Title of Invention

A CERAMIC ELECTROLYTE FOR A SOLID OXIDE FUEL CELL METHOD OF MAKING THEREOF; A SOLID OXIDE FUELCELL AND A FUEL CELL STACK .

Abstract A solid oxide fuel cell system, comprising any one or more of elements (a) to (g): (a) a temperature sensitive adsorption oxygen enrichment system [2]; (b) a load matched power generation system having a solid oxide fuel cell [68] and a heat pump [4] and an optional turbine [90]; (c) a textured fuel cell ceramic electrolyte [10]; (d) an environment tolerant fuel cell anode catalyst [503]; (e) a fuel water vapor replenishment system containing an anode side enthalpy wheel [601], (f) a felt seal [701] in a fuel cell; and (g) a felt connector [860] in a fuel cell.
Full Text SOLID OXIDE FUEL CELL AND SYSTEM
FIELD OF THE INVENTION
[0001] This application claims benefit of priority of US provisional
application 60/357,636 filed on February 20, 2002, which is incorporated
by reference in its entirety. The present invention is directed generally to
fuel cells and more particularly to solid oxide fuel cells and power
generation systems.
BACKGROUND OF THE INVENTION
[0002] Fuel cells generate electricity from hydrogen or various
hydrocarbon fuels. In some fuel cells, an oxygen containing gas, such as
air, is provided onto the cathode side of the electrolyte, while hydrogen or
a hydrocarbon fuel is provided onto the anode side of the electrolyte. The
fuel cell generates electricity through an electrochemical reaction. For
example, in a solid oxide fuel cell, oxygen containing air is provided onto
the cathode side of a solid ceramic electrolyte, while a hydrocarbon fuel is
provided onto the anode side of the electrolyte.
[0003] Fuel cells operate more efficiently when the oxygen content
of the inlet air is higher, primarily because the Nernst potential of the cell
increases when the partial pressure of oxygen is higher. Therefore, the
oxygen content of air being provided into the fuel cell is sometimes
increased or enriched using various processes, including pressure swing
adsorption (e.g., QuestAir Inc.'s Pulsar technology), oxygen-selective
membranes (e.g., Boyer et al., J. Appl. Electrochem., p.1095, 1999), or
magnetic separation devices (e.g., Nitta et al., U.S. Patent 6,106,963,
incorporated herein by reference in the entirety). However, these
methods are generally inefficient because they require the use of power

,..e., electricity), thus decreasing the efficiency of the fuel cell and the
power generation system.
BRIEF SUMMARY OF THE INVENTION
[0004] Preferred embodiments of the present invention provide a
system, comprising any combination of one or more elements (a) to (g):
(a) a temperature sensitive adsorption oxygen enrichment system;
(b) a load matched power generation system including a solid oxide
fuel cell and a heat pump and an optional turbine;
(c) a textured fuel cell ceramic electrolyte;
(d) an environment tolerant fuel cell anode catalyst;
(e) a fuel water vapor replenishment system containing an anode
side enthalpy wheel;
(f) a felt seal in a fuel cell; and
(g) a felt collector in a fuel cell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Figures 1-5 are schematic representations of oxygen
enrichment systems according to the first preferred embodiment.
[0006] Figures 6-10D are schematic representations of a combined
electrical power generation and cooling system according to the second
preferred embodiment.
[0007] Figure 11 is a schematic side cross sectional view of a prior
art solid oxide fuel cell.
[0008] Figure 12 is a schematic illustration of oxygen transport
through the electrolyte.
F0009] Figures 13, 15 and 16 are schematic side cross sectional
views of solid oxide fuel cells according to the third preferred
embodiment.
[0010] Figure 14 is a schematic side cross sectional view of a prior
art multi-layer solid oxide electrolyte.
[0011] Figures 17-24 are schematic side cross sectional views of
methods of making the electrolyte according to the third preferred
embodiment.
[0012] Figures 25-26 are schematic side cross sectional views of
fuel cells according to the fourth preferred embodiment.
[0013] Figures 27A-B are schematic diagrams of a system according
to the fifth preferred embodiment.
[0014] Figures 28-35 are schematic representations of seals according
to the sixth preferred embodiment.
[0015] Figures 36-48 are schematic representations of the repeating
elements of a fuel cell stack, including the felt current conductor / flow
distributor elements, according to the seventh preferred embodiment.
Figures 36-45 are cross-sectional, exploded views and Figures 46-48 are
three dimensional cut away views.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. The First Preferred Embodiment
[0016] In a first preferred embodiment of the present invention, the
inventors have realized that the oxygen content of air being provided into
the fuel cell can be increased using a temperature sensitive adsorDtion
cycle. Preferably, the temperature sensitive adsorption cycle utilizes the
heat generated by the fuel cell during power generation. The use of heat
generated by a fuel cell for increasing the oxygen content of the inlet air
stream in a cyclical adsorption separation process increases the efficiency
of power generation. However, heat generated by means other than the
fuel cell may be used instead.
[0017] In the temperature sensitive adsorption process, an air
stream (a mixture of nitrogen and oxygen) is passed through a cool
adsorbent medium that selectively removes a fraction of the nitrogen,
resulting in a gas stream that has a higher oxygen content than the '
original stream. When the adsorbent is saturated with nitrogen under the
process conditions, heat generated from the fuel cell operation or from,
another source is transferred to the adsorbent medium, .and the nitrogen
is driven out of the adsorbent medium through a vent. Thus, a separation
is effected.
[0018] Figure 1 schematically illustrates the temperature sensitive
oxygen enrichment system 1. The system includes an air source 3, an
adsorbent medium 5 and a fuel cell 7. The air source 3 may be an air
blower, an air inlet conduit and/or any other device which provides air into
the adsorbent medium 5. The adsorbent medium 5 may be any medium
which selectively adsorbs nitrogen compared to oxygen. Preferably, the
adsorbent medium 5 is a bed containing a nitrogen adsorbing material,
such as a zeolite or a mixture of zeolites. For example, silver X, sodium X
or calcium A zeolites may be used. The fuel cell 7 may be any fuel cell
into which air is provided. Preferably, the fuel cell 7 is a solid oxide fuel
cell. However, other fuel cells, such as PEM, direct methanol, molten-
carbonate, phosphoric acid or alkaline fuel cells may be used
[0019] The system 1 also preferably contains a heat transfer conduit
9 located between the fuel cell 7 and the adsorbent medium 5. The
conduit 9 transfers heat from the fuel cell 7 to the adsorbent medium 5.
The conduit 9 may comprise any device than may transfer heat from one
location to another. For example, the conduit 9 may comprise a pipe, a
duct, a space between walls or even a solid heat transfer material.
Preferably the conduit 9 is a pipe which transfers a heat transfer fluid
through the system 1.
[0020] An air inlet 11 is located in the adsorbent medium 5 housing.
The inlet provides air from the air source 3 into the adsorbent medium. 5.
An oxygen enriched air conduit 13 is located between the adsorbent
medium 5 and the fuel cell 7. The conduit 13 may be pipe, duct or open
space which provides oxygen enriched air from the adsorbent medium 5
to the fuel cell 7.
[0021] In one preferred aspect of the first embodiment, the heat
transfer conduit 9 comprises a pipe which is located adjacent to the fuel
cell 7, adjacent to a heat sink 15 and adjacent to the adsorbent medium
5. For example, as shown in Figure 2, the conduit 9 is wrapped around
the housing of the adsorbent medium 5 and around the fuel cell 7. The
conduit 9 also passes through the heat sink 15. The heat transfer
conduit 9 transfers a heated heat transfer liquid, such as water, from
adjacent to the fuel cell 7 to the adsorbent medium 5. The heated heat
transfer liquid heats the adsorbent medium 5 to desorb nitrogen from the
adsorbent medium 5. The heat transfer conduit 9 also transfers a cooled
heat transfer liquid, such as water, from adjacent to the heat sink 15 to
the adsorbent medium 5. The cooled heat transfer liquid cools the
adsorbent medium 5, which allows the adsorbent medium 5 to adsorb
nitrogen from air that is being provided from inlet 11.
[0022] The operation of the heat transfer conduit 9 illustrated in
Figure 2 will now be described in more detail. The conduit 9 is filled with
a heat transfer liquid. This liquid may be any liquid which is capable of
transferring heat. Preferably, this liquid is water. However, other liquids,
such as mineral oil, etc., or even heat transfer gases may be used. The
liquid is provided through conduit 9 and through at least one valve.
Preferably, the conduit 9 contains an outlet valve 17 and an inlet valve
19. However, only one of these two valves may be used. The outlet
valve 1 7 is preferably a three way valve which directs the liquid either
through a first segment 21 of the conduit 9, through a second segment
23 of the conduit 9, or prevents liquid flow through the conduit 9. If
liquid is provided through the first segment 21 which is located adjacent
to the fuel cell 7, then the liquid is heated by the heat generated in the
fuel cell 7. For example, "located adjacent" means that the first segment
21 of the conduit 9 is wrapped around the fuel cell 7 or a stack of fuel
cells if more than one fuel cell is used. However, "located adjacent" also
includes any other configuration of segment 21 which allows the fuel cell
7 to heat the liquid in the segment 21. For example, the segment 21 may
be located in contact with one or more surfaces of the fuel cell 7 or
segment 21 may be located near the fuel cell, rather than being wrapped
around the fuel cell.
[0023] The heated heat transfer liquid is then provided from the first
segment 21 through the inlet valve 19 into the portion of conduit 9 that is
located adjacent to the adsorbent medium 5. For example, "located
adjacent" means that the conduit 9 is wrapped around the housing of the
adsorbent medium 5. However, "located adjacent" also includes any
other configuration of conduit 9 which allows the heat transfer liquid to
heat the adsorbent medium 5. For example, the conduit 9 may be located
in contact with one or more surfaces of the adsorbent medium 5 or
conduit 9 may be located near the adsorbent medium 5, rather than being
wrapped around it. The heated heat transfer Jiquid heats the adsorbent
medium 5 and desorbs the nitrogen adsorbed in the adsorbent medium 5.
[0024] When it is desired to coo! the adsorbent medium 5, then the
valves 17 and 19 are switched to provide the heat transfer fluid through a
second segment 23 of the conduit 9. The second segment 23 is located
adjacent to a heat sink 15. The heat sink 15 may comprise any thing
which can cool the liquid in the second segment 23 of the conduit 9. For
example, the heat sink 15 may be a cooling tower, a heat exchanger, a
radiator with cool air, a cold air blower or even a portion of segment 23
which runs through the cool ground or wall. The segment 23 may pass
through the heat sink 15 or be placed in contact with or adjacent to the
heat sink 1 5, depending on what type of heat sink is used.
[0025] The cooled heat transfer liquid is then provided from the
second segment 23 through the inlet valve 19 into the portion of conduit
9 that is located adjacent to the adsorbent medium 5. The cooled heat
transfer fluid cools the adsorbent medium 5 while air from inlet 11 is
passing through the adsorbent medium 5 to desorb nitrogen from the air.
[0026] As shown in Figure 2, the heat transfer liquid is provided
through the conduit 9 in a closed control loop. The system 1 of Figure 2
operates in a batch or non-continuous mode. Thus, when air is provided
from the air source 3 through the adsorbent medium 5 into the fuel cell 7,
the heat transfer liquid is passed through the second segment 23 adjacent
to the heat sink 15. The cooled heat transfer jiquid cools the adsorbent
medium 5 to adsorb the nitrogen from the air. When no air is provided
from the air source 3 through the adsorbent medium 5 into the fuel cell 7,
the heat transfer liquid is passed through the first segment 21 adjacent to
the fuel cell 7. The heated heat transfer liquid heats the adsorbent
medium 5 to desorb the nitrogen.
[0027] However, in a second preferred aspect of the first
embodiment, the system 1 operates in a continuous mode. To operate in
a continuous mode, the system 100 contains two or more adsorbent
mediums 5A, 5B, as shown in Figure 3. In Figure 3, elements with like
numbers to elements in Figures 1-2 are presumed to be the same. In the
preferred aspect of Figure 3, while one adsorbent medium 5A is used to
adsorb nitrogen to oxygen enrich the air being provided into the fuel cell,
the other adsorbent medium 5B is heated by the heat from the fuel cell to
desorb the nitrogen from the adsorbent medium 5B.
[0028] The system 100 shown in Figure 3 contains the following
elements. The system 100 contains one or more air sources 3, such as
blowers, and a plurality of adsorbent mediums 5A, 5B which selectively
adsorb nitrogen compared to oxygen. While only two mediums are
shown in Figure 3, there may be more than two mediums if desired. The
system 100 also contains a plurality of heat transfer conduits 9A, 9B
which transfer heat from the fuel cell (not shown in Figure 3 for clarity) to
the plurality of adsorbent mediums 5A, 5B. The conduits 9A, 9B are
located between the fuel cell and the plurality of adsorbent mediums 5A,
5B.
[0029] There are also a plurality of air inlets 11 A, 11B into the
plurality of adsorbent mediums 5A, 5B, and a plurality of outlets 13A,
13B (i.e., a plurality of oxygen enriched air conduits) which provide
oxygen enriched air from the plurality of adsorbent mediums 5A, 5B to
the fuel cell. The conduits 13A, 13B are located between the plurality of
adsorbent mediums 5A, 5B and the fuel cell.
[0030] Preferably, the system 100 contains seven three way valves,
as will be described in more detail below. However, more or less than
seven valves may be used as desired. The system 100 contains least
one inlet selector valve 27 located between the air source 3 and the
plurality of adsorbent mediums 5A, 5B. The inlet selector valve 27
directs air from the air source 3 into either a first adsorbent medium 5A or
into a second adsorbent medium 5B.
[0031] The system 100 also contains at least one outlet selector
valve 29 located between the plurality of adsorbent mediums 5A, 5B and
the fuel cell. The outlet selector valve 29 directs oxygen enriched air
into the fuel cell through oxygen enriched air conduits 13A, 13B, 13C
from either the first adsorbent medium 5A or from the second adsorbent
medium 5B.
[00321 The system 100 contains at least one venting selector valve
31 located between the air source 3 and the plurality of adsorbent
mediums 5A, 5B. The venting selector valve 31 directs desorbed
nitrogen to be vented through vent 25 from either the second adsorbent
medium 5B or from the first adsorbent medium 5A.
[0033] At least one connecting conduit 33 is provided such that it
connects a plurality of oxygen enriched air conduits 1 3A, 13B. The
connecting conduit 33 directs purging air from one of the first or the
second adsorbent medium to the other one of the first or the second
adsorbent medium to purge the nitrogen from the receiving medium.
Preferably, the conduit 33 contains one or more flow restrictors 35. The
restrictors 35 restrict the flow of oxygen enriched air, such that the
majority of the oxygen enriched air exiting an adsorbent medium is
directed to the fuel cell through conduit 13C, rather than through the
connecting conduit 33.
[0034] The system 100 contains at least one heat transfer fluid inlet
valve 37A, 37B located in the heat transfer fluid conduits 9A, 9B.
Preferably there are two such valves as shown in Figure 3. Valve 37A

directs heated heat transfer fluid to the one of the adsorbent mediums
5A, 5B from the fuel cell stack, while valve 37B directs cooied heat
transfer fluid to another one of the adsorbent mediums 5A, 5B from the
heat sink.
[0035] Furthermore, the system 100 contains at least one heat
transfer fluid outlet valve 39A, 39B located in the heat transfer fluid
conduits 9A, 9B. Preferably there are two such valves as shown in Figure
3. Valve 39A directs heated heat transfer fluid from the adsorbent
mediums to the heat sink, while valve 39B directs cooled heat transfer
fluid from the adsorbent mediums to the fuel cell.
[0036] Thus, the conduits 9A, 9B actually comprise two segments
of one common conduit 9. For example, the output of conduit 9A is
provided through valve 39B, the fuel cell stack and valve 37A to input of
conduit 9B, while the output of conduit 9B is provided through valve 39A,
the heat sink and valve 37B to input of conduit 9A. However, the valves
37A, 37B and 39A, 39B may be set such that the conduits 9A and 9B
remain separate, as will be discussed in more detail below.
[0037] The method of operating system 100 will now be described
with respect to Figures 3 and 4. As shown in Figure 3, the valves are set
to allow the first adsorbent medium 5A to provide oxygen enriched air
into the fuel cell, while the nitrogen is desorbed from the second
adsorbent medium 5B. The first adsorbent medium 5A is cooled by a cool
heat transfer fluid in conduit 9A, while the second adsorbent medium 5B
is heated by a hot heat transfer fluid in conduit 9B.
[0038] Then, after some time, the valve positions are switched as
shown in Figure 4. As shown in Figure 4, the vaives are set to allow the
second adsorbent medium 5B to provide oxygen enriched air into the fuel
cell, while the nitrogen is desorbed from the first adsorbent medium 5A.

The second adsorbent medium 5B is cooled by a cool heat transfer fluid in
conduit 9B, while the first adsorbent medium 5A is heated by a hot heat
transfer fluid in conduit 9A. Thus, the system 100 can operate in a
continuous rather than in a batch mode. At least one adsorbent medium
may be used to provide oxygen enriched air into the fuel cell, while
another adsorbent medium may be heated and purged to desorb nitrogen
adsorbed therein.
[0039] The operation of the system 100 as shown in Figure 3 will
now be described in detail. Air from the air source 3 is directed to the
inlet selector valve 27, which directs air into at least one of plurality of
adsorbent mediums. For example the valve 27 directs the air into the first
adsorbent medium 5A but not into the second adsorbent medium 5B.
The first adsorbent medium 5A is cooled by the heat transfer fluid in the
first heat transfer conduit 9A, and first adsorbent medium 5A selectively
adsorbs nitrogen from the air. The oxygen enriched air exits the first
adsorbent medium 5A and is selectively directed to the fuel cell through
the oxygen enriched air conduits 13A, 13C and the outlet selector valve
29. The inlet selector valve 27 prevents air from flowing from the air
source 3 into the second adsorbent medium 5B. Furthermore, the outlet
selector valve 29 prevents flow from the second adsorbent medium 5B to
the fuel cell. Thus, no oxygen enriched air flows from the second
adsorbent medium 5B into the fuel cell.
[0040] A portion of the oxygen enriched air flows from the first
adsorbent medium 5A through conduit 1 3A, the connecting conduit 33
and the conduit 13B into the second adsorbent medium 5B. The flow
restrictor(s) 35 in the connecting conduit 33 ensure that only a small
portion of the oxygen enriched air flows into the second adsorbent
medium 5B. This oxygen enriched air from the first adsorbent medium 5A
is used as purging air for the second adsorbent medium 5B to purge the

nitrogen from the second adsorbent medium 5B. The second adsorbent
medium 5B is heated by the heated heat transfer fluid in the conduit 9B to
desorb the nitrogen in the second adsorbent medium 5B while the purging
air is passing through the second adsorbent medium 5B. The desorbed
nitrogen is selectively directed to be vented from the second adsorbent
medium but not from the first adsorbent medium by the venting selector
valve 31.
[0041] The heat transfer fluid is directed in the system 100 shown
in Figure 3 as follows. The heat transfer fluid is passed through a heat
smk to cool the heat transfer fluid. The cooled heat transfer fluid is
selectively directed to the first adsorbent medium 5A through the "cool
inlet" in the heat transfer fluid inlet valve 37B and through conduit 9A.
[0042] Then, the cooled heat transfer fluid from the first adsorbent
medium 5A is selectively directed through conduit 9A and through the
"cool outlet" in the heat transfer fluid outlet valve 39B to the fuel cell.
The heat transfer fluid from valve 39B is passed adjacent to the fuel cell
to heat the heat transfer fluid.
[0043] The heated heat transfer fluid is then selectively directed to
the second adsorbent medium 5B through the "hot inlet" in the heat
transfer fluid inlet valve 37A and through conduit 9B. Then, the heated
heat transfer fluid from the second adsorbent medium 5B is selectively
directed through conduit 9B and through the "hot outlet" in the heat
transfer fluid outlet valve 39A to the heat sink.
[0044] The operation of the system 100 as shown in Figure 4 will
now be described in detail. All of the valves in Figure 4 are set to provide
flow in the opposite direction from Figure 3. Air from the air source 3 is
directed to the inlet selector valve 27 which directs the air into the
second adsorbent medium 5B but not into the first adsorbent medium 5A.

The second adsorbent medium 5B is cooled by the heat transfer fluid in
the second heat transfer conduit 9B, and the second adsorbent medium
5B selectively adsorbs nitrogen from the air. The oxygen enriched air
exits the second adsorbent medium 5B and is selectively directed to the
fuel cell through the oxygen enriched air conduits 13B, 13C and the outlet
selector valve 29. The inlet selector valve 27 prevents air from flowing
from the air source 3 into the first adsorbent medium 5A. Furthermore,
the outlet selector valve 29 prevents flow from the first adsorbent
medium 5A to the fuel cell. Thus, no oxygen enriched air flows from the
first adsorbent medium 5A into the fuel cell.
[0045] A portion of the oxygen enriched air flows from the second
adsorbent medium 5B through conduit 13B, the connecting conduit 33
and the conduit 13A into the first adsorbent medium 5A. The flow
restrictor(s) 35 in the connecting conduit ensure that only a small portion
of the oxygen enriched air flows into the first adsorbent medium 5A. This
oxygen enriched air from the second adsorbent medium 5B is used as
purging air for the first adsorbent medium 5A to purge the nitrogen from
the first adsorbent medium 5A. The first adsorbent medium 5A is heated
by the heated heat transfer fluid in the conduit 9A to desorb the nitrogen
in the first adsorbent medium 5A while the purging air is passing through
the first adsorbent medium 5A. The desorbed nitrogen is selectively
directed to be vented from the first adsorbent medium but not from the
second adsorbent medium by the venting selector valve 31.
[0046] The heat transfer fluid is directed in the system 100 shown
in Figure 4 as follows. The heat transfer fluid is passed through a heat
sink to cool the heat transfer fluid. The cooled heat transfer fluid is
selectively directed to the second adsorbent medium 5B through the heat
transfer fluid inlet valve 37B and conduit 9B.
[0047] Then, the cooled heat transfer fluid from the second
adsorbent medium 5B is selectively directed through conduit 9B and the
heat transfer fluid outlet valve 39B to the fuel cell. The heat transfer fluid
from valve 39B is passed adjacent to the fuel cell to heat the heat
transfer fluid.
[0048] The heated heat transfer fluid is then selectively directed to
the first adsorbent medium 5A through the heat transfer fluid inlet valve
37A and conduit 9A. Then, the heated heat transfer fluid from the
second adsorbent medium 5A is selectively directed through conduit 9A
and the heat transfer fluid outlet valve 39A to the heat sink.
[0049] Therefore, conduits 9A and 9B comprise segments of the
same conduit because the heat transfer fluid makes a complete loop
through the system 100. However, if desired, the valves 37A, 37B, 39A
and 39B may be set such that the heated heat transfer fluid returns to the
fuel cell after heating one adsorbent medium, while the cooled heat
transfer fluid returns to the heat sink after cooling the other adsorbent
medium.
[0050] It should be noted that the present invention is not limited to
the system 100 illustrated in Figures 3 and 4. Several adsorbent
mediums (i.e., beds containing adsorbent medium) can be connected in
various different ways to achieve the desired oxygen enrichment
continuously.
[0051] Figure 5 illustrates another system 200 according to a third
preferred aspect of the first embodiment. The system 200 of Figure 5 is
similar to the system 100 of Figures 3 and 4, except that the adsorbent
mediums 5A, 5B are heated by the hot air emitted by the fuel cell 7,
rather than by a heat transfer liquid.
[0052] As shown in Figure 5 the air is provided from inlet 11 A into
the first adsorbent medium 5A. In the adsorbent medium 5A, nitrogen is
adsorbed, and oxygen enriched air is provided through conduits 13A, 13C
and valve 29 into the cathode side input of the fuel cell 7. No air is
provided into the second adsorbent medium 5B from inlet 11B due to the
position of valve 27 in Figure 5, similar to that of the system 100
illustrated in Figure 3.
[0053] The heat transfer conduit 9 is connected to the cathode side
output of the fuel cell 7. The hot air exits the cathode side output of the
fuel cell 7 and enters the conduit 9. The hot air then reaches a hot air
selector valve 41 which directs the hot air into a first segment 9A or a
second segment 9B of the conduit 9. As shown in Figure 5, the valve 41
is set to direct the hot air into the second segment 9B.
[0054] Since the second segment 9B is located adjacent to the
second adsorbent medium 5B, the heated air from the fuel cell 7 heats
the second adsorbent medium 5B to desorb nitrogen from the adsorbent
medium. After the hot air passes through conduit 9B, the air is either
vented through vent 43B or reused for some other purpose.
[0055] When the second adsorbent medium 5B is used to provide
oxygen enriched air into the fuel cell 7, then the position of the valves 27,
31, 29 and 41 is reversed (similar to that shown in Figure 4), and the first
adsorbent medium 5A is heated by the hot air from the fuel cell 7 to
desorb the nitrogen from the first adsorbent medium 5A. The hot air is
then vented through vent 43A or put to some other use.
[0056] In Figure 5, the fuel cell 7 also contains a fuel input 45 on
the anode side and a fuel output 47 on the anode side. In use, the
adsorbent mediums 5A, 5B may be cooled by external air or by another
heat transfer conduit (not shown in Figure 5) to adsorb the nitrogen from

the in passing from inlets 11A, 11B through the adsorbent mediums 5A,
5B into conduits 13A, 13B. Thus, the heat transfer gas (i.e., hot air) is
provided in an open loop in Figure 5 and the system 200 operates in a
continuous mode.
[0057] In each of these embodiments, conditioning of the incoming air
may be valuable. For example, the inlet air may be dried, heated, or
cooled depending on its initial state.
[0058] It is desirable to select the adsorbent material to optimize
both gas separation and rapid heat transfer. The pressure drop through
the bed should be minimized in order to reduce the capital and operating
costs of the blower. Thus, the particle size, bed geometry, and overall
system layout and design may be optimized to minimize the pressure
drop. The adsorbent material in different beds may be the same or
different depending on the system requirements.
[0059] For example, in one case an oxygen enrichment system may
consist of three adsorbent beds operating in parallel, similar to the two
beds shown in Figure 2. Each bed will contain 1 kg of AgX zeolite pellets
with a standard mesh size of 20x30. The beds will have a parallelipiped
geometry and will contain a network of heat transfer surfaces, preferably
made of metal foam.
[0060] It should be noted that the temperature sensitive adsorption
process to enrich the oxygen content of air of the first embodiment is not
limited to providing oxygen enriched air to a fuel cell. This process may
be used to provide oxygen enriched air for any other suitable use. For
example, the efficiency of a combustion process (such as a gas turbine)
may increase if the inlet air is oxygen-enriched as inert nitrogen will not
need to be heated.
II. The Second Preferred Embodiment
[0061] High powered electrical appliances pose challenges for
thermal management. Large electrical power consumers such as co-
located computers or' fabrication machinery dissipate most of the
electrical energy provided as heat. In order to maintain appropriate
operating conditions this heat needs to be removed. In conventional
arrangements, where electrical power is supplied through the grid,
electrical power is required to drive the appliances and to operate a
cooling mechanism. Certain distributed power systems offer new
perspectives. Power generators such as solid oxide fuel cells provide
electrical power and high quality waste heat. This heat can be utilized to
drive a cooling device, thereby reducing the electrical power requirement.
The inventors have realized that appropriate choice of the equipment
involved can provide a system where electrical power requirements and
cooling requirements can be ideally matched.
[0062] In a second preferred embodiment of the present invention,
the inventors have realized that a power generator, which includes a fuel
cell, such as a solid oxide fuel cell, a heat pump, and an electrical power
consuming appliance, such as a computer, form an ideally matched
system with respect to electrical power requirements and cooling
requirements.
[0063] Solid oxide fuel cells typically generate approximately the
same amount of heat as electrical power. This heat is available at
elevated temperatures, usually in the range of 250°C to 1000°C, and is
suitable to drive a heat driven heat pump.
[0064] There are heat driven heat pumps, which have an efficiency
of approximately unity. An efficiency of unity implies that the heat pump
can remove the same amount of heat which is supplied to drive the heat
pump. It is important to note that the heat streams involved are of
different temperature. The heat stream from the fuel cell to the heat
driven heat pump is provided at a higher temperature than the heat
stream from the cooling load (in this case an electrical appliance) into the
heat driven heat pump.
[0065] The electrical power supplied by the fuel cell is consumed by
an appliance. Part of the electrical power supplied to an appliance is
dissipated as heat. A close look at this part of the system reveals that all
of the electrical power supplied to the appliance, which is not stored in
the appliance or transmitted from the appliance beyond the system
boundaries is dissipated. For most appliances, such as computers or
machinery, only a small fraction of the power supplied is transmitted
beyond system boundaries and most of the electrical energy supplied is
dissipated as heat. The dissipated heat needs to be removed in order to
avoid excessive temperatures within the appliance.
[0066] The inventors have realized that the system described above
has the extremely convenient feature of matching cooling loads with
electrical loads. The combination of the heat driven heat pump with the
solid oxide fuel cell provides electrical supply and cooling capacity
matching the requirements of many electrical appliances. Such a system
is convenient, because it requires neither additional cooling devices, nor
additional electrical power of significance (i.e., over 10% of the total
power) to be incorporated. Careful selection of the power generator and
the heat driven heat pump can provide matched cooling and heating for a
variety of applications. The power generator can also be a combination of
a solid oxide fuel cell and a gas turbine, such as a bottoming cycle gas
turbine.
[0067] Additionally, the amount of cooling and electrical power
provided can be adjusted by selecting the appropriate operating conditions
for the fuel cell. If for example the fuel cell is supplied with an excess of
fuel, more high temperature heat can be created and thereby more cooling
power. This adjustment can be especially important in situations where
additional heat loads need to be removed. One example for an additional
heat load is heating of the conditioned appliance due to high ambient air
temperatures (i.e. hot climate zones).
[0068] Another preferred option is heating of appliances or thermally
conditioned space with the heat pump. For example in cold climate zones
heating can be crucial to the operation of appliances or for the personnel
operating the appliances. A heat driven heat pump can extremely
efficiently provide heating.
[0069] A variety of fuels can be used in the power generator.
Examples for gaseous fuel are hydrogen, biologically produced gas,
natural gas, compressed natural gas, liquefied natural gas, and propane.
Liquid fuels can also be used. The system can also be adapted to solid
fuels.
[0070] Figure 6 schematically illustrates the system of the second
preferred embodiment. The system contains an electrical power generator
2, a heat driven heat pump 4, an appliance 6, and a heat sink 8. The
electrical power generator 2 can be a solid oxide fuel cell. It can also be a
solid oxide fuel cell combined with a gas turbine. Other power generators,
such as molten carbonate fuel cells, which also provide high temperature
heat in addition to electrical power, can also be used. The heat driven
heat pump 4 can be an absorbtion chiller, such as a LiBr-Water or an
ammonia-water heat pump. Heat driven heat pumps use high temperature
heat to provide cooling (i.e. absorb heat at a low temperature), and reject
heat at an intermediate temperature. Compared to conventional Rankine-
cycle cooling devices, they require only a small amount of electrical or
mechanical power. A description of heat driven heat pumps can be found
in Bernard D. Woods, "Applications of Thermodynamics", Waveland
Press, Inc., Prospect Heights, Illinois, Second Edition, 1991, incorporated
herein by reference.
[0071] Another class of heat driven heat pumps suitable for this
embodiment is adsorption heat pumps. In an adsorption heat pump the
refrigerant, which is usually a gas, interacts with a solid. Adsorption and
desorption of the refrigerant on/from the solid provide pressurization of
the refrigerant. High pressure desorption of the refrigerant is
accomplished using high temperature heat. In the high-pressure portion of
the refrigerant loop, heat is rejected and in the low pressure portion heat
is absorbed. Adsorption heat pumps can be realized as solid state devices
without the need to handle liquids. This can be advantageous for example
in environments where handling of the liquids commonly involved in
absorption heat pumps is too hazardous. Environmentally friendly gases/
vapors can be used in the adsorption heat pump.
[0072] The appliance 6 is a device that consumes electrical power
for any purpose and generates heat (appliance cooling load), mostly as a
parasitic loss, which needs to be removed. One preferred example for this
appliance is a computer or a cluster of computers co-located in a data
center.
[0073] A heat sink 8 for the system can be a large body of solid,
liquid or gas. For example the heat sink can comprise, a cooling tower,
ambient atmospheric air, soil, or a stream of water.
[0074] Also shown in Figure 6 are the energies exchanged between
the subsystems. The electrical power 1 2 provided by the electrical power

generator 2 to the appliance 6 can be transferred using electrical wire, but
other electrical power transfer mechanisms can also be used. The high
temperature heat 1 0 is generated by the electrical power generator 2 and
consumed by the heat driven heat pump 4. The high temperature heat 10
can be transported with a pumped fluid loop, such as a liquid loop, in
which the fluid absorbs heat in or near the electrical power generator 2
and releases heat to the heat driven heat pump 4. Generally, this heat
transfer can be accomplished by any heat transfer mechanism (i.e.
conduction, convection, radiation, or any combination thereof). The
cooling loop can also consist of gas or vapor coolant and/ or solid beds.
The appliance cooling load 14 is the amount of heat generated by the
appliance 6, which needs to be removed by the heat pump 4. Heat is
absorbed at or near the appliance 6 and transported to the heat driven
heat pump 4. A liquid pumped loop or a stream of gas can be used to
absorb the cooling load 14 from the appliance 6 and transport it to the
heat driven heat pump 4. The moderate temperature heat 1 6 is the heat
' transferred from the heat driven heat pump 4 to the heat sink 8. Here
again, convection, conduction, radiation, or any combination of these heat
transfer mechanisms can be used to transport this heat. One possible
implementation is atmospheric air blown through a heat exchanger inside
the heat driven heat pump and released back to ambient. All three heat
transfers (10, 14, 16) can be realized with a single or multiple heat
streams. In the case of a LiBr-water heat driven heat pump, the moderate
temperature heat 16 from the heat driven heat pump 4 to the heat sink 8
is commonly realized with two transport loops.
[0075] An example for the heat transfer loop from the heat driven
heat pump 4 to the heat sink 8 is a pumped loop with tubes wrapped
around the part of the heat driven heat pump 4 that requires cooiing and
coils of tubes buried in the soil. Another example is a blower sucking in
ambient air, blowing it over the surface that needs to be cooled and a
conduit releasing the warm air back to ambient.
[0076] The subsystem formed by the electrical power generator 2
and the heat driven heat pump 4 is illustrated in Figure 7 for the case
where a high temperature fuel cell is used as the electrical power
generator 2. The fuel cell 68 is preferably a high temperature fuel cell,
such as a solid oxide fuel cell.
[0077] Fuel is delivered to the fuel cell with the help of a fuel blower
18, which can also be a compressor. For liquid fuels, the blower 1 8 is
replaced by a pump. An optional fuel preconditioner 104 preprocesses the
fuel. For example this device can remove contaminants detrimental to the
function of the power generator, such as sulfur. Another possible function
for the fuel preconditioner 104 is preformation and/ or reformation.
[0078] The fuel preheater 22 brings the fuel to fuel cell operating
temperature. This preheater can be external to or an integral part of the
fuel cell 68. It can be contained in one single or multiple devices. For a
liquid fuel, the fuel preheater 22 evaporates the liquid fuel. For a gaseous
fuel, the fuel preheater 22 can be a finned heat exchanger. A fuel
preconditioner 104 can also be implemented after the fuel preheater 22 or
integrated with the fuel preheater 22, or integral to fuel cell 68.
[0079] The fuel preheat 54 is the heat required raise the
temperature of the input fuel to the fuel cell operating temperature. The
fuel intake conduit 34 provides a path for the fuel from the fuel blower 1 8
to the fuel preheater 22. It may or may not have an intermediate fuel
preconditioner 104. The fuel delivery conduit 36 provides a path for the
fuel from the fuel preheater 22 to the fuel cell 68.
[0080] The oxidizer blower 20 drives air or any other suitable
oxidizer toward the fuel cell 68. The oxidizer intake conduit 42 provides a
transport path for the oxidizer between the oxidizer blower 20 and the
oxidizer preheater 24. An optional oxidizer preconditioner 106
preprocesses "the oxidizer flow. Examples of the preconditioner 106
include filters, and oxygen enrichment devices. The preconditioner heat
11A is heat required to operate this optional device. One example for one
component of the preconditioner 106 is an oxygen enrichment device
utilizing temperature swing adsorption, as described in the first preferred
embodiment. The oxidizer preconditioner 106 can also be installed
upstream of the oxidizer blower 20. The oxidizer preheater 24 brings the
input oxidizer to fuel cell operating temperature using the oxidizer preheat
62. The oxidizer preheater 24 can be contained in single or multiple
devices. In one preferred embodiment, the oxidizer is partially preheated in
oxidizer preheater 24 and picks up additional heat inside the fuel cell 68,
thereby cooling the fuel cell 68. One example for the oxidizer preheater
24 is a finned heat exchanger. The oxidizer delivery conduit 44 transports
the oxidizer from the oxidizer preheater 24 to the fuel cell 68.
[0081] In the fuel cell 68, the fuel and the oxidizer are
electrochemically reacted. This reaction produces electrical energy 12 and
high temperature heat. The fuel cell high temperature heat 58 represents
the part of the heat generated by the fuel cell which is harnessed for
further use and not removed by the exhaust or the depleted oxidizer. Not
all of the heat generated by the fuel cell can be harnessed and transported
to other devices.
[0082] The fuel cell high temperature heat 58 can be utilized for
various purposes. This heat can be used for the fuel preheat 54, the
oxidizer preheat 62, preconditioner heat 11 A, or the heat driven heat
pump high temperature input heat 10. The fuel cell high temperature heat

58 can be directed to any combination of these heat consumers (10, 54,
62,11 A). One possibility for harnessing the fuel cell high temperature heat
58 is a gas cooling loop, separate from the oxidizer flow loop to the fuel
cell.
[0083] The fuel cell outlet conduits 38 and 46 transport the
electrochemical reaction products. If the fuel cell 68 is a solid oxide fuel
cell, then the exhaust conduit 38 transports reacted fuel and the outlet
oxidizer conduit 46 transports oxygen depleted oxidizer. The fuel outlet
cooler 28 extracts the exhaust cooling heat 56 from the exhaust stream.
The fuel outlet cooler 28 can be one or multiple devices and can be partly
or fully integrated with the fuel cell 68. One example for the fuel outlet
cooler 28 is a finned heat exchanger. The exhaust cooling heat 56 can be
used for the fuel preheat 54, the oxidizer preheat 62, preconditioner heat
11 A, or the heat driven heat pump high temperature input heat 10. The
exhaust cooling heat 56 can be directed to any combination of these heat
consumers (10, 54, 62, 11A).
[0084] The oxidizer outlet cooler 26 extracts the oxidizer cooling
heat 60 from the outlet oxidizer stream. The oxidizer outlet cooler 26 can
be one or multiple devices and can be partly or fully integrated with the
fuel cell 68. One example for the oxidizer outlet cooler is a finned heat
exchanger. The oxidizer cooling heat 60 can be used for the fuel preheat
54, the oxidizer preheat 62, preconditioner heat 11A, or the heat driven
heat pump high temperature input heat 10. The oxidizer cooling heat 60
can be directed to any combination of these heat consumers (10, 54, 62,
11 A). ,
[0085] The fuel outlet (i.e., exhaust) conduit 38 and the oxidizer
outlet (i.e., exhaust) conduit 46 deliver fuel exhaust and oxygen depleted
oxidizer to the optional burner 30. In the burner 30, these two gas
streams are chemically reacted, generating the burner high temperature
heat 48. The chemical reaction can be initiated by an optional catalyst
material.
[0086] The burner high temperature heat 48 can be provided to the
fuel preheat 54, the oxidizer preheat 62, preconditioner heat 11A, or the
heat driven heat pump high temperature input heat 10. The burner high
temperature heat 48 can be directed to any combination of these heat
consumers (10, 54, 62,11A). One preferred example of-transport of the
burner high temperature heat 48 is direct integration of the burner with
the consumer (i.e. heat transfer by conduction to the consumer). Another
preferred example for this heat transport is a pumped fluid loop.
[0087] The burner exhaust conduit 50 transports the reaction
products from the burner 30 to the optional burner exhaust heat
exchanger 32. In the burner exhaust heat exchanger 32 the burner
exhaust heat 64 is extracted from the burner reaction products. One
example for the burner exhaust heat exchanger 32 is a finned heat
exchanger.
[0088] The burner exhaust heat 64 can be provided to the fuel
preheat 54, the oxidizer preheat 62, preconditioner heat 11A, or the heat
driven heat pump high temperature input heat 10. The burner exhaust
heat 64 can be directed to any combination of these heat consumers (10,
54, 62, 11A). The burner heat exchanger exhaust conduit 102 transports
the burner exhaust out of the system (preferably vented to ambient or
into an exhaust post-processor).
[0089] The heat driven heat pump 4 is driven by the high
temperature heat 10. After using heat from the high temperature heat 10
the heat driven heat pump 4 vents one heat stream in the heat pump low-
temperature outflow 16A. The appliance cooling load 14 from appliance 6

is removed by the cooling stream 16B. The high temperature heat 10 can
be provided by the fuel cell high temperature heat 58, the exhaust cooling
heat 56, the oxidizer cooling heat 60, the burner high temperature heat
48, or the burner exhaust heat 64. The high temperature heat 10 can also
be provided by any combination of these heat sources (48, 56, 58, 60,
64).
[0090] One preferred implementation for the appliance cooling load
14 and the heat 1 6B is ambient air driven by a blower into the heat driven
heat pump 4, cooled beiow ambient temperature in the heat driven heat
pump, and then directed to the appliance that requires cooling. At the
appliance the cool air picks up the cooling load 14 and is heated. The
heated air is vented back to ambient.
[0091] One preferred embodiment of the system shown in Figure 7
is presented in Figure 8A. The system shown in Figure 8A follows the
same outline presented for Figure 7. Figure 8A includes one preferred
routing of the heat streams shown in Figure 7. The fuel preheat 54 is
provided by the fuel exhaust cooling heat 56. Optionally, the fuel can pick
up additional heat in the fuel cell. The heat transfer from exhaust cooling
heat 56 to fuel preheat 54 can be realized in a heat exchanger, for
example a finned heat exchanger. One example of this configuration is to
combine heat exchangers 22 and 28 as a single component. Depending
on the choice of fuel, water vapor can be transferred from the exhaust to
the input fuel. This water transport can be integrated into a heat
exchanger or it can be realized with a separate device.
[0092] The oxidizer preheat 62 is provided partly by the oxidizer
exhaust cooling heat 60. The remainder of the heat needed to bring the
oxidizer to fuel cell operating temperature is absorbed in the fuel cell,
thereby removing all of the high temperature heat from the fuel cell
without an additional heat transfer ioop. The heat transfer from oxidizer
exhaust cooling heat 60 to oxidizer preheat 62 can be realized in a heat
exchanger, for example a finned heat exchanger. One example of this
configuration is to combine heat exchangers 24 and 26 as a single
component. The burner high temperature heat 48 is not immediately
extracted. Instead, it is extracted together with burner exhaust heat 64.
The burner exhaust heat 64 is directed to the high temperature heat 10,
which provides the necessary heat to actuate the heat driven heat pump
4. The heat transfer from the burner exhaust heat 64 to the heat driven
heat pump 4 can be realized with a heat exchanger incorporated in the
heat driven heat pump 4. Thus the burner exhaust heat exchanger 32 is
combined with the heat exchanger in the heat pump 4 to form a single
component. This heat exchanger can be a finned heat exchanger. The
cooling load 14 can be extracted from the appliance 6 by a cool air
stream provided by the heat driven heat pump 4, which is driven with a
cooling air blower 72 through cooling air inlet duct 74 directed to the
appliance with a cooling air conduit 76.
[0093] Table 1 presents an energy balance for a 100kW electrical
power system based on Figure 8A. The naming convention, where
applicable, is consistent with Figure 8A.
[0095] Figure 8B illustrates another preferred aspect of the second
embodiment of this invention. The system illustrated in Figure 8B shows
an alternative preferred routing of the heat streams shown in Figure 7.
The system depicted in Figure 8B is similar to the system depicted in
Figure 8A, with the exception that the oxidizer cooling heat 60 is
provided to the heat exchanger 4 as the high temperature heat 10, and
the burner exhaust heat 64 is provided to the oxidizer preheater 24 as
oxidizer preheat 62. Thus, the oxidizer outlet conduit 46 is provided into
the heat exchanger of the heat pump 4 and then into the burner 30, while
the burner exhaust conduit 50 is provided into the burner exhaust heat
exchanger 32. Both the heat transfer from the oxidizer cooling heat 60 to
the high temperature heat 10 and the burner exhaust heat 64 to the
oxidizer preheat 62 can be realized with heat exchangers. Thus, the
oxidizer preheater 24 and the burner exhaust heat exchanger 32 are
combined as a single component and comprise portions of the same heat
exchanger 24/32. Likewise, the outlet oxidizer cooler 26 and the heat
exchanger portion of the heat pump 4 are combined as a single
component and comprise a portion of the same heat exchanger.
[00961 Figure 8C illustrates another preferred aspect of the second
embodiment of this invention. The system illustrated in Figure 8C shows
an alternative preferred routing of the heat streams shown in Figure 7.
The system depicted in Figure 8C is similar to the system depicted in
Figure 8A, but differs by a cross-over of the exhaust fuel and oxidizer
paths. In Figure 8C, the fuel outlet conduit 38 is provided into the
oxidizer outlet cooler 28, while the oxidizer outlet conduit 46 is provided
into the fuel outlet cooler 26. Thus, the exhaust cooling heat 56 is
provided as oxidizer preheat 62 and oxidizer cooling heat 60 is provided
as fuel preheat 54. Both heat transfers can be realized with heat
exchangers. Thus, the oxidizer preheater 24 and the fuel outlet cooler 28
are combined as a single component and comprise portions of the same
heat exchanger 24/28. Likewise, the outlet oxidizer cooler 26 and the
fuel preheater 22 are combined as a single component and comprise a
portion of the same heat exchanger 22/26.
[0097] Figure 9 shows another preferred embodiment of the system
depicted in Figure 6. The main difference between Figure 7 and Figure 9
is the addition of a gas turbine driven electrical power generator. The gas
turbine can utilize the high temperature heat from the fuel cell to generate
additional electrical energy and thereby further increase the electrical
efficiency of the electrical power generator. High temperature waste heat
is still available to drive a heat driven heat pump and thereby form a
complementary system, which can provide matched electrical power and
cooling. The increase of efficiency of the power generator implies that
less high temperature heat per electrical power generated is available.
Such an embodiment is used preferentially when the electrical load
requirements are greater than the cooling load requirements and there are
no environmental and permitting issues against the use of gas turbines.
This embodiment can also be used with a heat driven heat pump of
higher efficiency such as to complete the balance between the electrical
and thermal loads in the system described above.
[0098] In Figure 9 the fuel is compressed and transported into the
system by the fuel compressor 80. A fuel compressor inlet conduit 82
delivers the fuel to the fuel compressor 80. For a liquid fuel, a fuel pump
can be used instead of the fuel compressor 80. An optional fuel
preconditioner 104 preprocesses the fuel. For example this device can
remove contaminants detrimental to the function of the power generator,
such as sulfur. Another possible function for the fuel preconditioner 104
is prereformation or reformation.
[0099] The fuel preheater 22 brings the fuel to fuel cell operating
temperature. If the fuel is provided as a liquid, the fuel is evaporated in
the fuel preheater 22. This preheater can be external to or an integral part
of the fuel cell 68. It can be contained in one single or multiple devices.
The fuel preheat 54 is the heat required to bring the fuel to fuel cell
operating temperature. The fuel intake conduit 34 provides a path for the
fuel from the fuel compressor 80 to the fuel preheater 22. The fuel
delivery conduit 36 provides a path for the fuel from the fuel preheater 22
to the fuel cell 68.
[0100] The oxidizer compressor 84 drives air or any other suitable
oxidizer to the fuel cell 68. The oxidizer compressor inlet conduit 86
delivers the oxidizer to the oxidizer compressor 84. An optional oxidizer
preconditioner 106 preprocesses the oxidizer flow. Examples of the
preconditioner 106 include filters, and oxygen enrichment devices. The
preconditioner heat 11A is heat required to operate this optional device.
One example for one component of the preconditioner 106 is an oxygen
enrichment device utilizing temperature swing adsorption. The oxidizer
preconditioner 106 can also be installed downstream of the oxidizer
compressor 84. The oxidizer intake conduit 42 provides a transport path
for the oxidizer between the oxidizer compressor 84 and the oxidizer
preheater 24. The oxidizer preheater 24 brings the input oxidizer to fuel
cell operating temperature using the oxidizer preheat 62. The oxidizer
preheater 24 can be contained in a single or multiple devices. In one
preferred embodiment, the oxidizer is partially preheated in oxidizer
preheater 24 and picks up additional heat inside the fuel cell 68, thereby
cooling the fuel cell 68. The oxidizer delivery conduit 44 transports the
oxidizer from the oxidizer preheater 24 to the fuel cell 68.
[0101] In the fuel cell 68, the fuel and the oxidizer are
electrochemically reacted. This reaction produces electrical energy 12A
high temperature heat 58.
[0102] The oxidizer outlet cooler 26 extracts the oxidizer cooling
heat 60 from the outlet oxidizer stream. The outlet oxidizer cooler 26 can
be one or multiple devices and can be partly or fully integrated with the
fuel cell 68. The fuel outlet cooler 28 extracts the exhaust cooling heat
56 from the exhaust stream. The fuel outlet cooler 28 can be one or
multiple devices and can be partly or fully integrated with the fuel cell 68.
One example for the coolers 26, 28 is a finned heat exchanger.
[0103] The fuel exhaust conduit 38 and the oxidizer outlet conduit
46 deliver fuel exhaust and oxygen depleted oxidizer to the optional
burner 30. In the burner 30 these two gas streams are chemically
reacted, generating the burner high temperature heat 48.
[0104] The burner high temperature heat 48 can be provided to the
fuel preheat 54, the oxidizer preheat 62, the preconditioner heat 1 1A, or
the high temperature heat 10. The burner high temperature heat 48 can
be directed to any combination of these heat consumers (10, 11 A, 54,
62).
[0105] The burner exhaust conduit 50 transports the reaction
products from the burner 30 to the optional burner exhaust heat
exchanger 32. In the burner exhaust heat exchanger the burner exhaust
heat 64 is extracted from the burner reaction products.
[0106] The burner exhaust heat 64 can be provided to the fuel
preheat 54, the oxidizer preheat 62, the preconditioner heat 11 A, or the
high temperature heat 10. The burner exhaust heat 64 can be directed to
any combination of these heat consumers (10, 11A, 54, 62).
[0107] The turbine inlet conduit 88 transports the burner exhaust to
the turbine 90. A mechanical coupling 92 transmits mechanical energy
from the turbine 90 to the oxidizer compressor 84, the fuel compressor
80, and/or the electrical generator 94. If desired, the compressors may be
actuated by another source of mechanical energy and/or electrical power.
The electrical generator 94 generates additional electrical power 12B.
[0108] The turbine outlet conduit 96 transports the turbine exhaust to
the optional turbine exhaust heat exchanger 98. In the turbine exhaust
heat exchanger the turbine exhaust heat 1 00A is extracted from the gas
flow. The turbine exhaust heat 100A can be provided to the fuel preheat
54, the oxidizer preheat 62, the preconditioner heat 11 A, or the high
temperature heat 10. The turbine exhaust heat 100A can be directed to
any combination of these heat consumers (10, 11A, 54, 62). The
exhaust conduit 102 transports the exhaust gases out of the system
(preferably vented to ambient or into an exhaust post-processor).
[0109] The heat driven heat pump 4 is driven by the high temperature
heat 10. After utilizing heat from the high temperature heat 10, the heat
driven heat pump 4 vents one heat stream in the moderate temperature
heat 16A. The appliance cooling load 14 from appliance 6 is removed by
the cooling stream 16B. The high temperature heat 10 can be provided by
the fuel cell high temperature heat 58, the exhaust cooling heat 56, the
oxidizer cooling heat 60, the burner high temperature heat 48, the burner
exhaust heat 64, or the turbine exhaust heat 100A. The high temperature
heat 10 can also be provided by any combination of these heat sources
(46, 56, 58, 60, 64, 100A).
[0110] One preferred embodiment of the system shown in Figure 9 is
presented in Figure 10A. The system shown in Figure 10A follows the
same outline presented for Figure 9. Figure 10A includes one preferred
routing of the heat streams involved. The fuel preheat 54 is provided by
the exhaust cooling heat 56. Optionally, the fuel can pick up additional
heat in the fuel cell. The heat transfer from exhaust cooling heat 56 to
fuel preheat 54 can be realized in a heat exchanger, for example a finned
heat exchanger 22/28. Depending on the choice of fuel, water vapor can
be transferred from the exhaust to the input fuel. This water transport can
be integrated into a heat exchanger or it can be realized with a separate
device. The oxidizer preheat 62 is provided partly by the oxidizer cooling
heat 60. The remainder of the heat needed to bring the oxidizer to fuel
cell operating temperature is absorbed in the fuel cell, thereby removing
all of the high temperature heat from the fuel cell without an additional
heat transfer loop. The heat transfer from oxidizer cooling heat 60 to
oxidizer preheat 62 can be realized in a heat exchanger, for example a
finned heat exchanger 24/26.
[0111] The burner high temperature heat 48 together with the high
temperature heat from the fuel cell carried by the burner exhaust gas 64
is first used to drive the turbine 90. The remaining heat after the turbine
is used as high temperature heat 10 to drive the heat driven heat pump 4.
[0112] The heat transfer from the turbine exhaust heat 1 00A to the
heat driven heat pump 4 can be realized with a heat exchanger
incorporated in the heat driven heat pump 4. Thus the turbine exhaust
heat exchanger 98 and the heat exchanger portion of the heat pump 4 are
combined as a single heat exchanger. This heat exchanger can be a finned
heat exchanger. The cooling load 14 can be absorbed from the appliance
6 by a cool air stream provided by the heat driven heat pump 4, which is
driven with a cooling air blower 72 through cooling air inlet duct 74
directed to the appliance with a cooling air conduit 76.
[0113] Figure 10B illustrates another preferred aspect of the second
embodiment of this invention. The system illustrated in Figure 10B shows
an alternative preferred routing of the oxidizer stream shown in Figures 9
and 10A. The system depicted in Figure 10B is similar to the system
depicted in Figure 10A, with the exception of the oxidizer routing. In the
system of Figure 10B, the gas turbine 90 and the fuel cell 68 are fed with
separate oxidizer streams. An oxidizer blower 20 is used for the oxidizer
supply for the fuel cell. This blower can also be a compressor. The
compressor 84 delivers oxidizer to the burner 30 via conduit 45A. The
unreacted fuel from the fuel cell is combusted in the burner. The burner
exhaust drives the turbine 90. The advantage of this system is that a
higher oxygen content oxidizer is supplied to the burner. This improves
the combustion process in the burner and subsequently improves the
turbine operation.
[0114] Figure 1 OC illustrates another preferred aspect of the second
embodiment of this invention. The system illustrated in Figure 10C
shows an alternative preferred routing of the heat streams shown in
Figure 9. The system in Figure 10C is differs from the system in Figure
10A by the sequence of heat usage from the oxidizer. In Figure 10C the
oxidizer leaving the fuel cell 68 first delivers the oxidizer cooling heat 60
to the high temperature input heat 10 in the heat pump 4, and then enters
the burner 30. The oxidizer preheat 62 is provided by the turbine exhaust
heat 1O0A. Thus, the oxidizer preheater 24 and the turbine exhaust heat
exchanger 98 are combined as a single component and comprise portions
of the same heat exchanger 24/98. Likewise, the outlet oxidizer cooler
26 and the heat exchanger portion of the heat pump 4 are combined as a
single component and comprise a portion of the same heat exchanger.
[0115] The system in Figure 10C relates similarly to Figure 10A as
the system in Figure 8B relates to the system in Figure 8A. The system

in Figure 10C can also incorporate the use of separate oxidizers for the
fuel cell and the burner 30, as shown in Figure 10B. It may be
advantageous to provide separate oxidizer streams for the fuel cell 68 and
the turbine 90.
[0116] Figure 1 0D illustrates another preferred aspect of the second
embodiment of this invention. The system illustrated in Figure 10D
shows an alternative preferred routing of the heat streams shown in
Figure 9. The system depicted in Figure 10D is similar to the system
depicted in Figure 10A, but differs by the routing of the heat fluxes. In
Figure 10D, the fuel preheat 54 is provided by the turbine exhaust heat
1 00A, while the high temperature heat 10D is provided by the fuel exhaust
cooling heat 56. Thus, the turbine outlet conduit 96 is provided into the
turbine exhaust heat exchanger 98, while the fuel cell fuel outlet conduit
38 is provided into the heat exchanger portion of the heat pump 4. Thus,
the turbine exhaust heat exchanger 98 and the fuel preheater 22 are
combined as a single component and comprise portions of the same heat
exchanger 22/98. Likewise, the outlet fuel cooler 28 and the heat
exchanger portion of the heat pump 4 are combined as a single
component and comprise a portion of the same heat exchanger. This
routing can be applied to any of the systems of Figures 10A, 10B and
10C previously discussed.
[0117] Figures 6 to 10D present the basic layouts of the
components of the systems of the preferred aspects of the second
embodiment. These components can also be combined in a large number
of other ways not shown in these Figures. Any component or
combination of components shown in one figure may be used in a system
shown in any other figure. For example, the cross over of the fuel cell
fuel and oxidizer exhaust paths shown in Figure 8C can be applied to the
systems shown in Figures 8A, 8B, 10A, 10B, 10C, 10D, as well as
combinations of these systems.
[0118] Parts List
electrical power generator......................................2
heat driven heat pump...........................................4
appliance ............................................................6
heat sink..............................................................8
high temperature heat...........................................10
preconditioner input heat.......................................11A
electrical power....................................................12
appliance cooling load...........................................14
moderate temperature heat....................................16
heat pump low-temperature outflow .......................1 6A
low temperature outflow.......................................1 6B
fuel blower ..........................................................18
oxidizer blower.....................................................20
fuel preheater ......................................................22
oxidizer preheater ................................................24
oxidizer outlet cooler.............................................26
fuel outlet cooler...................................................28
burner.................................................................30
burner exhaust heat exchanger...............................32
fuel intake conduit................................................34
fuel delivery conduit..............................................36
fuel cell fuel outlet conduit(s).................................38
oxidizer intake conduit...........................................42
oxidizer delivery conduit........................................44
conduit from oxidizer compressor to burner..............45A
fuel cell oxidizer outlet conduit(s)............................46
burner high temperature heat.................................48
burner exhaust conduit..........................................50
fuel preheat..........................................................54
fuel exhaust cooling heat.......................................56
fuel cell high temperature heat...............................58
oxidizer exhaust cooling heat.................................60
oxidizer preheat....................................................62
burner exhaust heat..............................................64
fuel cell .........:.....................................................68
appliance cooling load...........................................70
cooling air blower.................................................72
cooling air conduit................................................74
cooling air outlet...................................................76
burner exhaust cooler............................................78
fuel compressor..............................,.....................80
fuel compressor inlet conduit..................................82
oxidizer compressor..............................................84
oxidizer compressor inlet conduit............................86
turbine inlet conduit..............................................88
turbine.................................................................90
mechanical coupling..............................................92
electrical generator................................................94
turbine outlet conduit............................................96
turbine exhaust heat exchanger..............................98
turbine exhaust heat.............................................100A
exhaust conduit....................................................102
fuel cell electrical power........................................1 2A
generator electrical power output............................12B
fuel preconditioner................................................104
oxidizer preconditioner...........................................106
III. The Third Preferred Embodiment
[0119] In one prior art solid oxide fuel cell 100, the ceramic
electrolyte 101 is corrugated, as shown in Figure 11. While the whole
electrolyte 101 is bent or corrugated, its major surfaces 103, 105 are
smooth or uniform. Thus, the electrolyte 101 has the same thickness
along its length. However, the imaginary center line 107 running along
the length of the electrolyte 101 significantly deviates from an imaginary
straight line 109. The anode 111 and cathode 113 are formed on the
uniform surfaces 103, 105 of the electrolyte 101. Such a corrugated
electrolyte 101 is difficult to manufacture and even more difficult to
properly integrate in a fuel cell stack containing a plurality of fuel cells.
[0120] The present inventors have realized that if at least a portion
of at least one surface of the electrolyte is made non-uniform, then
several advantages may be realized. The oxygen diffusion through an
electrolyte in a solid oxide fuel cell proceeds between so-called "three
phase boundaries." These three phase boundaries are electrolyte grain
boundary regions at the boundary of an electrode (i.e., cathode or anode)
and electrolyte, as shown in Figure 12. Diffusing oxygen makes up the
third "phase." If the active portions of one or both major surfaces of the
electrolyte are made non-uniform, then the surface area between the
electrolyte and the electrode contacting the non-uniform surface is
increased. The "active portion" of the electrolyte is the area between the
electrodes that generates the electric current. In contrast, the peripheral
portion of the electrolyte is used for attaching the electrolyte to the fuel
cell stack and may contain fuel and oxygen passages. The increased
surface area results in more three phase boundary regions, which allows
more oxygen to diffuse through the electrolyte. This increases the power
density (i.e., watts per cm2) of the fuel cell and decreases the cost per
watt of the fuel cell. Furthermore, the non-uniform surface, such as a
textured or roughened electrolyte surface provides better adhesion to the
adjacent electrodes of the fuel cell due to improved mechanical
interlocking.
[0121] Figure 13 illustrates a solid oxide fuel cell 200 containing a
ceramic electrolyte 201 having at least one non-uniform surface portion,
according to a first preferred aspect of the third embodiment. The at
least one non-uniform surface in the first preferred aspect is a textured
surface. Preferably, two opposing major surfaces 203, 205 are textured.
A textured surface 203, 205 contains a plurality of protrusions (i.e.,
bumps, peaks, etc.) 206 having a height 208 that is 5% or less,
preferably 1 % or less of an average electrolyte thickness 209. In a
preferred aspect of this embodiment, the electrolyte is textured to obtain
an electrolyte having a surface roughness of 0.5 to 2 microns, preferably
1 to 2 microns. This surface roughness possesses good adhesion to
common SOFC electrodes. The height and width of the protrusions 206
is exaggerated in Figure 1 3 for clarity. The protrusions 206 may have
any desired shape, such as rectangular, polygonal, triangular, pyramidal,
semi-spherical or any irregular shape. Preferably, only the active portions
210 of the opposing major surfaces 203, 205 are textured, while the
peripheral portions 202 of the surfaces 203, 205 are not textured.
However, if desired, the entire major surfaces 203, 205 may be textured.
For example, in adhesive or compression seals, where the integrity of the
seal increases with the area of the contact surfaces, texturing the
peripheral portions can increase the seal integrity and/ or reduce the "non-
active" peripheral area of the fuel cell.
[0122] In contrast to the corrugated electrolyte of Figure 11, the
electrolyte shown in Figure 13 is substantially flat. The imaginary center
line 207 running along the length of the electrolyte 201 does not
significantly deviate from an imaginary straight Sine. While the whole
electrolyte 201 is substantially flat, its major opposing surfaces 203, 205
are non-uniform and textured. The anode 211 and cathode 213 are
formed on the textured surfaces 203, 205 of the electrolyte 201. The
substantially flat electrolyte is advantageous because it is easier to
manufacture, because it is easier to integrate into a fuel cell stack and
because it is more durable than a corrugated electrolyte. However, if
desired, the textured surface(s) may be located on a non-flat or
corrugated electrolyte.
[0123] The electrolyte, anode and cathode may be made of any
appropriate materials. Preferably, the electrolyte comprises a yttria
stabilized zirconia (YSZ) ceramic. The cathode preferably comprises a
Perovskite ceramic having a general formula ABO3, such as LaSrMnO3
("LSM"). The anode preferably comprises a metal, such as Ni, or a metal
containing cermet, such as a Ni-YSZ or Cu-YSZ cermet. Other suitable
materials may be used if desired.
[0124] The non-uniform surface of the electrolyte may be formed by
any suitable method. Preferably, the non-uniform surface is made by
providing a ceramic green sheet and patterning at least a portion of at
least one surface of the green sheet to form at least a non-uniform portion
of the at least one_surface. The green sheet may then be sintered (i.e.,
fired or annealed at a high temperature) to form the ceramic electrolyte.
It should be notea that the term "green sheet" includes a green tape or a
sheet of finite size. Preferably both sides of the green sheet are patterned
to form two opposing non-uniform surface portions of the green sheet.
[0125] Another preferred aspect of the third embodiment of the
present invention is directed to a composite electrolyte with a textured
interface. Figure 14 illustrates a prior art composite electrolyte, while
Figures 15 and 16 illustrate a composite electrolyte with a textured
interface according to the third preferred embodiement. It can be
advantageous to fabricate the electrolyte not from one single material,
which is typically yttria stabilized' zirconia (YSZ), but to use several layers
of materials. One example for composite electrolyte is a samaria-doped
ceria (SDC) electrolyte coated with YSZ on one or both sides. SDC has
the advantage over YSZ to provide higher ionic conductivity. However,
the application of SDC is limited by its ability to withstand low oxygen
partial pressures. At low oxygen partial pressures SDC can be reduced,
lose its ionic conductivity in part or in whole and thereby cause a critical
failure in a solid oxide fuel cell. YSZ has a lower ionic conductivity, which
implies higher electrical losses within this material, but it can withstand
lower oxygen partial pressures compared to SDC. Also, SDC displays
electron conductivity at elevated temperatures, which is detrimental to
the performance of a fuel cell. A layer of YSZ next to SDC can effectively
suppress electron conduction, since YSZ is a very weak electron
conductor.
[0126] Figure 14 shows a prior art YSZ electrolyte 300, which is
coated or laminated with a layer of SDC 305. One example is to use the
SDC on the cathode side of the solid oxide fuel cell, which is not exposed
to the reacting fuel, and thereby not exposed to low oxygen partial
pressure, while the YSZ is used on the anode side.
[0127] The high oxygen ion conductivity in SDC can create a rate
limiting step at the interface between SDC and YSZ. The losses at the
interface between the two materials can be reduced by increasing the
surface area of the interface. An increase in interface area can be
accomplished by texturing the interface. Figure 15 shows a cross section
of a composite electrolyte with a textured internal interface. Here a
textured layer of SDC 315 is attached to a layer of YSZ 310.
[0128] The combination of YSZ and SDC is one example where a
textured interface can be used. Other materia! combination can also be
used with textured interfaces. The composite electrolyte can consist of
two layers as shown in Figure 15 or of three or more layers 310, 315,
320 with at least one, and preferably more than one textured interface
303, 305 as shown in Figure 16.
[0129] Textured interfaces can be formed by any suitable method.
One method is the lamination of two textured matching surfaces. Another
method is the application of the second layer onto a textured surface of
the first material, for example by tape casting or by screen printing. In a
preferred example, the SDC is provided as a mechanically supporting
substrate with a thickness of about 50 to 200 micrometers, preferably
about 100 micrometers and the YSZ is deposited on the substrate as a
thin protective layer of about 1 0 to 50 micrometers, preferably about 20
micrometers. In this case, the surface texture can have a thickness of
about 10 micrometers. However, texturing on larger and smaller length
scales is also possible.
[0130] The textured internal interfaces (i.e., interface surfaces)
illustrated in Figures 15 and 16 can be formed on composite electrolytes
also having textured outer surfaces 203, 205 (i.e., surfaces that contact
the electrodes). One or both of the outer composite electrolyte surfaces
can be textured.
[0131] Additional layers that offer superior mechanical, thermal,
and/ or electrical properties may be added to composite or single layer
electrolytes to provide improved superior mechanical, thermal, and/ or
electrical properties compared to single layer electrolytes. Furthermore,
multiple layers of functionally graded electrodes (anodes and/ or cathodes)
may be provided on single layer or composite electrolytes.
[0132] The textured surface(s) 203, 205 illustrated in Figures 13
and 15 may be textured by several different methods. In one preferred
aspect of the third embodiment, the textured surface is formed by laser
ablating the green sheet, following by sintering the green sheet. Any
suitable laser ablation method and apparatus may be used to texture the
green sheet. A schematic illustration of a laser ablation apparatus 250
suitable for texturing the green sheet surface is shown in Figure 17. A
laser source 251 directs a laser beam 253 at a reflective mirror 255. The
mirror 255 directs the beam 253 through a focusing lens 257 onto the
green sheet (such as an unfired electrolyte tape) 261 located on the
precision XYZ table 259. Any laser source 251 which has sufficient
power to ablate the green sheet 261 may be used. For example, excimer
or YAG lasers may be used as the laser source 251. The laser beam 253
is scanned over the surface of the green sheet 261 by moving the XYZ
table and/or by moving the mirror 255. The laser beam power may be
varied during the scanning to achieve a non-uniform textured green sheet
surface. For example, the laser source 251 may be periodically turned on
and off, or it may be attenuated by an attenuator (not shown) to vary the
laser beam power. Alternatively, the XYZ table may be moved up and
down during the scanning of the beam 253 to vary the beam power that
impinges on the green sheet 261. The laser beam position and/or power
and/or table movement may be controlled by a computer to create a
desired pattern on the electrolyte. The laser beam 253 ablates (i.e.,
removes or roughens) a portion of a top surface of the green sheet 261 to
leaye a textured surface. The textured green sheet is then sintered or
fired to form the ceramic electrolyte. Alternatively, the laser ablation may
be conducted after the sintering step on the sintered electrolyte.
[0133] Alternatively, the textured surface of the green sheet may be
formed by photolithography methods that are used in semiconductor
manufacturing. For example, as shown in Figure 18, an etching mask
271 is formed on the green sheet 261. The etching mask 271 may
comprise a photoresist layer that has been exposed through an exposure
mask and developed. The unmasked portions 273 of the green sheet are
etched to form recesses in the top surface of the green sheet. The
masked portions 275 of the green sheet are protected from etching by the
mask 271, and remain as protrusions 275 between the recesses 273.
The protrusions 275 and recesses 273 form a textured surface. The
photoresist mask 271 is removed after etching by a conventional selective
removal process, such as ashing. Any etching gas or liquid that
preferentially etches the green sheet material to the mask material may be
used. As shown in Figure 18, an anisotropic etching medium was used to
form recesses 273 with straight sidewalls. This results in rectangular
protrusions 275 between the recesses. Alternatively, an isotropic etching
medium may be used to form recesses 273 with outwardly sloped walls.
This results is trapezoidal or pyramidal protrusions 275 between the
recesses.
[0134] The mask may comprise materials other than photoresist. In
one example, other photosensitive layers may be used. Alternatively, a
so-called "hard mask" may be used as a mask to etch the green sheet.
For example, as shown in Figure 19, a hard mask layer 281 is deposited
on the green sheet 261. The hard mask layer 281 may be any material
which resists being etched by an etching medium to a higher degree than
the green sheet 261. The hard mask layer may be any suitable metal,
ceramic, semiconductor or insulator. A photoresist mask 271 is formed,
exposed and developed over the hard mask layer 281. The hard mask
layer 281 is then etched using the photoresist as a mask. Then, the
green sheet 261 is etched to form a textured surface containing a
plurality of recesses 273 and protrusions 275 using the hard mask 281 as
a mask. The photoresist mask 271 may be removed before or after the
green sheet is etched. The hard mask 281 is removed after the green
sheet 261 is textured by a selective etching medium which removes the
hard mask 281 but does not etch the green sheet 261.
[0135] In another example, the mask may comprise a plurality of
particles. As shown in Figure 20, a plurality of discontinuous particles
291 are formed on the surface of the green sheet 261. The particles 291
may be any material which resists being etched by an etching medium to
a higher degree than the green sheet 261. The particles may be any
suitable metal, ceramic (such as titania or alumina), semiconductor (such
as polysilicon or silicon carbide) or insulator. The particles may be formed
by any particle deposition method, such as spray coating, dip coating, ink
jet deposition, sputtering or chemical vapor deposition. The portions 273
of the green sheet 261 that are not covered by the particles 291 are
etched to form recesses in the top surface of the green sheet. The

covered portions 275 of the green sheet are protected from etching by
the particles 291, and remain as protrusions between the recesses 273.
The protrusions 275 and recesses 273 form a textured surface. The
particles 291 are removed after the green sheet 261 is textured by a
selective etching medium which removes the particles 291 but does not
etch the green sheet 261.
[0136] Alternatively, rather than depositing the particles 291 directly
on the green sheet 261, the particles 291 may be formed by etching a
textured layer 293 on the green sheet 261. For example, as shown in
Figure 21, a layer 293 with a rough or textured surface is deposited on
the green sheet 261. The textured surface of layer 293 contains
protrusions 295. This layer 293 may be any material with has a rough
surface, such as hemispherical grain polysilicon, ceramic, insulator or
metal. Layer 293 is then anisotropicaily etched until only the protrusions
295 remain on the surface of the green sheet 261, as shown in Figure
22. The remaining protrusions 295 appear as a plurality of particles on
the green sheet 261. The green sheet 261 is then etched using the
protrusions 295 as a mask.
[0137] In other examples, the textured surface is formed without a
mask. In one example, an etching medium, such as an etching liquid,
which preferentially attacks the grain boundaries 297 of the green sheet
261 is applied to an upper surface of the green sheet. The etching
medium selectively etches the grain boundaries 297 of the green sheet to
form recesses 273. The regions of the green sheet 261 between the
grain boundaries 297 are not etched or are etched to a lesser degree and
remain as protrusions 275, as shown in Figure 23. Thus, a textured
surface comprising protrusions 275 and recesses 273 is formed without a
mask.
[0138] In another example, the textured surface is formed by
embossing. A body 298 (i.e., a press, a mold etc.) having a textured or
roughened lower surface 299 is pressed into or rolled against the top
surface of the green sheet 261, as shown in Figure 24. Alternatively, the
green sheet is pressed into or rolled against surface 299. The lower
surface 299 of body 298 has a higher hardness than the green sheet 261.
The body 298 may be a ceramic, insulator or a metal body with a suitable
hardness to emboss the green sheet. The embossing step leaves
impressions or recesses in the green sheet 261 to form the textured
surface in the green sheet. It should be noted that both sides of the
green sheet 261 may be textured by the methods described above. If
desired, heat may be applied to the process to soften the binder
component of the green sheet to allow it to be textured easier.
[0139] In another example, the textured surface is formed by
building the ridges on a flat green tape. This can be done using a cladding
process or by a powder / slurry spray process, where the powder and/or
slurry is made of the same material as the green tape. In another
example, the roughening or texturing can be applied to the electrolyte by
various mechanical and chemical-mechanical machining methods, such as
lapping, grinding or polishing (such as chemical-mechanical polishing)
using an abrasive. Preferred abrasives include diamond, boron carbide
and silicon carbide. Preferably, the sintered electrolyte is placed onto a
rotating lapping, grinding or polishing wheel containing the abrasive. The
abrasive may be an abrasive powder or slurry, such as a diamond, boron
carbide or silicon carbide powder or slurry. The abrasive powder size is
preferably 5 to 45 microns, such as 1 5 to 30 microns. Alternatively, the
upper surface of the wheel is made of the abrasive material. The wheel is
rotated against the electrolyte causing the electrolyte surface in contact
with the abrasive to be textured. The process can then be repeated for
the other side of the electrolyte. In a preferred aspect of this
embodiment, the electrolyte is textured to obtain a YSZ electrolyte having
a surface roughness of 0.5 to 2.5 microns, preferably 1 to 2 microns.
This surface roughness possesses good adhesion to common SOFC
electrodes.
[0140] It is also possible to create the textured surface on a flat
"sintered" sheet or tape as opposed to the green sheet or tape. While, in
general, the green sheet or tape is more easily textured than the sintered
ceramic product, etching agents that etch a sintered ceramic may be used
to etch the sintered electrolyte.
[0141] In one aspect of this embodiment, the green tape is prepared
by tape casting. In this fabrication procedure, a raw ceramic powder, for
example YSZ, is mixed with solvents, binders, plastisizers, and
defloculants to form a slurry. The slurry is applied to a mylar film
("carrier") and spread uniformly with a blade, which is dragged along the
length of the carrier with a precisely adjusted gap between the blade and
the carrier. In large scale fabrication, this process is run continuously by
moving the carrier under a static blade and applying slurry to the carrier
upstream of the blade. The thickness of the green tape can range
between about 20 micrometer and 10,000 micrometers, preferably about
50 to 1,000 micrometers. The amplitude of the surface texture can vary
between 5 micrometers and 1000 micrometers, preferably about 10 to 30
micrometers.
[0142] The surface texturing can also be applied to electrolytes
formed by other methods, such as electrolytes formed by extrusion. The
texturing is not limited to electrolytes with planar geometries, but can also
be applied to electrolytes with non-planar geometries.
IV. The Fourth Preferred Embodiment

[0143] In the fourth preferred embodiment of the present invention,
the inventors have realized that the quality, robustness and environmental
endurance of the solid oxide fuel cell can be improved by using an
environment tolerant anode catalyst. For example, when, feeding a fuel
contaminated with sulfur, a solid oxide fuel cell anode catalyst that is
tolerant to sulfur may be used. When the fuel cell is subject to operation
in a fuel starvation mode, a fuel ceil anode catalyst that is tolerant to fuel
starvation may be used.
[0144] In the prior art low temperature acid fuel cells, some minor
improvement in sulfur tolerance has been observed when certain
compounds are added to the fuel side anode catalyst. The compounds
that have shown some positive tolerance include MoWOx, RuO2, WOx
(such as WO2.5), MoS2, WS2, and PtSx. In the prior art molten carbonate
fuel cells, some minor improvement in sulfur tolerance has been observed
when certain compounds are added to the fuel side anode catalyst. The
compounds that have shown some positive tolerance include Cr2O3, FeO,
Fe2O3, Fe3O4, AI2O3, LiAIO2, LiCrO2, MO2, MO3 and WO3, as described in
U.S. Patent 4,925,745, incorporated herein by reference.
[0145] However, the low temperature acid fuel cell is fundamentally
different than the solid oxide fuel cell. In the acid fuel cell, the ionized fuel
must pass through the electrolyte to be reduced at the cathode by an
oxidant. The fuel ion in this case is the hydrogen proton. When sulfur is
present in the fuel, the ionization reaction at the anode is slowed. The
mechanism for this occurrence is not well known, but it is believed to be
related to the masking of the catalyst with the sulfur adsorbed onto the
active catalytic material. In contrast, in the solid oxide fuel cell, it is the
oxidant oxygen anion that must pass through the electrolyte to oxidize
the fuel. The sulfur contamination of the fuel creates no hindrance for the
ionization of the oxygen or its transport through the electrolyte.

[0146] The fundamental differences between the two types of fuel cells
can best be shown in Figure 25. Figure 25 compares the functionality of
the solid oxide fuel cell 400 and an acid fuel cell 410.
[0147] Referring to the acid fuel cell 410, the electrolyte 411 can be
a membrane such as duPont's Nafion® or an inert matrix filled with
phosphoric acid. Other acids may be used, but the Nafion© and matrix
phosphoric acids are the more frequently used. The cathode electrode
412 is attached to or placed against the electrolyte 411 and usually
contains platinum metal as the ionization catalyst for the air oxidant 414.
The platinum is often a finely divided platinum black bonded with Teflon
or platinum supported on carbon and bonded with Nafion® ionomer. The
anode electrode 41 3 is also attached to or placed against the electrolyte
411 and is similar to the cathode electrode 412, except that ruthenium,
rhodium, or other metals are frequently added to the platinum to make the
anode electrode 413 more tolerant to CO gas in the hydrogen fuel 415.
For many fuel cell applications, the source of hydrogen fuel 415 is a
reformed hydrocarbon fuel. Usually the fuel source is scrubbed of sulfur
down to the parts per billion (PPB) range. Otherwise, the anode electrode
413 functionality is significantly reduced. Additionally, the reformed fuel
is processed to reduce the CO volume content in the hydrogen fuel 415
to less than 50 parts per million (PPM) to minimize the poisoning effect on
the electrode. The hydrogen fuel 415 is ionized at anode electrode 413
producing hydrogen protons. The protons then pass through the
membrane 411 by the gradient created by the combination with oxygen
anions produced on the cathode electrode 412 from air oxidant 414 to
produce product water 412.
[0148] Referring to solid oxide fuel cell 400, the electrolyte 401 is
preferably yttria-stabilized zirconia (YSZ), although other ceramic oxides,
such as ceria are sometimes used together with or instead of YSZ. A

preferred cathode electrode 402 is made from a 50:50 mixture of YSZ
and LaO.BSrO.2MnO3 (LSM). Other materials may be used if desired. The
cathode electrode 402 is attached to or placed against the electrolyte 401
and ionizes the oxygen in the air oxidant 404. The oxygen anions pass
through the electrolyte 401 by the gradient created by the consumption
of the anions by combination with fuel ions. In the prior art solid oxide
fuel cells, the anode electrode 403 is a often a ceramic-metallic (cermet)
of Ni and YSZ, while Cu is sometimes used instead of Ni. Hydrogen fuel
405 is ionized at the anode electrode 403 and combines with the oxygen
anions to form water.
[0149] One of the significant advantages of the solid oxide fuel cell
is the potential for direct hydrocarbon fuel feed to the operating cell
anode. The prior art Ni/YSZ anode electrode performs very well with pure
hydrogen fuel, but when attempting to internally reform a hydrocarbon
fuel into a hydrogen rich fuel stream the Ni/YSZ anode electrode has
shortcomings related to carbon formation and sulfur poisoning. To reduce
carbon formation in the prior art solid oxide fuel cell, water (i.e., water
vapor) is added to the. hydrocarbon fuel to prevent carbon formation.
Although the fuel cell product water is generated within the anode
electrode, even more water must be added to the fuel to prevent the
carbon formation. This extra water must be introduced with the incoming
fuel, which complicates the operation of the fuel cell. Second, the prior
art Ni/YSZ electrode cannot tolerate even the 10 ppm sulfur normally
found in natural gas. Thus, expensive sulfur scrubbing equipment is often
used to reduce the sulfur content of the fuel, which increases the cost of
the electricity generation.
[0150] Thus, in a first preferred aspect of the fourth embodiment,
sulfur tolerant compounds are used in combination with or instead of Ni in
the anode cermet of a solid oxide fuel cell.. The sulfur tolerant

compounds include any compounds which increase the anode tolerance to
sulfur in the fuel stream. While the inventors do not want to be bound by
any theory of operation of the sulfur tolerant compounds, it is believed
that the sulfur tolerant compounds prevent or reduce the formation of
sulfur on the anode. The preferred sulfur tolerant compounds include
MoWOx, RuO2, WOx, such as WO2.5, MOS2, WS2, and PtSx. Some
compounds, such as WOx are also CO tolerant. Less preferred
compounds include sulfur tolerant catalysts usable in a molten carbonate
fuel cell, such as Cr2O3, FeO; Fe2O3, Fe3O4, AI2O3, LiAIO2, LiCrO2, MO2,
MO3 and WO3, as described in U.S. Patent 4,925,745, incorporated
herein by reference. Preferably, the anode cermet comprises the
ceramic, such as (YSZ), and a catalyst. The catalyst preferably comprises
1 0 to 90 weight % Ni or Cu and 10 to 90 weight percent of the sulfur
tolerant compound. Most preferably, the catalyst comprises 30 to 70
weight % Ni or Cu and 30 to 70 weight percent of the sulfur tolerant
compound. However, some sulfur tolerant compounds, such as PtS.x,
may be used without Ni or Cu and comprise 100% of the catalyst.
[0151] These sulfur tolerant catalyst compounds in combination
with or replacing the Ni in the anode electrode cermet provide an
increased tolerance to sulfur in the fuel. The sulfur tolerant catalyst
allows the solid oxide fuel cell to be used with a hydrogen fuel source
containing contaminate levels of sulfur compounds, such as more than 10
ppb, for example more than 100 ppb. The three elements that combine in
a non-obvious manner to achieve this tolerance include: weak tolerance of
the Ni cermet to sulfur, uninhibited availability of an oxidant within the
anode electrode, and elevated operational temperature.
[0152] In another preferred aspect of the fourth embodiment, the
environmental tolerant anode catalyst comprises a fuel starvation tolerant
catalyst. When the solid oxide fuel cell is operating at steady state, the

reactants are independently flow controlled. The cathode airflow is
generelly controlled to supply sufficient oxygen for the cathode reaction
and to remove the waste heat from the fuel cell reaction. Usually airflow
1.5 to 2.5 times the stoichiometric requirements is ample to satisfy the
cathode reaction. Heat removal will generally require much more airflow
than that required in satisfying the cathode reaction and therefore, there
is no reasonable concern that a cell will become oxygen starved.
[0153] On the other hand, the fuel is flow controlled only to support
the anode reaction. In this case, the fuel flow is generally set at about
1.2 times the stoichiometric requirements of the anode in order to
maintain a high level of fuel utilization. This high level of fuel utilization is
required to obtain a high overall system efficiency.
[0154] In the prior art solid oxide fuel cells, a problem develops
when there is an instantaneous requirement for an increased electrical
output from the solid oxide fuel cell stack. Under these conditions, the air
supply is more than ample to support the increased reaction rates within
all the cells. However, one or more cells in the stack can be fuel starved
until the fuel control adjusts the fuel flow to the new reaction rates.
During the few seconds that it takes to adjust the fuel flow, the anode
catalyst can be permanently damaged. Since the cells in a planar solid
oxide stack are in electrical series, the entire stack can be rendered
useless.
[0155] The fundamental reason for cell anode damage is illustrated
in Figure 26. Figure 26 shows the functionality of the solid oxide fuel cell
500 in the normal anode and normal cathode reaction modes and the
anode reaction in the fuel starved mode.
[0156] Referring to the solid oxide fuel cell 500 in the normal
operating mode, the electrolyte 501 is usually yttria-stabilized zirconia

(YSZ), although other ceramic oxides such as ceria are sometimes used.
The typical cathode electrode 502 is made from a 50:50 mixture of YSZ
and LaO.BSrO.2MnO3 (LSM). Other materials may be used if desired. The
cathode electrode 502 is attached to or placed against the electrolyte 501
and ionizes the oxygen in the air oxidant 504. The oxygen anions pass
through the electrolyte 501 by the gradient created by the consumption
of the anions by combination with fuel ions. A prior art anode electrode
503 is configured with a ceramic-metallic (cermet) of Ni and YSZ.
Alternately, Cu is sometimes used as the metal in the cermet for the
anode electrode. Hydrogen/CO fuel 505 is ionized at the anode electrode
503 and combines with the oxygen anions to form water and CO2.
[0157] When a section of an individual solid oxide fuel cell within a
stack becomes fuel starved, the cell becomes an electrical load instead of
an electrical power generator. This occurs because other cells in the stack
have sufficient fuel to support the reaction and these cells drive the cell(s)
that has become a load. Under these conditions, the fuel starved cell
polarity reverses and oxygen is evolved from the anode. The cathode
electrode and the electrolyte continue to operate as they had when
operation in the fuel cell mode.
[0158] When the fuel flow rate is restored to normal, the load cell(s)
reverts back to the power generating fuel cell mode. Unfortunately, in the
process of evolving oxygen, the standard Ni/YSZ anode electrode is
oxidized and permanently damaged because Ni is not a fuel starvation
tolerant catalyst.
[0159] The present inventors have realized that if a metal which
forms a reversible oxide without damage to the metal is added to the
anode, then the anode is rendered fuel starvation tolerant. Such a metal
forms an oxide when oxidized and reverts back to a pure metal without
significant damage when the oxide is reduced by the fuel reaction at the
anode. Preferably, the fuel starvation tolerant compound include platinum
group metals, such as platinum, palladium, rhodium, iridium, osmium and
ruthenium. Low temperature water electrolysis shows that platinum
metal electrodes can be oxidized and reduced without damage. Other
catalytic materials or additives that display this characteristic include
ruthenium and tungsten at various oxide levels. The use of these
metals/oxides in various ratios provides the tolerance to the oxidative
anode conditions during fuel starvation.
[0160] Preferably, the anode 503 comprises a cermet which
includes the ceramic, such as (YSZ), and a fuel starvation tolerant
catalyst. The catalyst preferably comprises 10 to 90 weight % Ni or Cu
and 10 to 90 weight percent of the fuel starvation tolerant material.
Most preferably, the catalyst comprises 30 to 70 weight % Ni or Cu and
30 to 70 weight percent of the fuel starvation tolerant material.
Preferably, the fuel starvation tolerant material oxidizes preferentially to Ni
during fuel starvation. However, some fuel starvation tolerant materials,
such as Pt, may be used without Ni or Cu and comprise 100% of the
catalyst.
[0161] In a third preferred aspect of the fourth embodiment, the
anode comprises an environmental tolerant catalyst which is both a sulfur
tolerant catalyst and a fuel starvation tolerant catalyst. For example, the
anode may contain a combination of similarly based fuel starvation and
sulfur tolerant materials, such as Pt and PtSx, Ru and RuO2, and W and
WOx. Alternatively, the anode may contain a combination of dissimilar
catalysts, such as a Pt-WOx or Pt-HxWO3 as disclosed in U.S. Patent
5,922,488 incorporated herein by reference in its entirety. Thus, any
combination of the sulfur tolerant and fuel starvation tolerant materials
described above may be selected for the anode composition.

[0162] Preferably, the anode 503 comprises a cermet which
includes the ceramic, such as (YSZ), and a environment tolerant catalyst.
The catalyst preferably comprises 10 to 90 weight % Ni or Cu, 5 to 45
weight percent of the sulfur tolerant material and 5 to 45 weight percent
of the fuel starvation tolerant material. Most preferably, the catalyst
comprises 30 to 70 weight % Ni or Cu, 15 to 35 weight percent of the
sulfur tolerant material and 15 to 35 weight percent of the fuel starvation
tolerant material. However, some sulfur tolerant and fuel starvation
tolerant materials, such as Pt, may be used without Ni or Cu and
comprise 1 00% of the catalyst.
[0163] The anodes may be formed using any known cermet
fabrication methods. The Ni or Cu metals, sulfur tolerant materials and/or
the fuel starvation tolerant materials may be incorporated into the cermet
by any suitable method. For example, these materials may be deposited
by co-deposition, co-electrodepositon, freeze drying or sequential
deposition. Thus, the environmental tolerant material may be alloyed or
admixed with Ni or Cu and then provided into the YSZ to form the
cermet. For example, the environmental tolerant material may be alloyed
or admixed with Ni or Cu and then provided into YSZ using a wet
(solution), a dry (powder) or a sputtering process. Alternatively, the
environmental tolerant material may be alloyed or admixed with Ni or Cu
and then placed on a support, such as a foam support or a dry ice
support, and then pressed into contact with the YSZ. The catalyst is
diffused into the YSZ to form the cermet by sintering and/or pressing. If
dry ice is used, then the dry ice is sublimed to diffuse the catalyst into the
YSZ.
V. The Fifth Preferred Embodiment
[0164] In the fifth embodiment of the present invention, the inventor
has realized that the solid oxide fuel cell system can be simplified, when
feeding a hydrocarbon fuel directly to the solid oxide fuel cell anode for
internal reforming to a hydrogen rich reactant by supplying the reforming
process steam from the anode exhaust enthalpy recovery. In other
words, only the product water (i.e., water vapor) is added to the fuel
provided into the anode.
[0165] In the low temperature PEM fuel cells, cathode enthalpy is
recovered and returned to the cathode inlet to prevent the dry out of the
water saturated membrane. In this case, the incoming oxidant air is
humidified and membrane dry out is avoided. Several methods have been
developed to accomplish this water and heat transfer including hydrated
membranes, water injection, and cycling desiccants. One method includes
using a device called an enthalpy wheel. The enthalpy wheel is a porous
cylindrical wheel with internal passages that are coated with desiccant. It
rotates slowly in one direction, allowing the transfer of sensible and latent
heat from the hot saturated air exhaust to the cool dry air inlet.
[0166] In the solid oxide fuel cell, there is no need to maintain the
saturation of any of the components. In the case of a solid oxide fuel cell
operating with pure hydrogen and air reactants, these reactants can be
absolutely free of any water vapor. The prior art Ni/YSZ anode electrode
performs very well with pure hydrogen fuel. However, when attempting
to internally reform a hydrocarbon fuel into a hydrogen rich fuel stream,
the Ni/YSZ anode electrode has shortcomings related to carbon formation.
To reduce carbon formation in the prior art solid oxide fuel cell, water
(i.e., water vapor) is added from an external boiler to the hydrocarbon fuel
to prevent carbon formation on the anode. For the purpose of fuel steam
reforming within the anode of a solid oxide fuel cell, a high rate of water
vapor (i.e., steam), amounting to approximately a 3:1 steam to carbon

ratio, must be injected into the fuel before introduction into the fuel cell
anode. The use of the extra boiler complicates the electricity generation
process and increases its cost.
[0167] The present inventors realized that product water vapor
emitted from the anode side exhaust of the solid oxide fuel cell may be
recirculated into the fuel being provided into the anode input to prevent or
reduce the carbon formation on the anode. The enthalpy wheel is a
preferred device to control the water and heat transferred from the anode
exhaust of a solid oxide fuel cell to the anode inlet. The control of the
amount of water introduced with the fuel is used to prevent carbon
formation with too little water and to prevent fuel starvation with too
much water. The water transfer rate is controlled by the speed of the
wheel.
[0168] The fundamentals of the system 600 employing an enthalpy
wheel in the solid oxide fuel cell fuel stream are illustrated in Figure 27A.
The hydrocarbon fuel supply is delivered through conduit 604 to enthalpy
wheel 601. Within the enthalpy wheel 601, the fuel supply receives
water vapor and heat from the anode side fuel exhaust. The warm wet
fuel supply is then delivered to an optional heat exchanger 602 through
conduit 605. Within the heat exchanger 602, the fuel exhaust heats the
warm wet fuel supply further. The hot wet fuel supply is then delivered to
the anode chambers within the solid oxide fuel cell stack 603 through
conduit 606. Within the solid oxide fuel cell anode chambers the hot wet
hydrocarbon fuel supply is reformed into a mixture of hydrogen, water
vapor, and carbon oxides. Nearly simultaneously, most of the hydrogen
and carbon monoxide are converted to more water vapor and more carbon
dioxide, respectively, from the reaction with the oxygen anions in the
anode catalyst.
[0169] The fuel exhaust gasses, with significantly more water vapor
than was introduced into the solid oxide fuel cell anode chambers, return
to heat exchanger 602 through conduit 607. Within heat exchanger 602
some of the heat in the exhaust stream is given up to the inlet fuel
supply. The fuel exhaust is then delivered back to the enthalpy wheel 601
through conduit 608. Within the enthalpy wheel 601, much of the water
vapor and remaining heat in the fuel exhaust is transferred to the inlet fuel
supply.
[0170] The rotational speed of the enthalpy wheel is modulated to
optimize the water vapor flux. The fuel exhaust then leaves the system
through outlet conduit 609. Preferably, 0% to 90%, such as 20 to 70%
of the product water vapor is transferred to the fuel supply. Preferably,
all heat transferred to the fuel supply is through the enthalpy wheel and
heat exchanger.
[0171] In an alternative embodiment, the enthalpy wheel is replaced
with at least two adsorption beds, as illustrated in Figure 27B. The first
adsorption bed 610 is used to adsorb water and water vapor from the
anode exhaust, while letting anode exhaust gases, such as CO, CO2, H2
and methane, to pass through to the outlet conduit 609. The second
adsorption bed 611 is used to provide water that was previously collected
from the anode exhaust. When the supply of water is exhausted in the
second bed 611, the anode exhaust is provided into the second bed,
while the first bed 610 is used to provide the water or water vapor into
the inlet fuel. If desired, a reformer may also be added between the fuel
inlet 604 and the fuel cell stack 603, preferably between the heat
exchanger 602 and the fuel ceil stack 603.
[0172] Any suitable method may be used to provide anode exhaust
and fuel supply through the adsorbent beds. For example, as shown in
Figure 27B, a first vaive 612, such as a four way valve, switches fuel
input from fuel inlet 604 between the first 610 and the second 611
adsorbent bed. The valve 612 also switches the exhaust being provided
from the first 61 0 or the second 611 beds to the outlet conduit 609. The
conduit 608 connects the first adsorbent bed 610 with a first heat
exchanger inlet 614 or a first heat exchanger outlet 615 via a second
valve 613, such as a four way valve. The conduit 605 connects the
second adsorbent bed 611 with the first heat exchanger inlet 614 or the
first heat exchanger outlet 615 via valve 613. When the valve 61 3 is in a
first position, it provides a fluid path between the first adsorbent bed 610
and the first heat exchanger outlet 615 and between the second
adsorbent bed 611 and the first heat exchanger inlet 614. When the
valve 613 is in a second position, it provides a fluid path between the
first adsorbent bed 610 and the first heat exchanger inlet 614 and
between the second adsorbent bed 611 and the first heat exchanger
outlet 615. If desired, other configurations may be used. For example,
four way valve 613 may be replaced with two three way valves, each
respective valve being located between the heat exchanger 602 and
respective conduits 605, 608.
[0173] During operation, the system 600 can be run without using a
boiler to provide water vapor into the inlet fuel. However, a small boiler
may be added to the system. This boiler may be run during operation
start up to provide water into the fuel inlet while the system is warming
up and sufficient water vapor is being generated at the anode exhaust.
[0174] This system is advantageous because it provides simple
transfer of water vapor and heat in a controlled fashion such that the
proper conditions at the solid oxide fuel cell anode electrodes for internal
steam reforming are met. The enthalpy wheel and heat exchanger may be
used to provide the entire supply of water vapor and heat for the fuel
supply to operate the solid oxide fuel cell.
VI. The Sixth Preferred Embodiment
[0175] The sixth preferred embodiment is directed to a felt seal. Fuel
cell stacks, particularly those with planar geometry, often use seals
between electrolyte and interconnect surfaces to contain fuel and air (see
Figure 28). These seals must maintain, their integrity at high operating
temperatures and (on the cathode side) in an oxidizing environment-
Furthermore, expansion and contraction of the seal and the components
in contact with the seal due to thermal cycling or compression should not
result in damage of any of the components during its expected life.
[0176] Many compliant seals, such as elastomeric o-rings and gaskets,
do not crack and tend to absorb stresses in an assembly that arise from
thermal expansion and compression. However, these seals cannot be
used at high temperatures because the elastomeric materials used in them
decompose, degrade, or oxidize.
10177] Many types of seals used at elevated temperatures, such as
brazes and metal gaskets, are not compliant or elastic. Some assemblies
are difficult to seal with brazes or gaskets because of operating conditions
or material incompatibilities. They may often have a limited life as well,
tolerating only a relatively few number of thermal cycles before they fail.
Also, when some assemblies are sealed with these materials, differences
in the coefficients of thermal expansion result in mechanical stresses that
can lead to failure of the seal or the components of the assembly. Also,
non-compliant seals often present difficulties and high costs of fabrication
and assembly due to the tighter tolerances which are required, in flatness
for example.
[0178] The sixth preferred embodiment is directed to a sealing
arrangement that is both compliant and capable of operating at high
temperatures in oxidizing and reducing environments. The sealing member
is capable of sealing dissimilar materials, such as a metal and a ceramic,
and similar materials that may or may not differ in composition, such as
two ceramics or two metals. Since the sealing member is elastic and
compliant at device operating temperatures, it may be used to seal two
materials with dissimilar coefficients of thermal expansion. This sea! may
be advantageously used in a solid oxide fuel cell, where the operating
temperatures are in the range of 600 to 800 °C.
[0179] A gas-tight compliant seal between surfaces can be made from
a felt. Here, "felt" is used to describe a compliant layer of a material that
can endure the elevated operating temperature and atmosphere of the
device it is being applied to. In some cases, the felt may be composed of
a malleable metal or alloy. However, this definition does not restrict this
term to metals. The compliant layer can for example be made from non-
metallic fibrous materials, such as silica. This compliant layer can be made
up from fibers, as indicated by the word "felt," but also other thick and
compliant constructions, for example foams, such as small cell foams.
Thus, the seal is preferably made from a compliant metal or a ceramic
fibrous or foam material.
[0180] The felt is made gas impermeable by one of several means, and
is sealed by one of several means to the mating surfaces. The felt gives
compliance to the seal, allowing it to absorb stresses caused by
compression and thermal expansion and contraction of the assembly of
which it is part. The means used to make the felt impermeable and to
seal the felt to the mating surfaces are also compliant in nature.
Appropriate selection of the composition of the various elements of the
seal allows the seal to be made according to various criteria, including
operating temperatures, oxidizing or reducing environments, and cost.
[0181] Two mating surfaces (701 and 702) are shown in Figure 28. A
seal must be made between these two surfaces in order to prevent gas
exchange in either direction between sides 705 and 706.
[0182] In one case shown in Figure 28, a felt sealing member 710 is
placed between the mating surfaces 701 and 702. The felt sealing
member 710 is sealed to the mating surfaces through application of a
sealing material 720 that is soft at the device operating temperature but is
impermeable to the gases of interest in the application. For example, this
may be a glass or glaze compound. One example of a glaze is a Duncan®
ceramic glaze GL611. This material can be applied to the felt or to the
mating surfaces prior to assembly, for example by dipping the felt sealing
member and/or the mating surfaces into the molten glass or glaze. The
material softens at elevated temperatures and mates the felt to the
surfaces, but remains impermeable to gases. The material 720 is optional
if the felt seal contains appropriate means of mating the felt to the
surfaces, as is the case in many preferred aspects.
[0183] The felt sealing member 710 is made impermeable to gases by
one of several ways. In one preferred aspect, the porous felt is filled prior
to assembly with a filler material 730 that is soft at the device operating
temperature. For example, this may be a glass, or glaze mixture. After
firing, the glassy residue makes the felt impermeable to gases, but
because the material 730 softens at the operating temperature, the felt-
glass composite remains compliant. In subsequent paragraphs and
figures, it is assumed that same-numbered items carry their previous
definitions.
[0184] In another preferred aspect (Figure 29), the felt sealing member
710 is made impermeable to gases by melting a felt surface 740 into a
solid layer that is non-parallel, such as perpendicular, to the mating
surfaces. The solid layer which is formed to be thin enough to remain
flexible. A solid layer means a layer that has a much lower porosity than
the felt, such as a porosity of 70% or less than the felt. This solid layer
may be formed by selectively heating a portion of the felt sealing member
710 to transform the heated portion to a solid layer, such as a closed cell
metal foam layer. For example, a surface 740 of the felt sealing member
710 may be selectively heated by a laser to form the solid layer.
[0185] in another preferred aspect (Figure 30), the felt sealing member
710 is made impermeable to gases by forming a solid layer 750 on felt
sealing member 710 that is perpendicular and parallel to the mating
surfaces described previously. The parallel solid surfaces provide an
improved contact area for the seal.
[0186] In another preferred aspect (Figure 31), the felt sealing member
710 is made impermeable to gases through application of a barrier foil
layer 760 that is non-parallel, such as perpendicular, to the mating
surfaces. The foil adheres to the felt via a material such as that which is
used to attach the felt to the mating surfaces. Alternatively, the foil may
be pressed into place and held by a second felt sealing member or other
component. The foil 760 is compliant because it is thin. Preferably, the
foil is a thin metal foil. The foil extends between mating surfaces 701,
702 to block the flow of gas between sides 705 and 706.
[0187] In another preferred aspect (Figure 32), the felt sealing member
710 is made impermeable to gases through application of several foils.
Foil 770 is non-parallel, such as perpendicular, to the mating surfaces as
described previously, and foils 772 and 774 extend into the area parallel
to the mating surfaces. These foils 772, 774 provide improved contact
area for the sealing member. They may also produce adhesion between
the sealing member and the mating surfaces. The foils 770, 772, and 774
may be the same or different materials depending on the various
compositions of the felt 710 and mating surfaces 701 and 702. They
may comprise separate components or one continuous piece of foil.
[0188] In another preferred aspect (Figure 33), the felt sealing member
710 is made impermeable to gases through deposition of a gas
impermeable material layer on the felt 710. This material may be
deposited on the felt by various methods, including but not restricted to,
dipping and evaporation, physical vapor deposition, chemical vapor
deposition, thermal spray, plasma spray, and precipitation from a liquid.
Material portion 780 is non-parallel, such as perpendicular, to the mating
surfaces 701, 702. Preferably, portions 782, 784 of the gas
impermeable material layer extend into the area parallel to the mating
surfaces 701, 702. These portions 782, 784 provide an improved
contact area for the sealing member. They may also produce adhesion
between the felt sealing member 710 and the mating surfaces. The
impermeable material layer portions 780, 782, and 784 may be the same
or different materials depending on the various compositions of the felt
710 and mating surfaces 701 and 702.
[0189] In another preferred aspect (Figure 34), the felt sealing member
790 is made impermeable to gases in its initial preparation. For example,
the felt may be prepared as a closed-cell foam.
[0190] The felt composition can be selected so as to operate well in the
atmosphere present in the device containing the felt seal. For example, in
an oxidizing atmosphere the felt may be composed of a suitable M-Cr-AI-Y
material, where M comprises at least one metal selected from Fe, Co, or
Ni. In another example, the felt may be composed of Inconel alloy, in
another example, in a reducing atmosphere, the felt may be composed of
nickel. Other metals, alloys, or indeed other malleable materials or
compounds metal may be used depending on the application
requirements. One example of forming a felt sealing member 710 (nickel
felt) with a gas impermeable material 730 (glass) is as follows. A nickel
felt (i.e. foam) with a density of 15% relative to solid nickel is saturated
with a molten glass. The felt is fired to remove volatiles, leaving behind a
glass residue that renders the felt impermeable to gases. The felt is placed
between two mating surfaces, for example a metal sheet and zirconia. To
each of the mating surfaces a layer of glass seal is applied where the felt-
glass composite will contact the surfaces. The felt is placed between the
surfaces, compressed, and fired.
[0191] The seal can take the shape of the mating surfaces to be sealed.
For example, if the mating surfaces are rectangular, the seal may take the
form of a rectangular gasket, if the mating surfaces contain open areas,
such as in an assembly with internal gas manifolds or flow ducts, the seal
can accommodate and seal such open areas. This is illustrated in Figure
35, where one of the mating surfaces (794) contains flow channels which
are sealed from the center of the surface and from the exterior of the
surface by the felt gasket 797.
[0192] All embodiments of the felt seal can be placed in a structure in
one or both mating surfaces, for example in a groove in a mating surface,
that provides containment and additional compression and adhesion
surfaces.
[0193] The felt part of the seal may also serve other roles, such as
current collector/distributor, flow distributor, etc. in a fuel cell stack, such
as a solid oxide fuel stack.
VII. The Seventh Preferred Embodiment
[0194] The seventh preferred embodiment is directed to felt current
conductors / gas flow distributors for fuel cell stacks. Fuel cell stacks,
particularly those with planar geometry, often use utilize some material to
conduct electrons from the anode to the separator plate and from the
separator plate to the cathode. This material typically has a better
electrical conductivity than the porous electrode (i.e., anode and/or
cathode) material. Usually this material is distinguished from the
electrodes in that it also must provide flow distribution of oxygen- or fuel-
bearing gases. This material is often called a current conductor / gas
flow distributor ("conductor/distributor" herein after). In some cases,
these conductor/distributors may provide structural support to the fuel cell
stack. Some examples of prior art conductor/distributors include metal
wire coils, wire grids, and metal ribs. These may be used independently or
in some combination.
[0195] The prior art conductor/distributors sometimes exhibit less-
than-optimal current conduction or gas flow distribution properties. They
are also costly to implement. Also, many of the prior art
conductor/distributors are not compliant (i.e., not elastic at the fuel cell
operating temperatures). Non-compliant components often present
difficulties and high costs in fabrication and assembly of the fuel cells due
to the tighter fuel cell tolerances which are required.
[0196] The present inventors realized that a porous conductive felt
can serve as a current conductor and gas flow distributor with better
properties than the prior art conductor/distributors and may be less costly
to implement. In some preferred aspects, the felt conductor/distributor
can also serve as a seal or as a support for other fuel cell stack
components. The use of a compliant, conductive felt reduces the
probability of component and assembly failure during thermal cycling and
compression of a fuel cell stack, preferably a high temperature fuel cell
stack, such as a solid oxide or molten carbonate fuel cell stack.
[0197] Here, "conductive felt" is used to describe a compliant layer
of electrically conductive material that can endure the operating
temperature and atmosphere of the device (i.e., fuel cell stack) in which it
is located. In some cases, the felt may be composed of a malleable metal
or alloy. However, this definition does not restrict the term "felt" to
metals. The felt conductor/distributor can for example be made from other
porous, conductive materials, such as a silica-metal composite. The felt
conductor/distributor should be made conductive and gas permeable and
can be made up from fibers, foams and other relatively thick, compliant,
conductive and gas permeable structures.
[0198] A conductor/distributor comprising a gas permeable (i.e.,
porous) conductive felt with composition chosen to be appropriate for the
conditions specified by the application. For example, the felt material is
chosen such that it remains conductive and gas permeable at the fuel cell
operating temperature. The felt conductor/distributor is located in contact
with the active area of the fuel electrode (i.e., anode or cathode). The fuel
cell separator plate is placed in contact with the conductor/distributor.
Various ways may be used to ensure electrical contact between
electrode, conductor/distributor, and separator plate.
[0199] Figure 36 shows repeating elements of a fuel cell stack
containing an electrolyte 810, an anode 820, a cathode 830, anode seal
840, cathode seal 845, and a separator plate 850, such as metal plates.
A second separator plate 850 is also shown in the diagram to illustrate
the connection to the next cell of the stack. The stack may be internally
or externally manifolded, as will be described in more detail below.
[0200] The anode 820 and cathode 830 are often optimized for the
electrochemical reactions they are catalyzing. Often, they are not
optimized for electrical conductivity or for distribution of fuel- and oxygen-
bearing gases. Therefore, anode conductor/distributors 860 and cathode
conductor/distributors 870 are provided to fill these roles. The separator
plates 850 may be omitted if the felt conductor/distributors are
constructed to also perform the function of the separator plates.
[0201] In one preferred aspect of the seventh preferred
embodiment, the anode conductor/distributor 860 is composed of a
conductive felt. The felt conducts electrons, from the anode to the
separator plate. Since the felt is gas permeable, it also allows fuel to
reach the anode surface, and the reaction byproducts to leave the surface
and exhaust from the cell. The electrical contact between anode and felt,
and between separator plate and felt, may be enhanced by adding a layer
of an optional adhesive or contact material. The composition of the felt is
chosen as appropriate for the fuel cell operating conditions. For example,
a nickel felt with a density of 1 5 to 35%, preferably about 25% relative
to the density of solid nickel and a thickness of 0.5 to 4 mm, preferably
about 2 mm may be used in a high temperature fuel cell, such as a solid
oxide fuel cell, with a reducing atmosphere and a temperature of 600 to
850°C, such as 800°C, The felt may be potted in a nickel-YSZ cermet on
either the anode or separator plate sides of the connection, or on both
sides.
[0202] In another preferred aspect of the seventh preferred
embodiment, the cathode conductor/distributor 870 is composed of a
conductive felt. The felt conducts electrons from the separator plate to
the cathode. It also allows oxygen to reach the cathode surface, and the
oxygen depleted air to leave the surface and exhaust from the cell. The
electrical contact between cathode and felt, and between separator plate

and felt, may be enhanced by adding a layer of an optional adhesive or
contact material. The composition of the felt is chosen as appropriate for
the fuel cell operating conditions. For example, a Fe-Cr-AI-Y felt with a
density of 5 to 30%, preferably about 15% relative to the density of the
solid metal alloy and a thickness of 0.5 to 4 mm, preferably 2 mm, may
be used in a high temperature fuel cell, such as a solid oxide fuel cell, in
an oxidizing atmosphere at 650 to 850oC, such as about 800°C. If
desired, some or all of Fe may be substituted by Co and/or Ni in the Fe-
Cr-Al-Y felt. The felt may be potted in a lanthanum-strontium manganite
(LSM) perovskite on either the cathode or separator plate sides of the
connection, or on both sides.
[0203] Preferably, both the anode 860 and cathode 870
conductor/distributors are made from a felt. In subsequent paragraphs
and figures, it is assumed that same-numbered items carry their previous
definitions.
[0204] In another preferred aspect of the seventh preferred
embodiment, the anode and/or cathode conductor/distributors contain a
non-uniform surface. Preferably, the conductor/distributor(s) contain ribs
which provide a desired pressure drop or flow distribution pattern. Other
surface features, such as dimples, lines, or a particular pore geometry
may be used to exercise control over pressure drop or flow distribution.
[0205] In another preferred aspect of the seventh embodiment
(Figure 37), the anode conductor/distributor 860 is combined with the
anode-side felt seal of the sixth preferred embodiment. The anode
conductor/distributor and seal is made of one continuous piece of
material. The anode conductor/distributor 860 can be used in conjunction
with any of the various preferred aspects of the sixth embodiment
describing the felt seal.
[0206] In another preferred aspect of the seventh embodiment
(Figure 38), the cathode conductor/distributor 870 is combined with the
cathode-side felt seal of the sixth preferred embodiment. The cathode
conductor/distributor and seal is made of one continuous piece of
material. The cathode conductor/distributor 870 can be used in
conjunction with any of the various preferred aspects of the sixth
embodiment describing the felt seal. Most preferably, both the anode and
cathode conductor/distributors are combined with the felt seal.
[0207] In another preferred aspect of the seventh preferred
embodiment (Figure 39), the anode conductor/distributor 860 provides the
structural support for the separator plate 850. In this aspect, the
separator plate material may be made as thin as practicality and
serviceability allows. Preferably, the separator plate comprises a thin film
deposited onto the anode conductor/distributor 860 by various thin film
deposition techniques, including but not limited to thermal or plasma
spray, chemical or physical vapor deposition (i.e., CVD or sputtering),
precipitation, and dipping. Alternatively, the thin separator plate 850 may
comprise an integral component that is placed in contact with the
conductor/distributor. Preferably, a "thin film", is less than 500 microns
thick, more preferably, less than 100 microns thick, most preferably 10 to
30 microns thick. In this case, the felt conductor/distributor thickness is
sufficient to act as a substrate for the thin film, such as a thickness of
greater than 30 microns, preferably greater than 100 microns.
[0208] In another preferred aspect of the seventh preferred
embodiment (Figure 40), the cathode conductor/distributor 870 provides
the structural support for the separator plate 850. In this aspect, the
separator plate material may be made as thin as practicality and
serviceability allows. Preferably, the separator plate comprises a thin film
deposited onto the cathode conductor/distributor 870 by various thin film

deposition techniques, including but not limited to thermal or plasma
spray, chemical or physical vapor deposition (i.e., CVD or sputtering),
precipitation, and dipping. Alternatively, the thin separator plate 850 may
comprise an integral component that is placed in contact with the
conductor/distributor. Preferably both the anode and cathode
conductor/distributors serve as a support for their respective separator
plates.
[0209] In another preferred aspect shown in Figure 41, the anode
conductor/distributor 860 serves as a seal and as separator plate support.
In the figure, the anode conductor/distributor renumbered 865 is shown in
one of its various preferred configurations.
[0210] In another preferred aspect shown in Figure 42, the cathode
conductor/distributor 870 serves also as seal and as separator plate
support. In the figure, the cathode conductor/distributor renumbered 875
is shown in one of its various preferred configurations.
[0211] In subsequent paragraphs and figures, the
conductor/distributors are described in their roles as support structures for
other elements of the fuel cell stack. In these paragraphs and figures,
item 865 refers to the anode conductor/distributor in one of its various
previously described configurations, and item 875 refers to the cathode
conductor/distributor in one of its various previously described
configurations.
[0212] In another preferred aspect shown in Figure 43, the anode
conductor/distributor 865 and the cathode conductor/distributor 875
together support a common separator plate 850 that is located between
them. The separator plate 850 may be placed or deposited in any way so
as to reduce the materials and assembly costs and increase the
performance and quality of the assembly. Typically the separator plate

850 would be made as thin as practicality and serviceability allows, such
as a thin film plate.
[0213] If the felt conductor/distributors 865 and 875 are combined
with the seals, then the seal portions of the conductor/distributors can be
made gas impermeable by any of the methods described in the sixth
preferred embodiment. Alternatively, portions of the separator plate 850
may be used to form a seal. For example, thin separator plate material or
foil can be extended around the edges of either or both
conductor/distributors as shown in Figure 44. These separator plate
extension act as a gas impermeable seal.
[0214] In another preferred aspect of the seventh embodiment
shown in Figure 45, the anode conductor/distributor 865 and the cathode
conductor/distributor 875 together support not only the separator plate
850, but they also support the cathode 830, electrolyte 810, and anode
820. The separator plate 850, cathode 830, electrolyte 810, and anode
820 may be placed or deposited in any way so as to reduce the materials
and assembly costs and increase the performance and quality of the
assembly. Typically these components would be made as thin as
practicality and serviceability allows. These components preferably
comprise thin films (as defined above) that are preferably deposited on the
conductor/distributor 865/875 "substrate" by various thin film deposition
techniques described above.
[0215] Figure 46 illustrates a three dimensional view of an internally
manifolded fuel cell stack containing a common felt conductor/distributor
and seal. In Figure 46, the fuel cell stack contains a separator plate 850,
an anode felt conductor/distributor/seal 860, an electrolyte 810, and
anode 820 and a cathode felt conductor/distributor/seal 870. The
cathode is not visible in Figure 46 because it is located "behind" the
electrolyte 820. The separator plate 850 and electrolyte 810 contain gas
passages or openings 876, 877, 878 and 879. Specifically, passages
876 are fuel inlet passages, passages 877 are fuel outlet passages,
passages 878 are oxidizer inlet passages and passages 879 are oxidizer
outlet passages.
[0216] The anode felt conductor/distributor/seal 860 is made of a
conductive felt. The entire anode felt conductor/distributor/seal 860 is
gas permeable, except for gas impermeable seal region or strip 880. The
cathode felt conductor/distributor/seal 870 is made of a conductive felt.
The entire cathode felt conductor/distributor/seal 870 is gas permeable,
except for gas impermeable seal region or strip 881.
[0217] In the anode felt conductor/distributor/seal 860, the gas
impermeable strip 880 circumscribes a gas permeable region 882 and
seals it from a gas permeable region 883. In the cathode felt
conductor/distributor/seal 870, the gas impermeable strip 881
circumscribes a gas permeable region 884 and seals it from a gas
permeable region 885.
[0218] Region 882 lines up with the anode 820 and with the fuel
passages 876 and 877 when the stack is assembled. Region 883 lines
up with the oxidizer passages 878 and 879. Region 884 lines up with
the cathode (not shown) and with the oxidizer passages 878 and 879.
Region 885 lines up with fuel passages 876 and 877.
[0219] The fuel cell stack operates as follows. The input or inlet
fuel 886 (dashed lines in Figure 46) is provided into fuel inlet passage 876
in separator plate 850. The fuel reaches the gas permeable region 882 in
the anode conductor/distributor/seal 860. From here, the input fuel splits
into two directions. One part of the fuel travels "down" through gas
permeable felt region 882 and reacts at the anode 820. The fuel reaction

products 887 then exit from region 882 through fuel outlet passage 877
in the separator plate 850. Another part of the fuel travels through
passage 876 in the electrolyte and passes through the gas permeable
region 885 in the cathode conductor/distributor/seal 870. The gas
impermeable strip or seal 880 prevents the fuel from entering region 883
and reacting with the oxidizer. The gas impermeable strip or seal 881
prevents the fuel from entering region 884 and contacting the cathode.
[0220] The input or inlet oxidizer 888 (dotted-dashed lines in Figure
46) is provided into oxidizer inlet passage 878 in separator plate 850.
The oxidizer passes through the gas permeable region 883 in the anode
conductor/distributor/seal 860. The oxidizer then travels through passage
878 in the electrolyte and reaches the gas permeable region 884 in the
cathode conductor/distributor/seal 870. From here, the input oxidizer
splits into two directions. One part of the oxidizer travels "right" through
gas permeable felt region 884 and reacts at the cathode. The reacted
oxidizer 889 then travels back and exits from region 884 through oxidizer
outlet passage 879 in the separator plate 850. The gas impermeable strip
or seal 880 prevents the oxidizer from entering region 882 and contacting
the anode. The gas impermeable strip or seal 881 prevents the oxidizer
from entering region 885 and reacting with the fuel.
[0221] The gas impermeable regions 880, 881 may be formed by
any method described in the sixth embodiment, such as by selective
heating or laser irradiation or selective addition of a gas impermeable
material to the felt. Thus, the gas impermeable regions 880, 881 act as
felt seals in the felt conductor/distributors 860, 870. They separate and
prevent the fuel and oxidizer from contacting each other in the fuel cell
stack. The fuel stacks and the seals 880, 881 may have any suitable
shape and should not be considered limited to the shape illustrated in
Figure 46. Furthermore, "down" and "right" are relative directions

depending on the orientation of the fuel cell stack. It should be noted
that the fuel and oxidizer cross the fuel stack in different, preferably
perpendicular directions.
[0222] The felt conductor/distributor/seals are not limited to unitary
conductive felt sheets 860, 870 containing both the gas impermeable
seals 880, 881 and the gas permeable conductor/distributors 882, 884.
The gas impermeable seals may be formed in separate felt gaskets that
are placed adjacent to the gas permeable felt conductor/distributors, as
shown in Figure 47.
[0223] In Figure 47, the conductive felt anode
conductor/distributor/seal 890 comprises a gas impermeable felt gasket
891 and a gas permeable felt conductor/distributor 860. The gasket 891
contains a large opening 892, which lines up with the
conductor/distributor 860 and with the fuel inlet and outlet passages 876,
877 in the separator plate 850 and the electrolyte 810 (shown in Figure
46). The inlet fuel enters the conductor/distributor through opening 892
and travels to the anode 820. Alternatively, the one large opening 892
may be replaced with two smaller openings which line up with the
conductor/distributor and the fuel passages 876, 877 in the separator
plate 850 and electrolyte 810. The gasket 891 also contains the oxidizer
inlet and outlet passages 878A, 879A, which do not line up with the
anode conductor/distributor 860. Thus, the oxidizer travelling through
these passages does not enter the conductor/distributor 860 and does not
reach the anode.
[0224] In Figure 47, the conductive felt cathode
conductor/distributor/seal 895 comprises a gas impermeable felt gasket
896 and a gas permeable felt conductor/distributor 870. The gasket 896
contains a large opening 897, which lines up with the
conductor/distributor 870 and with the oxidizer inlet and outlet passages
878, 879 in the separator plate 850 and the electrolyte 810 (shown in
Figure 46). The inlet oxidizer enters the conductor/distributor through
opening 897 and travels to the cathode 830. Alternatively, the one large
opening 897 may be replaced with two smaller openings which line up
with the conductor/distributor and the oxidizer passages 878, 879 in the
separator plate 850 and electrolyte 810. The gasket 896 also contains
the fuel inlet and outlet passages 876A, 877A, which do not line up with
the cathode conductor/distributor 870. Thus, the fuel travelling through
these passages does not enter the conductor/distributor 870 and does not
reach the cathode.
[0225] The conductor/distributor/seals may also be used in
externally manifolded fuel cells, as shown in Figure 48. In Figure 48, the
alternating conductive felt anode and cathode conductor/distributor/seals
860, 870 are shown as being located in a fuel cell stack housing 899.
The housing may have a cylindrical or any other suitable shape. The thin
electrolyte, separator plates and electrodes are located between the
conductor/distributor/seals 860, 870, but are not shown in Figure 48 for
clarity.
[0226] The fuel and oxidizer passages are located between the fuel
cell stack and the housing 899. Specifically, passage 876B is a fuel inlet
passage, passage 877B'is a fuel outlet passage, passage 878B is an
oxidizer inlet passage and passage 879B is an oxidizer outlet passage.
The "vertical" (i.e., "left" and "right") surfaces 880A of anode
conductor/distributor/seals 860 are rendered gas impermeable. The
"horizontal" (i.e., "top" and "bottom") surfaces 881A of cathode
conductor/distributor/seals 870 are also rendered gas impermeable. The
remainder of the conductor/distributor/seals 860, 870 remains gas
permeable. The sealing may be accomplished by any method described in

the sixth embodiment, such as by selective heating or laser irradiation,
selective impregnation of the surfaces with a gas impermeable material
(i.e., such as by dipping into such material), by selective deposition of
foils or thin films on the desired surfaces, or by bending portions of the
separator plates around the desired surface edges.
[0227] The fuel from passage 876B travels through gas permeable
surfaces 882A of sheets 860 to reach the anode. The oxidizer from
passage 878B travels through gas permeable surfaces 884A of sheets
870 to reach the cathode. The fuel in passages 876B and 877B does not
permeate through surfaces 881 A, and does not react with the oxidizer or
reach the cathode. The oxidizer in passages 878B and 879B does not
permeate through surfaces 880, A and does not react with the fuel or
reach the anode.
[0228] The fuel stacks and the conductor/distributors 860, 870 may
have any suitable shape and should not be considered limited to the shape
illustrated in Figure 48. Furthermore, "vertical" and "horizontal" are
relative directions depending on the orientation of the fuel cell stack. It
should be noted that the fuel and oxidizer cross the fuel stack in different,
preferably perpendicular directions.
VIII. Conclusion
[0229] The various components of the systems and fuel cells and
steps of the methods described in the first through the seventh
embodiments may be used together in any combination. Preferably, the
components and systems of all seven embodiments are used together.
Thus, the preferred method and system include a temperature sensitive
adsorption oxygen enrichment method and system of the first
embodiment, a load matched power generation system including a solid
oxide fuel cell and a heat pump and an optional turbine, and method of

using the system of the second embodiment, a textured fuel cell ceramic
electrolyte of the third embodiment, an environment toierant fuel cell
anode catalyst of the fourth embodiment, a water vapor replenishment
system including the preferred enthalpy wheel of the fifth embodiment, a
felt seal in the fuel cell of the sixth embodiment and a felt collector of the
seventh embodiment. However, any one, two, three, four or five of the
above features may be omitted from the preferred system, fuel cell and
method.
[0230] The foregoing description of the invention has been
presented for purposes of illustration and description. It is not intended to
be exhaustive or to limit the invention to the precise form disclosed, and
modifications and variations are possible in light of the above teachings or
may be acquired from practice of the invention. The drawings are not
necessarily to scale and illustrate the device in schematic block format.
The drawings and description of the preferred embodiments were chosen
in order to explain the principles of the invention and its practical
application, and are not meant to be limiting on the scope of the claims.
It is intended that the scope of the invention be defined by the claims
appended hereto, and their equivalents.
WE CLAIM :
1. A ceramic electrolyte for a solid oxide fuel cell, comprising at least one
non-uniform surface portion, wherein:
the electrolyte is substantially flat; and
the at least one non-uniform surface portion of the electrolyte comprises a
textured surface which is located only in an active portion of the electrolyte, while
a peripheral portion of the electrolyte does not contain the textured surface.
r2. The electrolyte as claimed in claim 1, wherein:
the non-uniform surface comprises a textured surface; and
the textured surface has a roughness of 0.5 to 2.5 microns.
3. A method of making a ceramic electrolyte for a solid oxide fuel cell,
comprising:
providing an|electrolyte precursor material comprising a green sheet;
texturing at least a portion of at least one surface of the green sheet by
embossing, wherein the step of embossing comprises pressing a body having a
textured surface against the green sheet; and
sintering the green sheet to form a substantially flat ceramic electrolyte
containing at least a textured surface portion.
4. A method of making a ceramic electrolyte for a solid oxide fuel cell,
comprising:
providing a substantially flat ceramic electrolyte; and
texturing at least a portion of one surface of the ceramic electrolyte by
lapping, grinding or polishing at least one surface of the electrolyte.
5. A solid oxide fuel cell, comprising:
a cathode comprising a perovskite ceramic;

a solid ceramic electrolyte comprising nickel or nickel and a stabilized
zirconia ceramic; and
an anode comprising a cermet containing an environment tolerant catalyst
such as a metal oxide catalyst such as described herein,
wherein:
the electrolyte is substantially flat; and
at least one non-uniform surface portion of the electrolyte comprises a
textured surface.
6. The fuel cell as claimed in claim 5, wherein the catalyst comprises at least
one of a sulfur tolerant catalyst such as described herein and a fuel starvation
tolerant catalyst such as described herein.
7. A fuel cell stack, comprising:
an electrolyte such as a solid ceramic electrolyte;
an anode;
a cathode;
a first conductive felt current conductor/gas flow distributor; and
a first separator plate;
wherein;
the electrolyte is substantially flat; and
at least one non-uniform surface portion of the electrolyte comprises a
textured surface which is located only in an active portion of the electrolyte, while
a peripheral portion of the electrolyte does not contain the textured surface.
8. A method of making a ceramic electrolyte for a solid oxide fuel cell,
comprising:
providing a textured material comprising a body, such as a press or a
mold, having a textured surface and an electrolyte precursor material comprising
a ceramic precursor material in contact with each other, and

sintering the electrolyte precursor material to form a substantially flat
ceramic electrolyte, wherein the electrolyte comprises at least one non-uniform
surface portion comprising a textured surface,
9. The method as claimed in claim 8, wherein the electrolyte precursor
material comprises a green tape such as described herein.
10. The method as claimed in claim 9, comprising spreading a slurry such as
a ceramic precursor material slurry using a blade to form a green tape electrolyte
precursor prior to the step of sintering.
11. The method as claimed in claim 9, wherein the step of providing
comprises pressing the textured material into the green tape.
12. The method as claimed in claim 11, wherein the step of pressing
comprises embossing at least a portion of one surface of the green tape by
rolling a body comprising a textured surface against the green tape.
13. The method as claimed in claim 9, wherein the step of providing
comprises placing the green tape onto the textured material.
A solid oxide fuel cell system, comprising any one or more of elements (a)
to (g): (a) a temperature sensitive adsorption oxygen enrichment system [2]; (b)
a load matched power generation system having a solid oxide fuel cell [68] and a
heat pump [4] and an optional turbine [90]; (c) a textured fuel cell ceramic
electrolyte [10]; (d) an environment tolerant fuel cell anode catalyst [503]; (e) a
fuel water vapor replenishment system containing an anode side enthalpy wheel
[601], (f) a felt seal [701] in a fuel cell; and (g) a felt connector [860] in a fuel cell.

Documents:

1093-KOLNP-2004-CORRESPONDENCE.pdf

1093-KOLNP-2004-FORM 27 1.1.pdf

1093-KOLNP-2004-FORM 27.pdf

1093-KOLNP-2004-FORM-27.pdf

1093-kolnp-2004-granted-abstract.pdf

1093-kolnp-2004-granted-assignment.pdf

1093-kolnp-2004-granted-claims.pdf

1093-kolnp-2004-granted-correspondence.pdf

1093-kolnp-2004-granted-description (complete).pdf

1093-kolnp-2004-granted-drawings.pdf

1093-kolnp-2004-granted-examination report.pdf

1093-kolnp-2004-granted-form 1.pdf

1093-kolnp-2004-granted-form 13.pdf

1093-kolnp-2004-granted-form 18.pdf

1093-kolnp-2004-granted-form 3.pdf

1093-kolnp-2004-granted-form 5.pdf

1093-kolnp-2004-granted-gpa.pdf

1093-kolnp-2004-granted-reply to examination report.pdf

1093-kolnp-2004-granted-specification.pdf


Patent Number 233867
Indian Patent Application Number 1093/KOLNP/2004
PG Journal Number 16/2009
Publication Date 17-Apr-2009
Grant Date 16-Apr-2009
Date of Filing 30-Jul-2004
Name of Patentee BLOOM ENERGY CORPORATION
Applicant Address P.O. BOX 97, MOFFET FIELD, CA
Inventors:
# Inventor's Name Inventor's Address
1 GOTTMEN MATTHIAS 684 TORREYA AVENUE, SUNNYVALE, CALIFORNIA 94086
2 MCELROY JAMES F. 278 HALLADAY AVENUE EAST, SUFFIELD, CT 06078
3 SRIDHAR K. R. 18351 OVERLOOK ROAD, LOS GATOS, CA 95030
4 NGUYEN DIEN 455-D COSTA MESA TERRACE, SUNNYVALE, CA 94085
5 FIN JOHN E. 13155 FRANKLIN AVENUE, MOUNTAIN VIEW, CA 94040
PCT International Classification Number C04B 38/00
PCT International Application Number PCT/US2003/004808
PCT International Filing date 2003-02-20
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/357,636 2002-02-20 U.S.A.