selected from the group consisting of: lanthanum
strontium manganate, La.sub.1-xSr.sub.xCrO.sub.3,
La.sub.1-xCa.sub.xCrO.sub.3, La .sub.1-xMg.sub.xCrO.sub.3,
LaCr(Mg)O.sub.3, LaCa.sub.1-xCr.sub.yO.sub.3,
La.sub.1-xSr.sub.xFeO.sub.3,
(La.sub.1-xSr.sub.x)(Fe.sub.1-yCo.sub.y)O.sub.3, stainless steel
316 and 316L, Ni-Yittria stabilized zirconia, Ni and doped zirconia
cermet, Ni doped--CeO.sub.2 cermet, Cu doped-ceria cermet,
silver-(Bi--Sr--Ca--Cu--O)-oxide cermet.
silver-(Y--Ba--Cu--O)-oxide cermet;
silver-alloy-(Bi--Sr--Ca--Cu--O)-oxide cermet;
silver-alloy-(Y--Ba--Cu--O)-oxide cermet; silver and its alloys.
Inconel steel and any super alloy, ferritic steel, SiC, and
MoSi.sub.2; and (c) a solid phase porous support matrix in which
the fuel cell is embedded, the matrix having sufficient mechanical
strength to support the fuel cell inside the system and sufficient
porosity to enable the first reactant fluid to flow through the
matrix and to the outer electrode layer.
22-24. (canceled)
25. The fuel cell system of claim 21 wherein the current collector
is a bundle of overlapping metal, electrically conductive ceramic
or cermet fibres.
26. The fuel cell system of claim 21 wherein the current collector
is a bundle of metal, electrically conductive ceramic or cermet
wool.
27-28. (canceled)
29. The fuel cell system of claim 21 wherein the current collector
has a porosity of between 25 and 95%.
30. The fuel cell system of claim 29 wherein the current collector
has a porosity of between 40 and 95%.
31. The fuel cell system of claim 30 wherein the current collector
has a porosity of about 60%.
32-36. (canceled)
37. The fuel cell system of claim 21 wherein the support matrix
composition includes a material selected from the group consisting
of: lanthanum strontium manganate, La.sub.1-xSr.sub.xCrO.sub.3,
La.sub.1-xCa.sub.xCrO.sub.3, La.sub.1-xMg.sub.xCrO.sub.3,
LaCr(Mg)O.sub.3, LaCa.sub.1-xCr.sub.yO.sub.3,
La.sub.1-xSr.sub.x,FeO.sub.3,
(La.sub.1-xSr.sub.x)(Fe.sub.1-yCo.sub.y)O.sub.3, stainless steel
316 and 316L, Ni-Yittria stabilized zirconia, Ni and doped zirconia
cermet, Ni doped--CeO.sub.2 cermet, Cu doped-ceria cermet,
silver-(Bi--Sr--Ca--Cu--O)-oxide cermet,
silver-(Y--Ba--Cu--O)-oxide cermet;
silver-alloy-(Bi--Sr--Ca--Cu--O)-oxide cermet;
silver-alloy-(Y--Ba--Cu--O)-oxide cermet; silver and its alloys,
Inconel steel and any super alloy, ferritic steel, SiC, and
MoSi.sub.2.
38. The fuel cell system of claim 1 wherein the matrix
substantially fills the inside of the outer fuel cell.
39. The fuel cell system of claim 21 wherein the current collector
substantially fills the inside of the fuel cell.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of PCT application Ser. No.
PCT/CA03/00761, which was filed May 23, 2003 designating the US and
published in English on Dec. 4, 2003 as WO 03/100881. The above PCT
application also claims priority to U.S. patent application Ser.
No. 10/156,755, filed May 23, 2002 and which is co-pending
herewith. The above PCT and U.S. patent applications are
incorporated herein by reference in their entireties and made part
of the present disclosure.
FIELD OF THE INVENTION
[0002] This invention relates to a fuel cell system having a stack
of tubular solid oxide fuel cells.
BACKGROUND OF THE INVENTION
[0003] In general, a solid oxide fuel cell (SOFC) comprises a pair
of electrodes (anode and cathode) separated by a ceramic,
solid-phase electrolyte. To achieve adequate ionic conductivity in
such a ceramic electrolyte, the SOFC operates at an elevated
temperature, typically in the order of about 1000.degree. C. The
material in typical SOFC electrolytes is a fully dense (i.e.
non-porous) yttria-stabilized zirconia (YSZ) which is an excellent
conductor of negatively charged oxygen (oxide) ions at high
temperatures. Typical SOFC anodes are made from a porous
nickel/zirconia cermet while typical cathodes are made from
magnesium doped lanthanum manganate (LaMnO.sub.3), or a strontium
doped lanthanum manganate (also known as lanthanum strontium
manganate (LSM)). In operation, hydrogen or carbon monoxide (CO) in
a fuel stream passing over the anode reacts with oxide ions
conducted through the electrolyte to produce water and/or CO.sub.2
and electrons. The electrons pass from the anode to outside the
fuel cell via an external circuit, through a load on the circuit,
and back to the cathode where oxygen from an air stream receives
the electrons and is converted into oxide ions which are injected
into the electrolyte. The SOFC reactions that occur include:
[0004] Anode reaction: H.sub.2+O.sup.=.fwdarw.H.sub.2O+2e.sup.-
[0005] CO+O.sup.=.fwdarw.CO.sub.2+2e.sup.- [0006]
CH.sub.4+4O.sup.=.fwdarw.2H.sub.2O+CO.sub.2+8e.sup.-
[0007] Cathode reaction: O.sub.2+4e.sup.-.fwdarw.2O.sup.=
[0008] Known SOFC designs include planar and tubular fuel cells.
Applicant's own PCT application no. PCT/CA01/00634 discloses a
method of producing a tubular fuel cell by electrophoretic
deposition (EPD). The fuel cell comprises multiple concentric
layers, namely an inner electrode layer, a middle electrolyte
layer, and an outer electrode layer. The inner and outer electrodes
may suitably be the anode and cathode respectively, and in such
case, fuel may be supplied to the anode by passing through the
tube, and air may be supplied to the cathode by passing over the
outer surface of the tube.
[0009] It is also known to arrange a plurality of tubular fuel
cells in an array or "stack" to increase electrical output. Designs
have been proposed for stacking together relatively large-diameter
(.gtoreq.5 mm) thick-walled tubular fuel cells that are essentially
self-supporting; for example it is known to stack large diameter
tubular fuel cells having diameters in a grid-like pattern and
interconnect the fuel cells with nickel felt spacers. This and
other known designs for large diameter self-supporting tubular fuel
cells are not particularly well suited for small diameter fuel
cells (.ltoreq.5 mm), especially if such small diameter fuel cells
are arranged into a tightly-packed array. It is therefore desirable
to provide an improved stack design that enables the close-packing
of a plurality of small-diameter tubular fuel cells, and a system
for such stack.
SUMMARY OF THE INVENTION
[0010] According to one aspect of the invention, there is provided
a fuel cell system comprising an outer tubular solid oxide fuel
cell, a solid phase porous matrix located inside the outer fuel
cell and attached to its inner electrode layer, and at least one
inner tubular solid oxide fuel cell embedded in the matrix
substantially inside the outer fuel cell. The outer fuel cell has
an inner electrode layer configured to receive a first reactant
fluid, an outer electrode layer configured to receive a second
reactant fluid, and an electrolyte layer sandwiched between the
electrode layers. The inner fuel cell has an outer electrode layer
configured to receive the first reactant fluid, an inner electrode
layer configured to receive the second reactant fluid, and an
electrolyte layer sandwiched between the inner and outer electrode
layers. The matrix has sufficient mechanical strength to support
the inner fuel cell within the outer fuel cell and sufficient
porosity to enable the first reactant fluid to flow through the
matrix to the inner electrode layer of the outer fuel cell and to
the outer electrode layer of the inner fuel cell.
[0011] The matrix can be a solid state porous foam or a metal mesh.
When the matrix is a foam, it can be an electronic or mixed
(electronic and ionic) conductive material and can be electrically
coupled to the cathode of the inner and outer fuel cells. The
foam's composition can include one or more materials selected from
the group consisting of: lanthanum strontium manganate,
La.sub.1-xSr.sub.xCrO.sub.3, La.sub.1-xCa.sub.xCrO.sub.3,
La.sub.1-xMg.sub.xCrO.sub.3, LaCr(Mg)O.sub.3,
LaCa.sub.1-xCr.sub.yO.sub.3, stainless steel 316 and 316L,
Ni-Yittria stabilized zirconia, Ni and doped zirconia cermet, Ni
doped--CeO.sub.2 cermet, Cu doped-ceria cermet,
silver-(Bi--Sr--Ca--Cu--O)-oxide cermet,
silver-(Y--Ba--Cu--O)-oxide cermet;
silver-alloy-(Bi--Sr--Ca--Cu--O)-oxide cermet;
silver-alloy-(Y--Ba--Cu--O)-oxide cermet; silver and its alloys,
Inconel steel and any super alloy, ferritic steel, SiC, and
MoSi.sub.2.
[0012] The inner fuel cell's inner electrode layer can be an anode,
in which case its outer electrode layer is a cathode;
correspondingly, the outer fuel cell's inner electrode layer is a
cathode, and its outer electrode is an anode. With such a
configuration, the first reactant is fuel, and the second reactant
is oxidant.
[0013] The inner fuel cell can have a diameter between 10 .mu.m and
10,000 .mu.m, or more particularly, between 10 .mu.m and 5,000
.mu.m.
[0014] The matrix can include at least one elongate void for
enhancing the delivery of oxidant to the cathode of the inner and
outer fuel cells. There can also be an oxidant diffuser that has an
inlet fluidly connectable to an oxidant source, and a plurality of
outlets fluidly coupled to the matrix.
[0015] The fuel cell system can also include a plurality of tab
openings through the outer electrode and electrolyte layers of the
inner fuel cell, and a gas-impermeable, electrically conductive tab
located in and sealing each opening. The tab openings are spaced
along the length of the inner fuel cell. Each tab is electrically
connected to the inner electrode layer of the inner fuel cell and
is electrically connectable to an external circuit. Each tab can be
an inert metal coating that is suitable for use under SOFC
operating conditions. At least one current collector rod can be
embedded in the matrix, and be electrically connected to at least
one of the tabs and be electrically connectable to an external
circuit. Alternatively, a current collector plate can be
transversely embedded in the matrix inside the outer fuel cell. The
plate is electrically insulated or isolated from the matrix by a
high temperature insulating material between the plate and the
matrix or by a gap between the plate and the matrix. The plate has
an opening for receiving the inner fuel cell, and perforations that
enable the flow through of a reactant fluid to the outer electrode
layer of the inner fuel cell and the inner electrode layer of the
outer fuel cell. The current collector plate in this case is
electrically connected to at least one of the tabs and is
electrically connectable to an external circuit.
[0016] The fuel cell system can include a fuel reformer, having a
reformer chamber with a fuel inlet for fluidly coupling to an
unreformed fuel source and a fuel outlet fluidly coupled to the
anode of the inner and outer fuel cells. The reformer chamber is
thermally coupled with at least one of the fuel cells so that the
heat produced by the fuel cell reaction is used to reform
unreformed fuel. The reformer chamber can be a double-walled cup
and in which case the fuel cell is located inside the cavity of the
cup. A catalyst-coated solid state porous matrix can be provided
inside the reformer chamber. Alternatively, the reformer chamber
can be a reformer tube coiled around the outer fuel cell; the fuel
inlet and outlet are located at opposite ends of the tube. The
reformer tube can include catalytic material dispersed along the
inside of the reformer tube.
[0017] The inner fuel cell can further comprise a porous
electrically conductive current collector located inside the inner
fuel cell, electrically coupled to its inner electrode layer, and
having sufficient porosity to enable the flow of the second
reactant fluid through the current collector and to the inner fuel
cell's inner electrode layer.
[0018] According to another aspect of the invention, there is
provided a fuel cell system comprising at least one tubular solid
oxide fuel cell, a porous electrically conductive current collector
located inside the fuel cell, and a solid phase porous support
matrix in which the fuel cell is embedded. The fuel cell has an
outer electrode layer configured to receive a first reactant fluid,
an inner electrode layer configured to receive a second reactant
fluid, and an electrolyte layer sandwiched between the electrode
layers. The current collector is electrically coupled to the inner
electrode layer, and has sufficient porosity to enable the second
reactant fluid to flow through the current collector and to the
inner electrode layer. The support matrix has sufficient mechanical
strength to support the fuel cell inside the system and sufficient
porosity to enable the first reactant fluid to flow through the
matrix and to the outer electrode layer.
[0019] The current collector can be a solid state porous matrix
lining at least part of the surface of the inner electrode layer.
Alternatively, the current collector can be one of the
following:
[0020] a bundle of overlapping metal, ceramic or cermet fibres;
[0021] a bundle of metal, ceramic or cermet wool;
[0022] a plurality of perforated sheets attached at their edges to
the surface of the inner electrode layer; or
[0023] an electrically conductive rod or wire extending
longitudinally through the inside of the fuel cell and a plurality
of electrically conductive filaments extending generally
transversely between the collector rod and the inner electrode
layer.
[0024] The current collector can have a porosity of between 25 and
95%, and more particularly, between 40 and 95%, and even more
particularly, about 60%.
[0025] The current collector can be coated with a catalyst
material. At least one current collector rod or wire can be
embedded in the current collector matrix inside the fuel cell. The
rod or wire can have at least one end that is electrically
connectable to an external circuit. The current collector matrix
can include at least one elongate void for enhancing the flow of
reactant through the matrix.
[0026] The current collector matrix can be a solid state foam; the
foam can be made of one or more materials selected from the group
consisting of: lanthanum strontium manganate,
La.sub.1-xSr.sub.xCrO.sub.3, La.sub.1-xCa.sub.xCrO.sub.3,
La.sub.1-xMg.sub.xCrO.sub.3, LaCr(Mg)O.sub.3,
LaCa.sub.1-xCr--.sub.yO.sub.3, La.sub.1-xSr.sub.xFeO.sub.3,
(La.sub.1-xSr.sub.x)(Fe.sub.1-yCo.sub.y)O.sub.3, stainless steel
316 and 316L, Ni-Yittria stabilized zirconia, Ni and doped zirconia
cermet, Ni doped--CeO.sub.2 cermet, Cu doped-ceria cermet,
silver-(Bi--Sr--Ca--Cu--O)-oxide cermet,
silver-(Y--Ba--Cu--O)-oxide cermet;
silver-alloy-(Bi--Sr--Ca--Cu--O)-oxide cermet;
silver-alloy-(Y--Ba--Cu--O)-oxide cermet; silver and its alloys,
Inconel steel and any super alloy, ferritic steel, SiC, and
MoSi.sub.2.
[0027] The support matrix can also be a solid-state foam. The
support foam can be made of an electronic or mixed (electronic and
ionic) conductive porous solid state material and be electrically
coupled to the inner electrode layer of the outer fuel cell and the
outer electrode layer of the inner fuel cell. The support foam can
be made of the same materials as the current collector foam.
[0028] According to another aspect of the invention, there is
provided a fuel cell system including:
[0029] a fuel cell stack comprising a plurality of tubular solid
oxide fuel cells and a stack support structure attached to each of
the fuel cells, the fuel cells each comprising an anode, a cathode,
and an electrolyte sandwiched between the anode and cathode;
[0030] a fuel reformer tube and including a reformer chamber having
a reformer fuel inlet fluidly couplable to a fuel source and a
reformer fuel outlet fluidly coupled with the anode of at least one
fuel cell;
[0031] external circuit electrical leads electrically coupled to
the anode and cathode of at least one fuel cell and electrically
couplable to an external electrical circuit; and
[0032] a thermal enclosure assembly enclosing the stack and
reformer tube and including a fuel inlet fluidly coupled to the
reformer fuel inlet, a fuel outlet fluidly coupled to the anode of
at least one fuel cell, and an oxidant inlet and outlet fluidly
coupled to the cathode of at least one fuel cell.
[0033] According to yet another aspect of the invention, there is
provided a fuel cell system that includes at least one tubular
solid oxide fuel cell, an electrically conductive tab for
electrically coupling to an external circuit, and a stack support
structure attached to each of the fuel cells. The fuel cell
includes an electrode inner layer, an electrode outer layer, an
electrolyte layer sandwiched between the electrode layers, and a
tab opening through the electrode outer layer and the underlying
electrolyte layer. The tab includes an electrically conductive
material coating the exposed portion of the inner layer.
BRIEF DESCRIPTION OF DRAWINGS
[0034] FIG. 1 is a schematic longitudinal section view of a tubular
solid oxide fuel cell (SOFC).
[0035] FIG. 2 is a schematic longitudinal section view of a tubular
SOFC having a porous matrix structure lining the inside of the fuel
cell.
[0036] FIG. 3 is a schematic longitudinal section view of a tubular
SOFC closed at one end.
[0037] FIG. 4 is a schematic longitudinal side view of a tubular
SOFC open at both ends and having a plurality of electrically
conductive anode tabs.
[0038] FIG. 5 is a schematic longitudinal side view of the tubular
SOFC of FIG. 3 having a plurality of electrically conductive anode
tabs.
[0039] FIG. 6 is a schematic sectional side view of a pair of
tubular SOFC and an anode current collector rod embedded in a
porous matrix.
[0040] FIG. 7 is a schematic sectional side view of a fuel cell
system having a pair of tubular SOFC embedded in a porous matrix
that has branched oxidant delivery channels.
[0041] FIG. 8 is a schematic sectional side view of a pair of fuel
cells embedded in a porous matrix and attached to a transverse
anode current collector plate.
[0042] FIG. 9 is a schematic sectional side view of a pair of fuel
cells attached to transverse anode current collector plates and
transverse cathode current collector plates.
[0043] FIG. 10 is a schematic sectional side view of a pair of fuel
cells attached to transverse anode current collector plates and
transverse cathode current collector plates and embedded in a
porous matrix.
[0044] FIGS. 11 and 12 are schematic end views of fuel cell stacks
comprising a plurality of tubular fuel cells embedded in the matrix
(FIG. 11) and a plurality of fuel cells and sub-stacks of fuel
cells embedded in the matrix (FIG. 12).
[0045] FIGS. 13 and 14 are schematic end views of two fuel cell
stack designs that each comprise a plurality of inner tubular fuel
cells embedded in a foam-like porous matrix and located inside an
outer fuel cell.
[0046] FIGS. 15 and 16 are schematic end views of two different
fuel cell stack designs that each comprise a plurality of fuel cell
sub-stacks and inner tubular fuel cells embedded in a foam-like
porous matrix and located inside an outer tubular fuel cell.
[0047] FIGS. 17 and 18 are schematic end views of two fuel cell
stack designs that each comprise a plurality of small-diameter and
intermediate-diameter fuel cells embedded in a foam-like porous
matrix and located inside an large-diameter outer tubular fuel
cell.
[0048] FIG. 19 is a schematic end view of a fuel cell system
comprising a plurality of the fuel cell stacks of FIG. 17.
[0049] FIG. 20 is a schematic sectional longitudinal view of a fuel
cell stack having a plurality of inner tubular fuel cells embedded
in a porous, foam-like matrix.
[0050] FIG. 21 is a schematic sectional longitudinal view of the
fuel cell stack of FIG. 20 having a plurality of longitudinal fluid
flow channels in the matrix.
[0051] FIG. 22 is a schematic sectional longitudinal view of the
fuel cell stack of FIG. 20 having a plurality of transverse fluid
flow channels in the matrix.
[0052] FIG. 23 is a schematic sectional longitudinal view of a fuel
cell stack having a plurality of tubular fuel cells embedded in a
discontinuous porous foam-like matrix.
[0053] FIG. 24 is a schematic end view of a fuel cell stack having
a plurality of tubular fuel cells embedded in a porous, foam-like
matrix and a plurality of longitudinal fluid flow channels in the
matrix.
[0054] FIG. 25 is a schematic end view of a fuel cell stack having
a plurality of hexagonal sub-stacks each having a plurality of
tubular fuel cells therein.
[0055] FIG. 26 is a schematic sectional side view of a fuel cell
system having a stack of tubular SOFCs each closed at one end and
having an oxidant inlet channel at the bottom of the system.
[0056] FIG. 27 is a schematic sectional side view of a fuel cell
system having a stack of tubular SOFCs each closed at one end and
having a fuel gas reformer surrounding the stack.
[0057] FIG. 28 is a schematic sectional side view of a fuel cell
system having a stack of tubular SOFCs each closed at one end, and
a fuel gas reformer tube wrapped around the stack.
[0058] FIG. 29 is a schematic sectional side view of the system of
FIG. 30 with the reformer tube embedded in a heat conductive matrix
structure.
[0059] FIG. 30 is a schematic sectional side view of a fuel cell
system having a stack of tubular SOFCs each open at both ends, and
a fuel gas reformer tube wrapped around the stack.
[0060] FIGS. 31 and 32 are schematic top and side views of an
apparatus for embedding a group of fuel cells in the matrix.
[0061] FIGS. 33 is a schematic sectional longitudinal view of a
fuel cell having a porous foam-like inner core.
[0062] FIGS. 34 is a schematic cross-sectional view of the inner
core of FIG. 33, and FIG. 35 shows the inner core of FIG. 34 having
interspersed reactant flow channels.
[0063] FIG. 36 is a schematic side view of the fuel cell in FIG. 33
having additionally an electrically conductive wire embedded in the
inner core.
[0064] FIGS. 37 is a schematic cross-sectional view of the inner
core of FIG. 36, and FIG. 38 shows the inner core of FIG. 37 having
interspersed reactant flow channels.
[0065] FIG. 39 is a schematic end view of an inner core having a
series of longitudinally extending plates in physical and
electrical contact with the electrode inner surface.
[0066] FIG. 40 is a schematic longitudinal view of an inner core
having a central conductor rod and a plurality of filaments wrapped
around the rod and physically and electrically contacting the
electrode inner surface.
[0067] FIG. 41 is a schematic end view of the inner core of FIG. 34
in which a plurality of electrically conductive wires are
embedded.
DETAILED DESCRIPTION
Definitions
[0068] When describing the present invention, the following terms
have the following meanings, unless indicated otherwise. All terms
not defined herein have their common art-recognized meanings.
[0069] The term "fibre" or "filament" refers to a single strand of
fibrous material; "fibre tow" or "fibre bundle" shall refer to a
multi-filament yarn or an array of fibres; and "fibre core" shall
refer to a fibre, filament, fibre tow or fibre bundle. In all
cases, the fibre core is electrically conductive or treated to be
electrically conductive to allow its use as an electrode.
[0070] The term "ceramic" refers to inorganic non-metallic solid
materials with a prevalent covalent or ionic bond including, but
not limited to metallic oxides (such as oxides of aluminum,
silicon, magnesium, zirconium, titanium, chromium, lanthanum,
hafnium, yttrium and mixtures thereof) and nonoxide compounds
including but not limited to carbides (such as of titanium
tungsten, boron, silicon), silicides (such as molybdenum
disicilicide), nitrides (such as of boron, aluminum, titanium,
silicon) and borides (such as of tungsten, titanium, uranium) and
mixtures thereof; spinels, titanates (such as barium titanate, lead
titanate, lead zirconium titanates, strontium titanate, iron
titanate), ceramic super conductors, zeolites, and ceramic solid
ionic conductors (such as yittria stabilized zirconia, beta-alumina
and cerates).
[0071] The term "cermet" refers to a composite material comprising
a ceramic in combination with a metal, typically but not
necessarily a sintered metal, and typically exhibiting a high
resistance to temperature, corrosion, and abrasion.
[0072] The term "porous" in the context of hollow ceramic, metal,
and cermet membranes and matrices means that the material contains
pores (voids). Therefore, the density of the porous material is
lower than that of the theoretical density of the material. The
voids in the porous membranes and matrices can be connected (i.e.,
channel type) or disconnected (i.e. isolated). In a porous hollow
membrane or matrix, the majority of the pores are connected. To be
considered porous as used herein in reference to membranes, a
membrane should have a density which is at most about 95% of the
theoretical density of the material. The amount of porosity can be
determined by measuring the bulk density of the porous body and
from the theoretical density of the materials in the porous body.
Pore size and its distribution in a porous body can be measured by
mercury or non-mercury porosimeters, BET or microstructural image
analysis as is well known in the art.
[0073] It is to be understood in this specification that
directional terms such as bottom, top, upwards, downwards etc. are
used only for convenient reference and are not to be construed as
limitations to the assembly or use of the apparatus described
herein.
[0074] Referring to FIG. 1, a small-diameter tubular solid oxide
fuel cell 12 comprises three concentric hollow inorganic membranes
(HIM) that are in continuous contact with each other to form a
multi-membrane structure. The inner membrane layer is an anode 14,
the outer membrane is a cathode 16, and the middle membrane is an
electrolyte 18. The anode 14 or cathode 16 membranes can each be
single-layered, or multiple-layered, as is known in the art. In the
latter case, the multiple layers can include a functional or
electrochemically active electrode sub-layer and an electrode
current collector sub-layer (both not shown). The current collector
sub-layer can cover the entire surface of the electrode sub-layer,
or can be in the form of strips. The current collector sub-layer
can made from Ni, Cu, Ag, Au or Cu--Ni-alloy, Ag--Ni alloy or any
other metallic or electronic conductor.
[0075] To serve as electrodes, the inner and outer membranes 14, 16
are made of a material that is porous, catalytic, and electrically
and ionically conductive. This enables the electrodes 14, 16 to
collect electrical current, to allow reactant to flow to the
electrolyte 18, to encourage electrochemical reactions, and to
conduct ions that permeate through the electrolyte 18. In this
embodiment, the anode 14 is made of a nickel and zirconia cermet.
The anode 14 may optionally have a thin layer of nickel on the
inner surface of the cermet layer, such that a two-layered anode
structure is provided. The cathode 16 is made of LSM. The
electrolyte 18 is made of a zirconia ceramic material. The anode 14
preferably has a thickness of between 1 .mu.m to 800 .mu.m. The
cathode 16 preferably has a thickness of between 1 .mu.m to 200
.mu.m. The electrolyte 18 preferably has a thickness of between 0.5
.mu.m to 25 .mu.m. The total diameter of the fuel cell 12 is
preferably between 10 .mu.m to 3000 .mu.m but may be as large as
10,000 .mu.m. The fuel cell length is .gtoreq.50.times. the
diameter.
[0076] To provide a tubular fuel cell 12 with these
characteristics, and in particular, with the desired dimensions,
the inner anode layer 14 may be formed by depositing cermet
material on a combustible electrically conductive core (not shown,
and commonly referred to as a "deposition electrode") by
electrophoretic deposition (EPD). The electrolyte layer 18 may be
formed by depositing YSZ material onto the inner electrode layer 14
by EPD. One suitable process for producing an inner electrode and
electrolyte by EPD is described in Applicant's PCT application no.
PCT/CA01/00634. The outer electrode layer 16 may be formed by
applying a LSM layer onto the electrolyte 18 by one of dip-coating
or painting as known in the art, or by EPD. One or more sintering
steps are carried out to combust the conductive core.
[0077] In certain commercial applications, it is desirable to
provide a fuel cell system having a relatively high power density,
i.e. a fuel cell system that provides a high power-to-volume ratio.
Such high power densities may be achieved by assembling the fuel
cells 12 in close proximity to each other to produce a fuel cell
stack 10. Also, higher power densities can be achieved by
increasing the active surface area per unit volume of the system;
for example, the active surface area per unit volume can be
increased by decreasing the diameter of each tubular fuel cell 12,
thereby increasing the number of fuel cells 12 that can be stacked
in a given volume. Therefore, it is preferred to employ
small-diameter tubular fuel cells 12 having a diameter between
10-10,000 .mu.m and more preferably between 10 and 5,000 .mu.m.
Such small-diameter fuel cells 12 especially if made of ceramic or
some of its composites tend to be somewhat fragile, and are
relatively vulnerable to damage when assembled into a tightly
packed array; that is, ceramic structures being brittle tend to
fail catastrophically. Thin-walled elongate ceramic structures tend
to be particularly fragile, and may fail when subjected to bending
forces or vibrations that exceed the fracture stress of the
ceramic. Therefore, the fuel cells 12 are embedded in a solid phase
porous foam matrix 20 (shown, for example, in FIG. 6). "Matrix" as
used in this specification means a solid phase material in which
another material is embedded, such as the solid-phase foam used in
this embodiment, or a metal mesh.
[0078] The matrix 20 is made from ceramic or another material that
is able to withstand typical SOFC operating temperatures, e.g.
steel or a superalloy. The matrix 20 may be made of LSM to enable
it to operate at up to around 1000.degree. C. and to serve to
collect current, to ionize oxygen into oxide ions, and to conduct
these ions to the electrolyte. The matrix 20 fills the spaces
between the fuel cells 12 and contacts the outer surface of each
fuel cell 12, i.e. the cathode layer 16 of each fuel cell 12.
Because the matrix 20 is of the same material as the cathode layer
16 and provides a continuous conductive pathway between the fuel
cells 12, the matrix 20 serves to increase the effective surface
area of the cathode 16, thereby increasing the area for collecting
electrons, and ionizing oxygen.
[0079] Instead of LSM, the matrix 20 may alternatively be made of
any suitable electronic or mixed (electronic and ionic) conductive
porous solid state material. When made from an electronic
conductive material (e.g. metal), the matrix 20 can carry
electricity by electron transportation. When made from a mixed
conductor material (e.g. LSM or metal/ceramic composite), the
matrix 20 can carry electricity by electron and ion transportation.
When made from an ionic conductor material (e.g. Yittria-doped
zirconia), the matrix 20 can carry electricity by ion
transportation. Suitable alternative materials for the matrix
include: doped LaCrO.sub.3 (e.g. La.sub.1-xSr.sub.xCrO.sub.3,
La.sub.1-xCa.sub.xCrO.sub.3, La.sub.1-xMg.sub.xCrO.sub.3,
LaCr(Mg)O.sub.3, LaCa.sub.1-xCr.sub.yO.sub.3), stainless steel
(e.g. 316, 316L), cermets such as: Ni-Yittria stabilized zirconia,
Ni and doped zirconia cermet, Ni doped--CeO.sub.2 cermet, Cu
doped-ceria cermet, silver-(Bi--Sr--Ca--Cu--O)-oxide cermet,
silver-(Y--Ba--Cu--O)-oxide cermet;
silver-alloy-(Bi--Sr--Ca--Cu--O)-oxide cermet;
silver-alloy-(Y--Ba--Cu--O)-oxide cermet; silver and its alloys,
Inconel steel or any super alloy, ferritic steel, SiC, and
MoSi.sub.2. Alternatively, when the outer surface of the fuel cell
is the anode 14, the matrix 20 can be made from Ni/YSZ, Ni/tri- or
divalent cation doped cerium oxide, cermet, Ni, Cu, or Cu/YSZ,
Cu/tri- or divalent cation doped cerium oxide.
[0080] When the matrix 20 is made entirely of steel or a
superalloy, it serves to provide mechanical support to hold the
single cells together, as well as to serve as a current collector.
If the matrix 20 is made of a steel or a superalloy coated with a
catalyst, it serves to provide mechanical support, collect current,
and promote chemical reactions, such as ionization. If the matrix
20 is made of a steel or a superalloy coated with catalyst and an
ionic or mixed conductor, it serves to provide mechanical support,
collect current, promote chemical reactions, and provide an ionic
conduction path.
[0081] The matrix 20 is porous (with channel-type connected pores)
to allow the flow of oxidant through the stack 10, and to the outer
cathode layer 16 of each fuel cell 12 (in an embodiment where the
outer layer is the anode 14, the matrix 20 has sufficient porosity
to allow the flow of a fuel to the anode 14). The porosity of the
matrix 20 is selected to provide a sufficient oxidant flow-through
rate and sufficient mechanical strength to serve as a support
structure for the fuel cell stack 10. In this connection, the
matrix 20 has a porosity of between 25 to 95% and more preferably
about 60%. The matrix 20 in this embodiment is a solid foam made by
sintering a foam slurry having a foaming agent. Alternatively,
other structures may be substituted for the matrix 20, such as
metal wire wrapped around each fuel cell 12, a wool made of metal,
ceramic, or cermet in which the fuel cells are embedded, or a
fibrous bundle comprised of a plurality of entangled fibres
visually resembling "cotton candy" (not shown).
[0082] Optionally, and referring to FIG. 2, the fuel cell 12 may be
lined on its inner surface with a porous electrically conductive
anode matrix 21. The anode matrix 21 serves to enhance anode
catalytic activity and current collection. The anode matrix 21 may
be made from the following materials:
[0083] Porous metal, e.g. silver, nickel, copper, stainless steel,
superalloy. Main function: collect current.
[0084] Porous metal covered with catalyst. Main functions: collect
current, promote chemical reaction.
[0085] Porous metal coated with catalyst and ionic or mixed
conductor. Main functions: collect current, promote chemical
reaction, provide ionic conduction path.
[0086] Anode materials, e.g. nickel/zirconia cermet, wherein the
cermet has a higher porosity than an anode layer, the porosity
being sufficient to provide a fuel gas flow path. Main functions:
collect current, promote chemical reactions, provide ionic
conductive path.
[0087] The fuel cell 12 in this embodiment is an elongate
cylindrical tube, but it is to be understood that it is within the
scope of the invention for the fuel cell 12 to have other cross
sectional or longitudinal shapes; for example, the fuel cell 12 may
have a "U" shape or a coil shape. For elongate circular
cross-sectional tubes, the fuel cell 12 may be open at both ends,
as shown in FIGS. 1 and 2, or may be closed at one end, as shown in
FIG. 3. If open at both ends, fuel is fed through an inlet end 22
of the fuel cell 12 and is electrochemically reacted as it travels
along the length of the tube. Unreacted fuel and reaction products
are discharged at an opposite outlet end 24 of the fuel cell 12.
For fuel cells open only at one end, a feed tube 26 made out of a
metal such as nickel, stainless steel, or a superalloy that can
withstand SOFC operating conditions is embedded in the anode matrix
21, and has an inlet 28 for receiving fuel and an outlet 29 near
the bottom of the closed end of the fuel cell 12. The tube 26
serves to deliver gas as well as collect current. Fuel is fed into
the feed tube inlet 28 and travels downwards to the bottom of the
feed tube 26, wherein it is discharged at the outlet 29 for upward
travel towards the top of the tube; as the fuel travels upwards, it
is electrochemically reacted at the anode 14. Unreacted fuel and
reaction products are discharged at the top of fuel cell 12, i.e.
at the open end of the fuel cell 12. Alternatively, the feed tube
26 may be made of ceramic material (e.g. alumina) and that outside
of the tube is coated with an electronically conductive material,
the material being selected to withstand SOFC operating conditions.
Such a feed tube 26 serves to deliver gas well as collect
current.
[0088] One or both ends of the anode layer can be electrically
connected to an external circuit for transmitting current. However,
to reduce the I.sup.2R losses during current collection, a series
of current collector tabs 30 are interspersed along the length of
the fuel cell 12. Referring to FIGS. 4 and 5, these tabs 30 are
spaced along the length of fuel cell 12 to reduce the electrical
path length, thereby reducing losses. The tabs 30 are a silver or
other inert metal coating on an exposed anode layer portion that is
suitable for use under SOFC operating conditions. The tabs 30 are
produced as follows: after the electrolyte layer 18 has been
deposited on the anode layer 14, but prior to applying the outer
cathode layer 16 to the electrolyte 18, and prior to sintering the
electrolyte 18, a section of the electrolyte layer 18 is removed to
expose a portion or the inner anode layer 14. The electrolyte layer
portion can be removed when dry by using abrasive paper, cotton,
etc. or be removed before completely dry by gently rubbing with wet
or dry cotton, paper, etc. After sintering the anode and
electrolyte layers 14, 18, the exposed anode portion is coated with
silver paint (or any other electrically conductive material). The
coating is applied such that the tab opening is made gas
impermeable. Then, a drying and sintering step is applied to bond
the silver to the exposed anode surface. Then, the outer cathode
layer 16 is applied to the electrolyte 18, and the tab-bearing fuel
cell 12 is sintered at between 700 and 1300 EC.
[0089] The fuel cell 12 may be embedded with other fuel cells 12 in
the matrix 20 to form the fuel cell stack 10. In one optional
embodiment as shown in FIG. 6, also embedded in the matrix 20 is an
anode current collector rod 32. The collector rod 32 is made from a
suitable material that is electrically conductive and able to
withstand SOFC operating conditions; suitable materials include
stainless steel, superalloy, and silver. The collector rod 32 is
electrically coupled to the anode tabs 30. The collector rod 32 is
connectable to an external circuit (not shown) to conduct the
current collected from the tabs 30 to the external circuit. The
tabs 30 and rod 32 are wrapped in an electrical insulator 31 to
electrically separate the tabs 30 and rod 32 from the cathode 16
and the portion of the matrix 20 electrically contacting the
cathode 16.
[0090] Referring to FIG. 7, the matrix 20 may optionally have a
number of oxidant distribution channels 33 that serve to enhance
the transmission of oxidant/air to the cathode 16 of each fuel cell
12. Such distribution channels 33 may be formed by inserting
elongate combustible cores in the matrix material during formation
of the matrix 20, then combusting away the cores to leave elongate
voids in the matrix 20. Oxidant or air may be supplied to the
distribution channels 33 via a diffuser 35; such diffuser 35 may
extend transversely at one end of the stack in the matrix 20 and
have an inlet connected to an oxidant source and perforations to
discharge oxidant or air into the matrix 20 in addition to
discharging oxidant or air into the distribution channels 33. Used
oxidant and reaction products are discharged through outlet 37.
[0091] Referring to FIGS. 8 to 10, an alternative approach is
illustrated for collecting current from the anode of each fuel cell
12. In this alternative embodiment, a series of anode current
collection plates 34 are attached to the tabs 30 such that the
plates 34 extend transversely from the length of each fuel cell 12.
The plates 34 are made from a suitable material that is
electrically conductive and able to withstand SOFC operating
conditions; suitable materials include stainless steel, superalloy,
and silver. The plates 34 have spaced openings (not shown) for
receiving each fuel cell 12 and perforations to allow air/oxidant
gas to flow through the plates 34. The plates 34 serve to collect
current from the tabs 30 and transmit the current to an external
electrical circuit (not shown) connected to the outside edges of
the plates 34. The plates 34 may also be constructed with such
properties and be physically attached to each fuel cell 12 in such
a manner that the plates 34 provide structural support to the fuel
cells 12 that complements the support provided by the matrix 20 (as
in FIGS. 8 and 10). The plates 34 are electrically isolated from
the matrix 20 by a porous electrical insulator layer 36 that covers
both surfaces of each plate 34; the matrix 20 thus are physically
and electrically coupled only to the cathodes 16 of each fuel cell
12 whereas the plates 34 are physically and electrically coupled
only to the anodes 14 of each fuel cell 12.
[0092] Alternatively, and as shown in FIG. 9, transverse plates
serve to provide the entire structural support for the fuel cells
12, i.e. the plates replace the matrix 20. In such case, cathode
plates 35 are provided that physically and electrically connect to
the cathode 16 of each fuel cell 12. Like the anode plates 34, the
cathode plates 35 are made from a suitable material that is
electrically conductive and able to withstand SOFC operating
conditions, and have spaced openings to receive fuel cells 12 and
perforations to allow the transmission of oxidant/air gas
therethrough. The cathode plates 35 are electrically connected to
the external circuit to return current conducted through the
external circuit back to the cathode 16 of each fuel cell 12 for
the electrochemical process.
[0093] Referring to FIGS. 11 to 25, a plurality of fuel cells 12
can be assembled into a stack 10 to produce commercially useful
electrical power levels. These figures show stack configurations
that are particularly suitable for certain performance
requirements.
[0094] Referring to FIG. 11, the fuel cell stack 10 can comprise a
plurality of fuel cells 12 embedded in the matrix 20. Each of the
fuel cells 12 in this stack 10 are electrically connected in
parallel, since the matrix 20 is electrically conductive and is
electrically coupled to the cathode 16 of each of the fuel cells 12
in the stack 10. As a result, the effective voltage of the stack 10
is equal to the voltage of the single fuel cell 12 in the stack 10
with the highest voltage and the effective current of the stack 10
is the additive sum of the current produced by each fuel cell
12.
[0095] Another stack configuration is shown in FIG. 12. Here, the
fuel cell stack 10 comprise a mixture of individual fuel cells 12
and fuel cell sub-stacks 40 all embedded in the matrix 20. A fuel
cell sub-stack 40 is one or more fuel cells 12 that are
electrically isolated from other fuel cells 12 in the stack 10 in
such a manner that the sub-stack 40 can be electrically connected
in series with other sub-stacks 40 or fuel cells 12 in the stack
10. Each sub-stack 40 is encased within an electrical or a thermal
and electrical insulator 42. The insulator 42 prevents the matrix
20 inside the sub-stack 40 ("sub-stack matrix") from electrically
contacting the matrix 20 outside the sub-stack 40 ("stack matrix"),
thereby preventing the fuel cells 12 inside the sub-stack 40 from
short-circuiting with other fuel cells 12 or sub-stacks 40 in the
stack 10. Current may be collected from the ends of each fuel cell
12.
[0096] The insulator 42 is a flexible sheet that wraps around the
sub-stack 40; the sheet extends the length of the fuel cells 12,
and may be made of Al.sub.2O.sub.3 (dense or porous), ceramic felt,
or a composite material of an exterior metal shell with an interior
insulating ceramic lining. Alternatively, the insulator 42 may be a
rigid two-layered shell having an exterior ceramic layer and an
interior conducting metal lining.
[0097] Another stack configuration is shown in FIG. 13. Here, a
stack 44 comprises a plurality of small diameter tubular fuel cells
12 embedded in the matrix 20 in a parallel electrical connection
like that shown in FIG. 11. However, this stack configuration
differs from that shown in FIG. 11 in that the small-diameter fuel
cells 12 ("inner fuel cells") are located within a large-diameter
tubular fuel cell 13 ("outer fuel cell"). The outer fuel cell 13
may be made from the same materials and by the same method
(described below) as the inner fuel cells, or by materials and
techniques known in the art for making large-diameter fuel cells,
e.g. by extrusion. The outer fuel cell 13 differs from the inner
fuel cells 12 in that the inner electrode layer is the cathode 16
and is physically and electrically connected to the matrix 20, and
the outer electrode layer is the anode 14. A container 46 contains
the outer fuel cell 13 in such a manner that space is provided
between the container inner wall and the anode surface of the outer
fuel cell 13 thereby creating a fuel delivery channel 48 for
flowing fuel to the anode of the outer fuel cell 13. Spacers (not
shown) may be provided to affix the stack 10 to the container
46.
[0098] The fuel cell stack 50 shown in FIG. 14 is the same as the
stack 44 in FIG. 13 except that porous matrix material is
substituted for the spacers in the fuel delivery channel 48.
[0099] If the container 46 is removed from the fuel cell stacks 10
of FIGS. 13 and 14, the stacks 10 resemble a "tube-within-a-tube"
fuel cell assembly, and can replace large diameter tubular fuel
cells used in known fuel cell systems. Because of the plurality of
small diameter fuel cells 12 within the large diameter fuel cell
13, a tube-within-a-tube fuel cell assembly is expected to provide
a higher power output than a conventional single tubular
large-diameter fuel cell.
[0100] FIGS. 15 and 16 illustrate another pair of stack
configurations 52, 54. Essentially, these are additional
tube-within-a-tube designs; however, here, the small-diameter fuel
cells 12 are arranged in the same manner as that shown in FIG. 12.
The stack 10 shown in FIG. 15 is attached to the container 46 by
spacers, and the stack 10 shown in FIG. 16 is attached to the
container 46 by the porous matrix material.
[0101] FIGS. 17 and 18 illustrate another tube-within-a-tube fuel
cell assembly 56, 58. Tube-within-a-tube fuel cell assemblies 56,
58 comprise a plurality of small-diameter fuel cells 12 and fuel
cell sub-stacks 60 arranged in generally the same manner as shown
in FIGS. 15 and 16. However, the sub-stacks 60 in this
configuration differ from the sub-stacks 40 shown in FIG. 15 and
16: instead of an insulator 42 surrounding the fuel cells 12, each
sub-stack 60 is enclosed inside an intermediate-diameter fuel cell
15 that has a smaller diameter than the large-diameter outer fuel
cell 13, and a larger diameter than the small-diameter inner fuel
cells 12.
[0102] The fuel cell stacks 56, 58 are located inside the container
46 in the same manner as the stacks 52, 54 respectively.
Alternatively, the stacks 56, 58 without the container 46 may serve
as tube-within-a-tube fuel cell assemblies and be assembled with
other stacks in a conventional large-diameter tubular fuel cell
system as discussed above. FIG. 19 shows a stack of the fuel cell
assemblies of FIGS. 17 and 18 arranged in series, or in parallel
inside a larger thermal enclosure.
[0103] Referring to FIGS. 20-24, the small-diameter fuel cells 12
extend the length of the stack 10 such that the ends of each inner
fuel cell 12 are open at each end of the stack 10 and are free of
matrix material, and can be electrically connected to the external
circuit. Referring to FIGS. 21 and 22, the matrix 20 can be
provided with distribution channels 33 that enhance the flow of
reactant through the matrix 20 and to the electrode surface of each
small-diameter fuel cell 12 (as shown also in FIG. 7); FIG. 21
shows a series of longitudinal distribution channels 33
substantially parallel with the small-diameter fuel cells 12 (see
also FIG. 24), and FIG. 22 shows a series of transverse
distribution channels 33 that are perpendicular to the
small-diameter fuel cells 12. As will be discussed below, these
channels 33 can be formed by inserting combustible members that
burn away during a sintering treatment to leave behind the channels
33, or, can be formed from the gaps left by a porous matrix
structure that is discontinuous along the length of the fuel cells
12, as shown in FIG. 23. A plan view of a series of longitudinally
extending channels 33 interspersed within the fuel cells 12 is
shown in FIG. 24.
[0104] Referring to FIG. 25, a hexagonal-shaped fuel cell stack 62
is provided having 25 sub-stacks 64. Each sub-stack 64 has 7 single
fuel cells 12. As an illustrative example, when each fuel cell 12
is rated at 0.7 V, 1.43 A and 1 W, each 7 cell sub-stack 64
produces 7 W. As the single cells in the 7 cell sub-stack 64 are
connected in parallel, the voltage output from the sub-stack 64
equals the voltage from a single cell 12, i.e. 0.7V, and the
current will be additive sum of the current produced by each cell
12, i.e. 1.43.times.7=10 A.
[0105] Given that the sub-stacks 64 are electrically insulated from
each other, the stack 62 can be electrically connected in different
ways to produce different outputs. The electrical connections are
established at the ends of each cells, and are known in the
art.
[0106] In one embodiment, all 25 sub-stacks 64 can be connected in
parallel, and in such case, TABLE-US-00001 stack power 7 W .times.
25 sub-stacks = 175 W stack voltage 0.7 V stack current 10 A
.times. 25 sub-stacks = 250 A
[0107] In another embodiment, the stack 62 may be divided into 5
electrically isolated sub-groups, each group having 5 sub-stacks.
The 5 sub-stacks in each group are connected in parallel, and the 5
groups are connected in series. In such case, each sub-stack
produces 7 W, 0.7V and 10 A, each group produces 35 W, 0.7V and 50
A, and TABLE-US-00002 stack power 35 W .times. 5 groups = 175 W
stack voltage 0.7 V .times. 5 groups = 3.5 V stack current 50 A
[0108] In another embodiment, the 5 sub-stacks in each group are
connected in series, then for each group, the power output is 35 W,
voltage is 3.5V and the current is 10 A. If the groups are
connected in series, TABLE-US-00003 stack power 35 W .times. 5
groups = 175 W stack voltage 3.5 V .times. 5 groups = 17.5 V stack
current 10 A
[0109] If the groups are connected in parallel, TABLE-US-00004
stack power 35 W .times. 5 groups = 175 W stack voltage 3.5 V stack
current 175 W / 3.5 V = 50 A
[0110] FIGS. 26 to 30 show various fuel cell system designs that
incorporate one of the fuel cell stack configurations as described
above. Generally speaking, the fuel cell system includes oxidant
and fuel delivery and discharge means, the fuel cell stack, a
thermal enclosure for the stack, and electrical leads for
connecting the stack to an external electrical circuit.
[0111] FIG. 26 illustrates a simple fuel cell system 70 design
having a stack 10 of one-ended fuel cells 12 embedded in the matrix
20. The stack 10 is contained inside a cup-shaped thermal insulator
layer 72 made of a suitable ceramic material such as aerogel or
another like porous ceramic, ceramic felt or another like fibrous
ceramic such as Saffil. The stack 10 and insulator layer 72 are
contained inside a cup-shaped casing 74. A suitable material for
the casing 74 is a ceramic such as alumina, zirconia,
alumina-zirconia composite, spinel, silica, ceramic aerogel, or
porous ceramics where the pores are disconnected. The casing 74 may
have two layers wherein the outer layer is made of a steel or
aluminum, and the inner layer is made of ceramic. Air inlet and
outlet conduits 76 and 78 are provided through the insulator 72 and
casing 74 for the delivery of air/oxidant to and from the stack
10.
[0112] The casing 74 has an annular lip 80 that extends outwards
around the periphery of the rim of the casing 74. The lip 80
enables the mounting of a lid 82 via a plurality of electrically
non-conductive fasteners 84 in such a manner that a fluid seal is
established between the lid 82 and the casing 74. The lid 82 has a
thermal and electrical insulator layer 86 of similar construction
to the insulator layer 72, and a reactant impermeable electrically
conductive metal layer 88 in contiguous adjacent contact with the
insulator layer 86. The metal layer 88 is electrically connected to
the anode of each fuel cell 12 via anode connectors 90 and is
electrically connected to an external circuit via anode lead 91.
The casing 74 is electrically connected to the external electrical
circuit via cathode lead 92 and electrically coupled to the cathode
of each fuel cell 12 via a cathode connector 94, which is
electrically connected to the casing 74 and the matrix 20.
[0113] A dome-shaped fuel discharge chamber cover 96 is fastened
over the lid 82 via fasteners 84 to establish a fluid seal between
the cover 96 and the lid 82. The cover 96 is provided with openings
that receive the feed tube 26 of each fuel cell 12, and with a fuel
discharge outlet 98. A fuel discharge chamber 99 is defined by the
space inside the cover 96 and lid 82; the chamber 99 is fluidly
coupled to the fuel outlet of each fuel cell 12.
[0114] In operation, fuel is fed into each fuel cell 12 of the
system 70 via the inlet 28 of each fuel cell feed tube 26. Oxidant
is fed into the matrix 20 via the oxidant feed tube 76. Fuel and
oxidant are electrochemically reacted at the anode and cathode of
each fuel cell 12, respectively. Unused fuel and reaction products
exit the fuel cells 12 into the fuel discharge chamber 99 and are
discharged from the fuel cell system through the fuel discharge
outlet 98. Unused oxidant and reaction products are discharged
through the outlet channel 78. Electrical current generated as a
result of the electrochemical reactions are conducted between the
electrical circuit via anode and cathode leads 91, 92.
[0115] Referring now to FIG. 27, a fuel cell system 100 is provided
that has a similar design to the system 70 shown in FIG. 26, except
for the following notable differences. First, an air/oxidant inlet
102 extends into the matrix 20 from the top of the system 100.
Second, a fuel gas reformer 104 is provided to reform a suitable
supply fuel (e.g. natural gas) into hydrogen. Supply fuel is
delivered to the reformer 104 via a fuel supply inlet conduit 106
fluidly coupled to the reformer 104; the fuel supply inlet conduit
106 has a discharge portion comprising a plurality of perforations
that discharge fuel into the bottom of the reformer 104. The
reformer 104 has a reformer chamber being the space between two
cup-shaped layers, namely, the insulator layer 72 and a cup-shaped
metal current-collecting layer 108. The top of the reformer chamber
is closed by the lid 82. The chamber is filled with a
catalyst-coated foam-like porous matrix structure. Near the top rim
of the reformer 104 is a reformer outlet 110 that discharges
reformed fuel from the reformer chamber into a fuel supply chamber
112 via a fuel supply conduit 114 (shown coupled to the reformer
outlet 110 and in dotted line in FIG. 27). The fuel supply chamber
112 is a cavity within a dome-shaped fuel supply chamber cover 116
and the fuel discharge chamber cover 96.
[0116] The cathode current collecting layer 108 is in contiguous
adjacent contact with the fuel cell stack 10, and more
particularly, in electrical contact with the support structure 20.
The cathode current collecting layer 108 is also electrically
connected to cathode lead 92. The stack 10, cathode current
collecting layer 108, reformer 104 and insulating layer 72 are all
enclosed inside the outer casing 74 and lid 82.
[0117] In operation, natural gas (or another suitable hydrocarbon
fuel) supply fuel is delivered to the bottom of the reformer
chamber by the fuel inlet conduit 106. As the fuel travels upwards
through the catalyst-coated matrix in the reformer chamber, it is
reformed into hydrogen and is discharged from the reformer 104
through the reformer outlet 110 and into the fuel supply chamber
112. Hydrogen fuel in the fuel supply chamber 112 is then fed into
each fuel cell 12 via the feed tube 26. Heat from the
electrochemical reaction reforms the natural gas supply fuel into
hydrogen; in this connection, the current collecting layer 108 is
made of a material that is a good heat conductor. As the reforming
process is endothermic, the reformer 104 serves an additional
useful function of cooling the stack 10. The remainder of the
system operation is similar to the system 70 as shown in FIG.
26.
[0118] Another fuel cell system 120 is shown in FIG. 28. This
system 120 is similar to the system shown in FIG. 27 except that a
reformer channel 122 is provided that winds around the reformer
chamber. This shape is deliberately selected to lengthen the
reformer pathway, thereby increasing the effectiveness of the
reforming process. A fuel supply inlet 124 fluidly connected to the
upstream end of the reformer channel 122 replaces the fuel supply
inlet 106 shown in FIG. 27. The downstream end of the reformer
channel 122 is fluidly coupled to the fuel supply chamber 112.
[0119] The fuel cell system 130 illustrated in FIG. 29 is identical
to the system 120 illustrated in FIG. 28, except that the reformer
channel 122 is embedded in a matrix material 132 to improve the
heat conduction from the reformer enclosure to the reformer channel
122.
[0120] FIG. 30 illustrates another fuel cell system 140 design
having a stack 10 of elongate two-ended fuel cells 12 embedded in
the matrix 20. The ends of the stack 10 are capped by a fuel
delivery manifold 142 and a fuel discharge manifold 144. The
manifolds 142, 144 have openings that receive the ends of each fuel
cell 12 in the stack 10 such that a fluid seal is established
between the inside of each fuel cell 12 and the respective
manifolds 142, 144. This enables fuel to be delivered to and from
each fuel cell 12 in fluid isolation from the oxidant pathway via
inlet 145 and outlet 147. Oxidant is fed into and out of the fuel
cell stack via an oxidant inlet 146, and outlet 148, respectively.
The stack is surrounded by a cylindrical shaped insulator 72 and
outer casing 74. Between the insulator and a metal cathode current
collecting layer 108 are the spiral reformer channels 122.
Manufacture
[0121] A method of manufacturing the tubular fuel cells 12 and of
embedding these fuel cells 12 in the porous matrix 20 is described
in the following paragraphs.
A. Forming a Tubular Fuel Cell
[0122] As discussed above, the process for making a small diameter
tubular SOFC by producing an inner electrode and electrolyte by EPD
is described in Applicant's PCT application no. PCT/CA01/00634. The
outer electrode layer of the fuel cell may be formed by applying a
LSM layer onto the electrolyte 18 by one of dip-coating, painting
as known in the art, or by EPD.
B. Producing a Stack or Sub-Stack of Fuel Cells
[0123] A plurality of fuel cells 12 can be assembled into a stack
10 or sub-stack 40 for use in a fuel cell system. To hold the fuel
cells 12 in place, the fuel cells 12 are embedded in a relatively
rigid but porous solid-state foam matrix 20 that serves as a
support structure. When made with certain materials, the matrix 20
can also serve as part of the cathode 16, by collecting current and
conducting oxygen (oxide) ions to the electrolyte 18.
[0124] There are different processes to embed fuel cells in the
porous matrix. According to one process, and referring to FIGS. 31
and 32, an apparatus 152 is provided for immersing a plurality of
fuel cells 12 in a slurry of matrix material. The apparatus 152
comprises a pair of end plates 154 made of a ceramic, superalloy or
another material capable of withstanding sintering, a combustible
flexible sheet 156, and means for supplying the slurry to the
container (not shown). The end plates 154 each have a plurality of
indentations 158 on one of their major faces; the indentations 158
are shaped and sized to accept the ends of fuel cells 12. The
flexible sheet 156 may be made of paper board or a suitable plastic
material. Upon sintering (described below), the flexible sheet 156
burns away. Alternatively, the flexible sheet 156 may be replaced
by a non-combustible container wall (not shown) of ceramic such as
alumina or zirconia, or metal. Such container serves to contain the
slurry during heat treatment/sintering, but can also serve as an
integral component of the fuel cell stack 10.
[0125] Each end of each fuel cell 12 is taped with a protective
masking tape (not shown) or a suitable combustible coating to keep
the ends free from the slurry. Then, each end plate 154 is clamped
to each end of each fuel cell 12, holding each fuel cell 12 in
place. Then, the flexible sheet 156 is wrapped around the fuel
cells 12; the sheet 156 is large enough to wrap completely around
the fuel cells 12 and to attach to each end plate 154. When
wrapped, the sheet 156 and end plates 154 form a cylindrical
container that encloses the fuel cells 12. A slurry injection port
160 is provided in one of the base plates.
[0126] The slurry is a suspension of the matrix material, water or
organic solvent, a dispersant, a foaming agent, organic monomers
and an initiator. The matrix material in this case is LSM
(lanthanum strontium manganate), but can be any ceramic and/or
metal powder having suitable properties, such as doped LaCrO.sub.3
(e.g. La.sub.1-xSr.sub.xCrO.sub.3, La.sub.1-xCa.sub.xCrO.sub.3,
La.sub.1-xMg.sub.xCrO.sub.3, LaCr(Mg)O.sub.3,
LaCa.sub.1-xCr.sub.yO.sub.3), stainless steel (e.g. 316, 316L),
cermets such as: Ni-Yittria stabilized zirconia, Ni and doped
zirconia cermet, Ni doped--CeO.sub.2 cermet, Cu doped-ceria cermet,
silver-(Bi--Sr--Ca--Cu--O)-oxide cermet,
silver-(Y--Ba--Cu--O)-oxide cermet;
silver-alloy-(Bi--Sr--Ca--Cu--O)-oxide cermet;
silver-alloy-(Y--Ba--Cu--O)-oxide cermet; silver and its alloys,
Inconel steel or any super alloy, ferritic steel, SiC, and
MoSi.sub.2. The organic monomers may be mehty methacrylate, butyl
arcylate, acrylamide, or other acrylates. The dispersant may be
polyacrylic acid. The foaming agents may be Tergiton TMN10 or
Triton X114. The initiator may be ammonium persulphate (APS) The
slurry upon heat treatment will produce a foam that has a porous
structure wherein the majority of the pores are interconnected to
provide continuous fluid pathways. Upon sintering, this foam
becomes the solid-state porous matrix 20.
[0127] Instead of or in addition to the foaming agent, combustible
additives may be added to the slurry, such as polymer powder,
organic powder, saw dust and fibres. Upon sintering at a
temperature hot enough to combust the combustible additives, the
additives burn away, leaving behind the solid-state matrix 20 with
a foam-like porous microstructure.
[0128] Instead of or in addition to the foaming agent and
combustible additives, a porous foam-like microstructure can be
formed by using hollow ceramic particles. Spherical ceramic
particles such as commercially available alumina bubbles
(Al.sub.2O.sub.3) are first coated with matrix material, e.g. by
dipping or spraying the particles with the slurry, or by
electroless coating of matrix material onto the particles. Then,
the coated particles are placed in a container having a plurality
of tubular fuel cells arranged in the desired stack configuration.
The container is packed with the particles such that tubular fuel
cells are held securely in place. Then, a lid is placed on the
container, and the filled container is subjected to a sintering
process whereby the coating will bond with the particles thereby
physically interconnecting the particles.
[0129] The slurry is injected or poured through the slurry port 60
until the container is filled and the fuel cells 12 are immersed
with slurry. The slurry is left to completely dry at ambient
temperature (or at an elevated temperature up to about 120.degree.
C.).
[0130] After the slurry has dried, the container and its contents
are sintered. The sintering cycle involves first increasing the
temperature from ambient to 200.degree. C. for and holding at that
temperature 1-10 hours, then increasing the temperature to
500.degree. C. and holding at that temperature for 1-10 hours, then
increasing the temperature to 650.degree. C. and holding at that
temperature for 1-10 hours, then increasing the temperature to
900.degree. C. and holding at that temperature for 1-10 hours, then
finally increasing the temperature to 1000-1400.degree. C. and
holding at that temperature for 5 hours. The rate of temperature
increase in each step is between 20-300.degree. C. The temperature
is then allowed to drop to ambient temperature at a rate of between
60-300.degree. C.
[0131] During sintering, the combustible flexible sheet 56 is
burned away, leaving behind a fuel cell stack 10 or sub-stack 40
having the fuel cells 12 embedded in the solidified porous matrix
20 such that the matrix surrounds the length of each embedded fuel
cell (because the ends of the fuel cells are masked prior to
coating with slurry, they are free of the matrix). The end plates
54 are then removed, and the stack 10 is ready for combining with
other components to produce a fuel cell system, or the sub-stack 40
is ready for combining with other sub-stacks to form the stack
10.
[0132] According to an alternative embodiment of the invention (not
shown), the stack or sub-stack can be formed by first coating each
fuel cell with slurry, then stacking the slurry-coated fuel cells
onto a plate such that the slurry coat on each fuel cell contacts
the slurry coat in adjacent fuel cells. The coating may be effected
by dip-coating or spraying or other suitable known means.
Combustible spacers may be placed between the fuel cells during
stacking, to maintain a desired separation between fuel cells in
the stack. The spacers may have different geometries depending on
the desired geometrical configuration of the stack, e.g. hexagonal
inserts will form a stack of fuel cells in a honeycomb-like
configuration. Then, the stacked cells are allowed to dry, and
sintered according to the sintering steps described above, such
that a sub-stack having the fuel cells embedded in the porous
matrix is formed. Upon sintering, the combustible spacers, if any,
burn away. Alternatively, the spacers may be made from a
non-combustible material such as metal; such spacers remain with
the fuel cells after sintering, and in such case, are provided with
channels therethrough to allow reactant to flow through the
spacers.
[0133] According to another alternative embodiment of the invention
(not shown), the stack or sub-stack can be formed by first coating
each fuel cell with slurry, then stacking the slurry-coated fuel
cells onto a flexible sheet of paper, plastic or other suitably
flexible material such that the slurry coat on each fuel cell
contacts the slurry coat in adjacent fuel cells. Again, combustible
spacers may be inserted between fuel cells. The flexible sheet can
then be folded, bent, or otherwise manipulated into a desired shape
of the sub-stack, e.g. the sheet can bent into a cylindrical or
another desired shape to form a stack or sub-stack. The fuel cells,
slurry, and sheet are then dried and sintered according to the
steps described above. The sheet may be made of a combustible
material that burns away upon sintering.
[0134] According to yet another alternative embodiment of the
invention (not shown), the stack or sub-stack can be formed by
first pouring the slurry into a container, then inserting one or
more combustible rods or other suitable elongate member into the
slurry. The slurry and rods are then dried and sintered according
to the steps described above, and the rods burn away, leaving
behind a porous matrix with channels corresponding to the
burned-away rods. Then, a fuel cell corresponding in shape and size
to the channel is inserted into each channel. If the fuel cell is
not securely embedded in the channel, additional slurry may be
poured between the fuel cell and the channel, and an additional
drying and sintering step can be carried out to solidify the slurry
and fasten the fuel cell in place.
[0135] Any of the above methods of producing the sub-stack can
optionally include a further step of inserting combustible rods,
filaments, fibres, tows or other suitable elongate members into the
slurry before it dries, so that channels in the matrix are formed
when the slurry is dried and sintered at a temperature sufficient
to solidify the slurry into the matrix, and to burn away the
combustible inserts. These channels can be parallel, perpendicular,
or in any other direction relative to the fuel cells.
[0136] According to yet another alternative embodiment of the
invention (not shown), the stack or sub-stack can be formed using a
templated processing technique. This technique involves first
inserting fuel cells into a suitable template material, such as a
sponge, carbon felt, or graphite felt, such that the fuel cells are
securely held in place. Then, the template material is impregnated
with the slurry. Then, the slurry and fuel cell containing template
is dried and sintered. During sintering, the template material will
burn away, leaving behind a foam-like porous matrix.
[0137] If the fuel cells are too fragile to survive inserting
directly into the template material, metal or plastic tubes (having
an inside diameter at least as large as the outside diameter of the
fuel cell) are first inserted into the template material, then the
fuel cells are inserted into the tubes. The tubes are then
withdrawn from the template material, leaving behind the embedded
fuel cells. Alternatively, combustible tubes or rods may be
inserted into the template material. The template is then
impregnated with slurry and dried and sintered. Upon sintering, the
combustible tubes/rods burn away, leaving behind channels that
enable the fuel cells to be inserted into template material. If the
fuel cells are not securely held inside these channels, additional
slurry may be added, that upon drying and sintering will secure the
fuel cells in place.
[0138] The template may be a non-combustible material such as an
electrically conductive metal felt. The metal felt may be
impregnated with a slurry that is ionically conductive and/or
catalytic, to enhance the performance of the stack. In this case, a
bonding slurry can be added between the felt and the fuel cells
embedded in the felt. Upon heat treating, the bonding slurry will
secure the fuel cells to the metal felt and improve the electrical
conductivity between the felt and the fuel cell. The bonding slurry
may be composed of cathode material, or the same metal as the felt.
As an alternative to or in addition to adding bonding slurry, the
fuel cell embedded felt may be placed inside a thermally and
electrically insulating container and compressed by the container
until a suitable contact is established between the felt and the
fuel cells.
[0139] According to yet another embodiment of the invention, a fuel
cell stack of small diameter tubular fuel cells are formed by
wrapping each single cell in metal wire; two or more cells may be
mechanically interconnected by wrapping the cells with a single
wire. The wire serves as a support structure for the fuel cells, as
well as a current collector. If the wire is coated with catalyst
material, the wire can enhance the catalytic activity of the fuel
cell stack.
[0140] According to another embodiment of the invention, a fuel
cell stack of small diameter tubular fuel cells are formed by
wrapping each single cell in a metal mesh; two or more cells may be
mechanically interconnected by wrapping the cells with a single
strip of metal mesh. The mesh serves as a support structure for the
fuel cells, as well as a current collector. If the mesh is coated
with catalyst material, the mesh can enhance the catalytic activity
of the fuel cell stack.
[0141] According to yet another embodiment of the invention, and
referring to FIGS. 33-40, the inside of the fuel cell 12 may be
lined with a porous current conductor 162. In particular, the
current collector can be a porous electrically conductive inner
foam core 162. The foam core 162 is electrically connected to the
anode surface 14 of the fuel cell 12, and serves to collect current
and provide mechanical support for the fuel cell 12. The porosity
of the foam core 162 is selected to be sufficient to allow fuel to
flow through the foam core 162 and reach the anode surface 14 of
the fuel cell 12. The foam core 162 may be coated with a catalyst
material to promote the electrochemical reaction. As seen in FIGS.
36 to 38, a metal wire 164 may be embedded in the centre of the
core 162 such that one end extends out of the fuel cell 12 and is
electrically couplable to the external circuit. Such a wire 164
serves to collect current. Alternatively, and referring to FIG. 41,
multiple wires 164 are embedded in the foam core 162 at the
electrode surface. A plurality of flow channels 166 may be formed
in the core 162 to enhance the flowthrough of reactant.
[0142] Referring to FIG. 39, instead of a inner foam core 162, the
current collector may be a series of porous metal sheets 168
inserted inside each fuel cell 12 to provide mechanical support to
the fuel cell 12 as well as to collect current. The metal sheets
are attached at their longitudinal edges to the anode wall of the
fuel cell 12.
[0143] Referring to FIG. 40, instead of a inner foam core 162, the
current collector is a plurality of metal filaments 170 wrapped
around a longitudinally extending (parallel to the fuel cell 12)
central metallic wire 172 such that the filaments extend
transversely to the central wire to contact the anode inner wall.
Such a core resembles a "wire brush".
[0144] While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the scope and
spirit of the invention.
* * * * *