US20040200187A1 - Compliant, strain tolerant interconnects for solid oxide fuel cell stack - Google Patents

Compliant, strain tolerant interconnects for solid oxide fuel cell stack Download PDF

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Publication number
US20040200187A1
US20040200187A1 US10/758,843 US75884304A US2004200187A1 US 20040200187 A1 US20040200187 A1 US 20040200187A1 US 75884304 A US75884304 A US 75884304A US 2004200187 A1 US2004200187 A1 US 2004200187A1
Authority
US
United States
Prior art keywords
compliant
superstructure
assembly
interconnect
fuel cell
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/758,843
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English (en)
Inventor
Sunil Warrier
Jean Yamanis
Wayde Schmidr
Raymond Benn
John Smeggil
Shihong Song
Venkata Vedula
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
UTC Power Corp
Original Assignee
UTC Fuel Cells LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/307,008 external-priority patent/US7144649B2/en
Application filed by UTC Fuel Cells LLC filed Critical UTC Fuel Cells LLC
Priority to US10/758,843 priority Critical patent/US20040200187A1/en
Priority to PCT/US2004/002865 priority patent/WO2004070858A2/en
Priority to JP2006503238A priority patent/JP2007524956A/ja
Priority to KR1020057013981A priority patent/KR20050096960A/ko
Priority to EP04707406A priority patent/EP1595304A4/en
Priority to CA002514488A priority patent/CA2514488A1/en
Publication of US20040200187A1 publication Critical patent/US20040200187A1/en
Assigned to UTC FUEL CELLS, LLC reassignment UTC FUEL CELLS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SMEGGIL, JOHN G., VEDULA, VENKATA R., WARRIER, SUNIL G., SONG, SHIHONG G., YAMANIS, JEAN, BENN, RAYMOND C., SCHMIDT, WAYDE R.
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/023—Porous and characterised by the material
    • H01M8/0232—Metals or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0247—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the form
    • H01M8/0254—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the form corrugated or undulated
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/24—Grouping of fuel cells, e.g. stacking of fuel cells
    • H01M8/241—Grouping of fuel cells, e.g. stacking of fuel cells with solid or matrix-supported electrolytes
    • H01M8/2425—High-temperature cells with solid electrolytes
    • H01M8/2432—Grouping of unit cells of planar configuration
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
    • H01M2008/1293—Fuel cells with solid oxide electrolytes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells

Definitions

  • the invention relates to solid oxide fuel cell (SOFC) stacks and, more particularly, to an interconnect that enhances the lifetime of SOFC stacks.
  • SOFC solid oxide fuel cell
  • a fuel cell is a device which electrochemically reacts a fuel with an oxidant to generate a direct current.
  • the fuel cell typically includes a cathode, an electrolyte and an anode, with the electrolyte being a non-porous material positioned between the cathode and anode materials.
  • such fuel cells are typically connected together using interconnects or bipolar plates to form a stack, or fuel cell stack, through which fuel and oxidant fluids are passed. Electrochemical conversion occurs, with the fuel being electrochemically reacted with the oxidant, to produce a DC electrical output.
  • Cathode interconnect materials that have been used to date include perovskite-based ceramics, e.g. lanthanum chromite, high temperature chromium-based alloys or composites thereof, and nickel-based alloys or intermetallics have been used typically for cells operating in the 800-1000° C. range.
  • perovskite-based ceramics e.g. lanthanum chromite, high temperature chromium-based alloys or composites thereof, and nickel-based alloys or intermetallics have been used typically for cells operating in the 800-1000° C. range.
  • the oxidation resistance is clearly a concern on the cathode/oxidant side of the interconnect.
  • the partial pressure of oxygen at the anode/fuel electrode may also be high enough to form Cr 2 O 3 and the oxide may be even thicker (viz. the presence of electrochemically formed water) than on the cathode side of the interconnect, so the resistivity of the interconnect may increase on both sides.
  • the construction materials on the anode side of the interconnect could be the same as the cathode, although prior art has shown that, in the case of a ferritic steel interconnect in contact with a nickel anodic contact, weld points that formed between the steel and the nickel still formed a thin electrically insulating Cr 2 O 3 layer over time which degraded performance.
  • an interconnect which comprises a compliant porous member, compliant in all three-dimensions and having first portions defining a separator plate contact zone and second portions spaced from said first portions and defining an electrode contact zone.
  • a solid oxide fuel cell assembly which comprises a plurality of fuel cells arranged in a stack; and a plurality of interconnect assemblies positioned between adjacent cells of said stack, said interconnect assemblies comprising a separator plate having two opposed surfaces and at least one interconnect positioned adjacent to at least one of said two opposed surfaces and comprising a compliant porous member, compliant in all three dimensions and having first portions defining a separator plate contact zone and second portions spaced from said first portions and defining an electrode contact zone.
  • FIGS. 4 and 5 illustrate another preferred embodiment of an interconnect of the present invention
  • FIG. 6 illustrates an alternate embodiment of an interconnect of the present invention
  • the compliant interconnects described herein are designed such that high values of both in-plane and out-of-plane compliance are achieved.
  • the compliant superstructure is compliant in at least three orthogonal axes, and is compliant with respect to a load applied from any direction.
  • Assembly 10 preferably includes a plurality of fuel cells 12 arranged in a stack with bipolar plates 14 positioned therebetween.
  • Fuel cells 12 typically include an electrolyte 16 , a cathode layer 18 positioned on one side of electrolyte 16 , and an anode layer 20 positioned on the other side of electrolyte 16 . Bonding or current carrying layers 22 may be used on the two sides.
  • a particular aspect of the present invention is the design of cathode-side and anode-side interconnects 30 , 32 , wherein the interconnects are provided as a sheet of woven wire material formed to have a plurality of first portions 34 or 38 defining an electrode contact zone, and a plurality of second portions 36 defining a separator plate contact zone which is spaced from the electrode contact zone.
  • interconnects 30 , 32 in accordance with the present invention consists of compliant sub-structure, preferably wire weaves, material as described above which is formed, for example through die stamping, rolling, bending or the like, to have a three-dimensional superstructure defining first and second portions 34 , 36 .
  • FIG. 3 shows a perspective view of an interconnect 30 , 32 to further illustrate a preferred sub-structure and superstructure thereof.
  • interconnects 30 , 32 could equally provide for the spaced contact zones connected by compliant members which provide for advantageous reduction in stresses between components as desired in accordance with the present invention.
  • FIG. 6 shows a substantially square channeled superstructure interconnect 30 , 32 with spaced contact zones present in both the cross sectional and the transverse direction.
  • FIG. 7 shows a substantially trapezoidal superstructure interconnect 30 , 32 made from compliant sub-structures.
  • FIG. 9 illustrates an embodiment wherein wires 52 are provided with compliance loops 54 as described above.
  • This structure serves to enhance the ability of the wire to resiliently deform as needed to respond to different CTE, and also to provide desired manufacturing tolerances.
  • This compliance loop structure can be incorporated into the substructure and/or the superstructure of the interconnect of the present invention.
  • Anode-side interconnect 32 can advantageously be provided having the same architecture, or having a foam architecture defining foam cells which, themselves, define the contact zones for contact on one side with separator plate 24 and on the other side with the anode of a fuel cell 12 .
  • Anode-side interconnect 32 is advantageously provided of a material selected from the group consisting of Ni, Ni—Cu, Ni—Cr—, Ni—Cr—Fe—, Fe—Cr—, Fe—Cr—Ni and Co-based alloys as well as Cr-based alloys and noble metal/alloys and including such alloys coated with Ni, Cu or Ni—Cu as well as noble metals.
  • Other materials include composites of metals and ceramics containing any of the above mentioned metals and alloys.
  • the wire weave sub-structure of interconnect 30 , 32 in accordance with the present invention is preferably provided having a wire diameter of between 0.05 mm and 5 mm, a sub-structure weave wavelength of between 0.05 mm and 50 mm, a weave amplitude of between 0.05 mm and 50 mm, a weave pattern which may be square, plain, satin, twill or other patterns, and a weave periodicity which may be uniform or random.
  • the wire weave sub-structure and three-dimensional superstructure of the interconnects in accordance with the present invention advantageously serves to alleviate stresses at the anode and cathode interfaces, and minimizes fracture of the interface and the cells themselves.
  • a compliant seal is further advantageously provided for sealing between edges of bipolar plate 14 and adjacent fuel cells 12 .
  • the seal design is provided in the form of a rail or spacer 44 defining therein a groove 46 , and a seal member 48 positioned in groove 46 and compressed between bipolar plate 14 and adjacent fuel cells 12 to provide the desired seal therebetween.
  • a compression stop 50 is provided to control the amount of deflection of the compliant seals and to advantageously assemble compliant interconnects, compliant seals and all other elements of the stack.
  • seal member 48 is advantageously provided as a compliant or compressible member formed from a suitable material, preferably alumina fibers.
  • Alumina is most desirable in accordance with the present invention because alumina does not contaminate the fuel cell as do other seal materials which have conventionally been used, such as glass, glass-ceramics and the like.
  • seal member 48 is advantageously provided as compliant alumina fibers which can preferably be impregnated with another material selected so as to provide substantial gas impermeability of seal member 48 while nevertheless allowing for compliance or compressibility thereof.
  • the seal member 48 in accordance with the present invention can advantageously be impregnated with a material selected from the group consisting of zirconia, alumina, yttrium aluminum garnate, alumino-silicate and magnesium silicate ceramics, and similar oxides, and combinations thereof, and it is preferred that seal member 48 be provided so as to reduce permeability to gas.
  • Seal member 48 can advantageously be provided having a fiber architecture such as tows, yarns, fiber weave architecture and the like. Such architectures can be loaded with secondary particles within the fibers as discussed above so as to provide desired seal properties. Further, rail/spacer 44 and compression stop 50 is provided having a height and groove depth which are selected to provide for additional decoupling of various parameters which are conventionally required to be related.
  • the system of the present invention provides for cells and interconnects having less stringent dimensional tolerances since the interconnect provides out-of-plane compliance and, therefore, increased dimensional freedom. Further, the provision of fixed thickness rail/spacers 44 and compression stops 50 ensures decoupling of the sealing and interconnection requirements and therefore provides substantial flexibility for building stacks that are based upon stable and compatible materials.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Fuel Cell (AREA)
US10/758,843 2002-11-27 2004-01-16 Compliant, strain tolerant interconnects for solid oxide fuel cell stack Abandoned US20040200187A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US10/758,843 US20040200187A1 (en) 2002-11-27 2004-01-16 Compliant, strain tolerant interconnects for solid oxide fuel cell stack
PCT/US2004/002865 WO2004070858A2 (en) 2003-01-31 2004-02-02 Compliant, strain tolerant interconnects for solid oxide fuel cell stack
JP2006503238A JP2007524956A (ja) 2003-01-31 2004-02-02 固体酸化物燃料電池スタック用の柔軟性耐歪み性の相互接続部
KR1020057013981A KR20050096960A (ko) 2003-01-31 2004-02-02 고체 산화물 연료 셀 스택을 위한 유연한, 스트레인 허용오차를 갖는 상호 연결부
EP04707406A EP1595304A4 (en) 2003-01-31 2004-02-02 SUBSEQUENT, LOAD-TOLERANT COMPOUNDS FOR A SOLID OXYGEN FUEL CELL STACK
CA002514488A CA2514488A1 (en) 2003-01-31 2004-02-02 Compliant, strain tolerant interconnects for solid oxide fuel cell stack

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US10/307,008 US7144649B2 (en) 2002-11-27 2002-11-27 Interconnect for solid oxide fuel cells
US44402503P 2003-01-31 2003-01-31
US45489903P 2003-03-14 2003-03-14
US10/758,843 US20040200187A1 (en) 2002-11-27 2004-01-16 Compliant, strain tolerant interconnects for solid oxide fuel cell stack

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US10/307,008 Continuation-In-Part US7144649B2 (en) 2002-11-27 2002-11-27 Interconnect for solid oxide fuel cells

Publications (1)

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US20040200187A1 true US20040200187A1 (en) 2004-10-14

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US10/758,843 Abandoned US20040200187A1 (en) 2002-11-27 2004-01-16 Compliant, strain tolerant interconnects for solid oxide fuel cell stack

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US (1) US20040200187A1 (ja)
EP (1) EP1595304A4 (ja)
JP (1) JP2007524956A (ja)
KR (1) KR20050096960A (ja)
CA (1) CA2514488A1 (ja)
WO (1) WO2004070858A2 (ja)

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US20060204808A1 (en) * 2005-03-11 2006-09-14 Kabushikikaisha Equos Research Separator unit
US20060204806A1 (en) * 2005-03-11 2006-09-14 Kabushikikaisha Equos Research Separator unit and fuel cell stack
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US8158057B2 (en) 2005-06-15 2012-04-17 Ati Properties, Inc. Interconnects for solid oxide fuel cells and ferritic stainless steels adapted for use with solid oxide fuel cells
US8173328B2 (en) 2005-06-15 2012-05-08 Ati Properties, Inc. Interconnects for solid oxide fuel cells and ferritic stainless steels adapted for use with solid oxide fuel cells
WO2014049523A1 (fr) 2012-09-26 2014-04-03 Commissariat A L'energie Atomique Et Aux Energies Alternatives Composant constituant un interconnecteur d'electrolyseur eht ou de pile a combustible sofc et procedes de realisation associes
US8852825B2 (en) 2011-11-17 2014-10-07 Bloom Energy Corporation Multi-layered coating providing corrosion resistance to zirconia based electrolytes
US8962219B2 (en) 2011-11-18 2015-02-24 Bloom Energy Corporation Fuel cell interconnects and methods of fabrication
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US9468736B2 (en) 2013-11-27 2016-10-18 Bloom Energy Corporation Fuel cell interconnect with reduced voltage degradation over time
US9478812B1 (en) 2012-10-17 2016-10-25 Bloom Energy Corporation Interconnect for fuel cell stack
US9502721B2 (en) 2013-10-01 2016-11-22 Bloom Energy Corporation Pre-formed powder delivery to powder press machine
US9583771B2 (en) 2013-05-16 2017-02-28 Bloom Energy Coporation Corrosion resistant barrier layer for a solid oxide fuel cell stack and method of making thereof
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US9847520B1 (en) 2012-07-19 2017-12-19 Bloom Energy Corporation Thermal processing of interconnects
US9923211B2 (en) 2014-04-24 2018-03-20 Bloom Energy Corporation Fuel cell interconnect with reduced voltage degradation over time
US9993874B2 (en) 2014-02-25 2018-06-12 Bloom Energy Corporation Composition and processing of metallic interconnects for SOFC stacks
US10079393B1 (en) 2014-01-09 2018-09-18 Bloom Energy Corporation Method of fabricating an interconnect for a fuel cell stack
US10270118B2 (en) * 2015-05-25 2019-04-23 Nissan Motor Co., Ltd. Solid oxide fuel cell
US10763533B1 (en) 2017-03-30 2020-09-01 Bloom Energy Corporation Solid oxide fuel cell interconnect having a magnesium containing corrosion barrier layer and method of making thereof
US11217797B2 (en) 2012-08-29 2022-01-04 Bloom Energy Corporation Interconnect for fuel cell stack
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EP1595304A2 (en) 2005-11-16
KR20050096960A (ko) 2005-10-06
JP2007524956A (ja) 2007-08-30
WO2004070858A3 (en) 2004-10-07
WO2004070858A2 (en) 2004-08-19
EP1595304A4 (en) 2012-02-15
WO2004070858A9 (en) 2004-11-18

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