WO2004070858A2 - Interconnexions compliantes, resistant aux contraintes pour empilement de pile a combustible a oxyde solide - Google Patents

Interconnexions compliantes, resistant aux contraintes pour empilement de pile a combustible a oxyde solide Download PDF

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Publication number
WO2004070858A2
WO2004070858A2 PCT/US2004/002865 US2004002865W WO2004070858A2 WO 2004070858 A2 WO2004070858 A2 WO 2004070858A2 US 2004002865 W US2004002865 W US 2004002865W WO 2004070858 A2 WO2004070858 A2 WO 2004070858A2
Authority
WO
WIPO (PCT)
Prior art keywords
compliant
superstructure
assembly
interconnect
fuel cell
Prior art date
Application number
PCT/US2004/002865
Other languages
English (en)
Other versions
WO2004070858A9 (fr
WO2004070858A3 (fr
Inventor
Sunil G. Warrier
Jean Yamanis
Wayde R. Schmidt
Raymond C. Benn
John G. Smeggil
Venkata R. Vendula
Original Assignee
Utc Fuel Cells, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Utc Fuel Cells, Llc filed Critical Utc Fuel Cells, Llc
Priority to EP04707406A priority Critical patent/EP1595304A4/fr
Priority to JP2006503238A priority patent/JP2007524956A/ja
Priority to CA002514488A priority patent/CA2514488A1/fr
Publication of WO2004070858A2 publication Critical patent/WO2004070858A2/fr
Publication of WO2004070858A3 publication Critical patent/WO2004070858A3/fr
Publication of WO2004070858A9 publication Critical patent/WO2004070858A9/fr

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Classifications

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

Definitions

  • a fuel cell is a device which electrochemically reacts a fuel with an oxidant to generate a direct current.
  • the fuel cell typically includes a cathode, an electrolyte and an anode, with the electrolyte being a non-porous material positioned between the cathode and anode materials.
  • such fuel cells are typically connected together using interconnects or bipolar plates to form a stack, or fuel cell stack, through which fuel and oxidant fluids are passed. Electrochemical conversion occurs, with the fuel being electrochemically reacted with the oxidant, to produce a DC electrical output.
  • Cathode interconnect materials that have been used to date include perovskite- based ceramics, e.g. lanthanum chxomite, high temperature chromium-based alloys or composites thereof, and nickel-based alloys or intermetallics have been used typically for cells operating in the 800-1000 °C range.
  • ferritic steels may have suitable oxidation resistance at temperatures less than about 600°C or for short lifetimes, but do not have the required oxidation resistance to last for 40,000 hours, or longer, due to the increasing ohmic resistance across the oxide scale with time under load.
  • the oxidation resistance is clearly a concern on the cathode/oxidant side of the interconnect.
  • the partial pressure of oxygen at the anode/fuel electrode may also be high enough to form Cr 2 O 3 and the oxide may be even thicker (viz. the presence of electrochemically formed water) than on the cathode side of the interconnect, so the resistivity of the interconnect may increase on both sides.
  • the construction materials on the anode side of the interconnect could be the same as the cathode, although prior art has shown that, in the case of a ferritic steel interconnect in contact with a nickel anodic contact, weld points that formed between the steel and the nickel still formed a thin electrically insulating Cr 2 O 3 layer over time which degraded performance.
  • the present invention provides a solid oxide fuel cell design having a compliant porous interconnect which alleviates the thermal expansion mismatch stresses which are typically generated by higher thermal expansion oxidation resistant interconnect metals and/or alloys for the cathode.
  • the interconnect of the present invention advantageously allows for the use of higher thermal expansion oxidation resistant metals or alloys for the separator plate. [0018]
  • the interconnect of the present invention further advantageously allows for less stringent dimensional tolerances of the stack components since the mterconnect is compliant in all three dimensions and permits displacement with minimal increase in stress to accommodate dimensional variations.
  • an interconnect which comprises a compliant porous member, compliant in all three-dimensions and having first portions defining a separator plate contact zone and second portions spaced from said first portions and defining an electrode contact zone.
  • a solid oxide fuel cell assembly which comprises a plurality of fuel cells arranged in a stack; and a plurality of interconnect assemblies positioned between adjacent cells of said- tack, said interconnect assemblies comprising a separator plate having two opposed surfaces and at least one interconnect positioned adjacent to at least one of said two opposed surfaces and comprising a compliant porous member, compliant in all three dimensions and having first portions defining a separator plate contact zone and second portions spaced from said first portions and defining an electrode contact zone.
  • Particularly desirable eoi-figuratioiis of the interconnect involve three- dimensional compliant superstructures made out of wire weaves or other compliant substructures. BRIEF DESCRIPTION OF THE DRAWINGS
  • Figure 1 schematically illustrates a fuel cell stack assembly in accordance with the present invention
  • Figure 2 schematically illustrates a portion of the fuel cell stack assembly of claim 1;
  • FIGS 4 and 5 illustrate another preferred embodiment of an interconnect of the present invention
  • Figure 6 illustrates an alternate embodiment of an interconnect of the present invention
  • Figure 8 illustrates another alternate embodiment of an interconnect of the present invention
  • the invention relates to a fuel cell assembly and, more particularly, to a solid oxide fuel cell (SOFC) stack having improved metallic interconnect which decouples the need for good coefficient of thermal expansion (CTE) match with other stack components from other requirements such as oxidation resistance and oxide scale electron conductance.
  • SOFC solid oxide fuel cell
  • the invention relates further to a fuel cell stack and, more particularly, to a solid oxide fuel cell stack having an improved interconnect, whereby stresses due to difference in thermal expansion coefficient between adjacent fuel cell stack components, and specifically between the cathode or anode interconnect and adjacent fuel cell or separator plate, are minimized so as to provide for enhanced fuel cell stack lifetime and robustness under steady state and thermal cycling.
  • the compliant interconnects described herein are designed such that high values of both in-plane and out-of-plane compliance are achieved.
  • any such interconnect that provides for acceptable levels of either in-plane compliance or out-of-plane compliance, or both, will be within the broad scope of the invention.
  • the compliant superstructure is compliant in at least three orthogonal axes, and is compliant with respect to a load applied from any direction.
  • Narious approaches to achieve this include wire weave based superstructures as described above, 3-dimensional knitted wire structures, helical coils in various configurations including slanted helical coils provided by pre-buckled highly compliant sub-structures, wires with in-built highly compliant compliance loops, similar interconnects made from sheet metal, foil, foam, or expanded metals formed into superstructures, etc.
  • Preferred compliance values of the interconnects are 5x10 mm / ⁇ (in strain stress units) and higher for typical interconnects at room temperature. More preferred compliancy values are 5x10 "5 mm 2 ⁇ and higher for typical interconnects.
  • a fuel cell stack assembly 10 in accordance with the present invention is schematically illustrated.
  • Assembly 10 preferably includes a plurality of fuel cells 12 arranged in a stack with bipolar plates 14 positioned therebetween.
  • Fuel cells 12 typically include an electrolyte 16, a cathode layer 18 positioned on one side of electrolyte 16, and an anode layer 20 positioned on the other side of electrolyte 16. Bonding or current carrying layers 22 may be used on the two sides.
  • the compliant wire weave sub-structure of interconnects 30, 32 in accordance with the present invention is advantageously a wire weave such as that illustrated in Figure 2, which advantageously provides a pre-buckled architecture that increases compliance of interconnect 30, 32.
  • This compliance allows for movement or deflection without stressing of first portions 34, relative to second portions 36 during thermal cycling and the like, which advantageously serves to eliminate stresses caused by CTE mismatch between various components.
  • the compliant interconnects formed from such sub-structures and superstructures also advantageously allows for movement between first portion 34 with respect to second portion 36 without stressing during assembly, thereby permitting larger dimensional tolerance variations.
  • the wire weave as shown in Figure 2 may include a first plurality of wires or substructures disposed in one direction, and a second plurality of wires or substructures disposed in a different direction, so as to define a woven wire structure which is porous to operating fuel cell gaseous materials and compliant as desired in different directions, in accordance with the present invention.
  • Figure 3 shows a perspective view of an interconnect 30, 32 to further illustrate a preferred sub-structure and superstructure thereof.
  • Figures 1, 2 and 3 illustrate interconnects 30, 32 as members having a substantially sinusoidal cross section, wherein peaks 38 on one side of a centerline 40 define the electrode contact zone, and peaks 42 on the other side of centerline 40 define the separator plate contact zone.
  • the undulating or vertically contoured shape of interconnect 30, 32 extends in the transverse direction to the cross section illustrated in Figures 1 and 2 so as to define a series of spaced peaks 38, 42, each extending in opposite directions from centerline 40, so as to define the spaced contact zones discussed above.
  • interconnects 30, 32 within the broad scope of the present invention, which could equally provide for the spaced contact zones connected by compliant members which provide for- advantageous reduction in stresses between components as desired in accordance with the present invention.
  • Figure 4 illustrates interconnect 30, 32 with compliant superstructures shaped in a substantially orthogonal, for example square or retangular channel pattern, made from a compliant sub-structure material, preferably wire weave, wherein the interconnects form spaced contact zones in the cross sectional view.
  • Figure 4 further illustrates a preferred wire weave structure according to the invention.
  • Figure 5 shows a perspective view of such an interconnect 30, 32 on bipolar plate 14.
  • Figure 6 shows a substantially square channeled superstructure interconnect 30, 32 with spaced contact zones present in both the cross sectional and the transverse direction.
  • Figure 7 shows a substantially trapezoidal superstructure interconnect 30, 32 made from compliant sub-structures.
  • Figure 8 illustrates a superstructure interconnect 30, 32 made into a circular or a helical, preferably slanted, structure wherein a compliant sub-structure such as a pre-buckled wire or wire weave forms the three-dimensional superstructure.
  • Figure 9 illustrates an embodiment wherein wires 52 are provided with compliance loops 54 as described above.
  • This structure serves to enhance the ability of the wire to resiliently deform as needed to respond to different CTE, and also to provide desired manufacturing tolerances.
  • This compliance loop structure can be incorporated into the substructure and or the superstructure of the interconnect of the present invention.
  • Interconnect 30, 32 in these examples can be positioned between components of the stack in similar fashion to the embodiment described above in connection with
  • Cathode-side interconnect 30 is preferably provided -having the architecture as described above and illustrated in Figures 1 and 2.
  • Anode-side interconnect 32 can advantageously be provided having the same architecture, or having a foam architecture defining foam cells which, themselves, define the contact zones for contact on one. side with separator plate 24 and on the other side with the anode of a fuel cell 12.
  • HAYNES® alloy 230-W Hastelloy X
  • Other materials include composites of at least 2 materials, for example metals and ceramics containing any of the above mentioned metals and alloys.
  • Another set of materials include noble metal coated super-alloys.
  • Anode-side interconnect 32 is advantageously provided of a material selected from the group consisting of Ni, Ni-Cu, Ni-Cr-, Ni-Cr-Fe-, Fe-Cr-, Fe-Cr-Ni and Co- based alloys as well as Cr-based alloys and noble metal/alloys and including such alloys coated with Ni, Cu or Ni-Cu as well as noble metals.
  • Other materials include composites of metals and ceramics containing any of the above mentioned metals and alloys.
  • interconnects 30, 32 when provided having the configuration of Figures 1 and 2 preferably define a superstructure wherein peaks 38, 42 define a superstructure wavelength of between 0.1 mm and 100 mm, a superstructure amplitude of between 0.1 mm and 50 mm, and a superstructure periodicity which may be uniform or random.
  • separator- plate 24 can advantageously be bonded to anode-side interconnect 32 and cathode-side interconnect 30 through various methods to produce high-strength interfaces therebetween.
  • such joints or components can be bonded, welded or brazed together, or can be secured together in other manners which would be well known to a person of ordinary skill in the art.
  • the wire weave sub-structure and three-dimensional superstructure of the interconnects in accordance with the present invention advantageously serves to alleviate stresses at the anode and cathode interfaces, and minimizes fracture of the interface and the cells themselves.
  • a compliant seal is further advantageously provided for sealing between edges of bipolar plate 14 and adjacent fuel cells 12.
  • the seal design is provided in the form of a rail or spacer 44 defining therein a groove 46, and a seal member 48 positioned in groove 46 and compressed between bipolar plate 14 and adjacent fuel cells 12 to provide the desired seal therebetween.
  • a compression stop 50 is provided to control the amount of deflection of the compliant seals and to advantageously assemble compliant interconnects, compliant seals and all other elements of the stack.
  • seal member 48 is advantageously provided as a compliant or compressible member formed from a suitable material, preferably alumina fibers. Alumina is most desirable in accordance with the present invention because alumina does not contaminate the fuel cell as do other seal materials which have conventionally been used, such as glass, glass-ceramics and the like.
  • seal member 48 is advantageously provided as compliant alumina fibers which can preferably be impregnated with another material selected so as to provide substantial gas impermeability of seal member 48 while nevertheless allowing for compliance or compressibility thereof.
  • seal member 48-in accordance with the present-invention can- advantageously be impregnated with a material selected from the group consisting of zirconia, alumina, yttrium aluminum garnate, alumino-silicate and magnesium silicate ceramics, and similar oxides, and combinations thereof, and it is preferred that seal member 48 be provided so as to reduce permeability to gas.
  • Seal member 48 can advantageously be provided having a fiber architecture such as tows, yarns, fiber weave architecture and the like. Such architectures can be loaded with secondary particles within the fibers as discussed above so as to provide desired seal properties. Further, rail/spacer 44 and compression stop 50 is provided having a height and groove depth which are selected to provide for additional decoupling of various parameters which are conventionally required to be related. [0071] It should be noted that a significant parameter is the response of the interconnect and seal to the clamping compressive load which must be applied to the fuel cell stack as schematically illustrated in Figure 1.
  • Figure 1 shows a compressive load applied to the top and bottom of assembly 10 which compressive load is advantageously selected to provide for sufficient interconnect bonding and sufficiently reduced leakage in the seals while nevertheless allowing micro- sliding in the seal area to relieve thermal mismatch stresses and to minimize compressive creep of the interconnects.
  • an interconnect superstructure and compliant seal assembly have been provided which advantageously allow for reduced stringency in tolerances in manufacture and assembly of solid oxide fuel cell stacks, and further which reduce the stresses conveyed between various components of the stack, thereby advantageously decoupling different design concerns of the stack and allowing selection of materials to provide long stack life.
  • the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Fuel Cell (AREA)

Abstract

L'invention concerne une interconnexion destinée à une pile à combustible à oxyde solide comprenant une superstructure compliante dotée d'une première partie définissant une zone de contact de plaque de séparateur et une seconde partie définissant une zone de contact d'électrode, ladite superstructure étant poreuse. Dans un mode de réalisation, cette superstructure est définie par une pluralité de substructures compliantes prévues dans un premier sens et une pluralité de substructures compliantes prévues dans un second sens afin de définir une structure tissée.
PCT/US2004/002865 2003-01-31 2004-02-02 Interconnexions compliantes, resistant aux contraintes pour empilement de pile a combustible a oxyde solide WO2004070858A2 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP04707406A EP1595304A4 (fr) 2003-01-31 2004-02-02 Interconnexions compliantes, resistant aux contraintes pour empilement de pile a combustible a oxyde solide
JP2006503238A JP2007524956A (ja) 2003-01-31 2004-02-02 固体酸化物燃料電池スタック用の柔軟性耐歪み性の相互接続部
CA002514488A CA2514488A1 (fr) 2003-01-31 2004-02-02 Interconnexions compliantes, resistant aux contraintes pour empilement de pile a combustible a oxyde solide

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US44402503P 2003-01-31 2003-01-31
US60/444,025 2003-01-31
US45489903P 2003-03-14 2003-03-14
US60/454,899 2003-03-14
US10/758,843 2004-01-16
US10/758,843 US20040200187A1 (en) 2002-11-27 2004-01-16 Compliant, strain tolerant interconnects for solid oxide fuel cell stack

Publications (3)

Publication Number Publication Date
WO2004070858A2 true WO2004070858A2 (fr) 2004-08-19
WO2004070858A3 WO2004070858A3 (fr) 2004-10-07
WO2004070858A9 WO2004070858A9 (fr) 2004-11-18

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Country Link
US (1) US20040200187A1 (fr)
EP (1) EP1595304A4 (fr)
JP (1) JP2007524956A (fr)
KR (1) KR20050096960A (fr)
CA (1) CA2514488A1 (fr)
WO (1) WO2004070858A2 (fr)

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EP1678774A2 (fr) * 2003-07-18 2006-07-12 UTC Fuel Cells, LLC Joints elastiques pour empilement de piles a combustible a oxyde solide
WO2006127045A3 (fr) * 2004-11-30 2007-03-01 Univ California Structure de joint scelle pour dispositif electrochimique
EP2111664A1 (fr) * 2006-12-27 2009-10-28 UTC Power Corporation Interconnexion à queue d'aronde asymétrique pour cellule à combustible d'oxyde solide
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FR2996065B1 (fr) 2012-09-26 2017-02-24 Commissariat Energie Atomique Composant constituant un interconnecteur d'electrolyseur eht ou de pile a combustible sofc et procedes de realisation associes
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TWI621302B (zh) 2013-05-16 2018-04-11 博隆能源股份有限公司 用於固體氧化物燃料電池堆的抗腐蝕障壁層及其製造方法
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CA2514488A1 (fr) 2004-08-19
EP1595304A2 (fr) 2005-11-16
WO2004070858A9 (fr) 2004-11-18
US20040200187A1 (en) 2004-10-14
EP1595304A4 (fr) 2012-02-15
KR20050096960A (ko) 2005-10-06
JP2007524956A (ja) 2007-08-30
WO2004070858A3 (fr) 2004-10-07

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