Abstract:
The present invention relates to a fuel cell system. A hot zone chamber has a wall thickness T and a heat source coupled thereto. An elongate fuel cell device is positioned with a first lengthwise portion within the hot zone chamber, a second lengthwise portion outside the hot zone chamber, and a third lengthwise portion of length T within the chamber wall. The third portion has a maximum dimension L in a plane transverse to the length where T≧½L.
Abstract:
Fuel cell devices and systems are provided. In certain embodiments, the devices include a ceramic support structure having a length, a width, and a thickness. A reaction zone positioned along a portion of the length is configured to be heated to an operating reaction temperature, and has at least one active layer therein comprising an electrolyte separating first and second opposing electrodes, and active first and second gas passages adjacent the respective first and second electrodes. At least one cold zone positioned from the first end along another portion of the length is configured to remain below the operating reaction temperature. An artery flow passage extends from the first end along the length through the cold zone and into the reaction zone and is fluidicly coupled to the active first gas passage, which extends from the artery flow passage toward at least one side. The thickness of the artery flow passage is greater than the thickness of the active first gas passage. In other embodiments, fuel cell devices include an electrolyte having at least a portion thereof comprising a ceramic material sintered from a nano-sized powder. In yet other embodiments, cold zones are provided at each end of the device with the reaction zone therebetween having at least two discrete power sections, each having one or more active layers, the power sections fed by discrete fuel passages to provide a device and system capable of operating at more than one power level.
Abstract:
The invention relates to a method of making fuel cell devices. Anode and cathode layers are applied on respective first and opposing second sides of a first portion of a first green ceramic layer, and a second green ceramic layer of thickness approximately equal to that of the anode and cathode layers is applied on a second portion of each of the first and second sides of the first green ceramic layer. A sacrificial layer is applied over each of the anode, cathode and second green ceramic layers, and a third green ceramic layer is applied over the sacrificial layers. The layered structure is heated to sinter all the layers and burn out the sacrificial layers. A pair of gas passages is thus formed with a thick sintered ceramic therebetween as a passive supporting portion and an anode, thin electrolyte and cathode therebetween as an active portion of the device.
Abstract:
The present invention relates to a method of making fuel cell devices. A stack structure is formed having plural ceramic layers, anode layers, cathode layers, and sacrificial layers, where the sacrificial layers are sized to provide internal gas passages. Removable structures are placed in contact with the sacrificial layers and extend to an edge. After laminating the stacked structure, the removable structures are pulled out to form bake-out paths that facilitate removal of the sacrificial material during a heating step, which paths are later sealed.
Abstract:
A fuel cell device is provided in which the gas input passages are separate from the exhaust gas passages to provide better flow of reactants through the pores of the electrodes. First and second porous electrodes are separated by an electrolyte layer that is monolithic with a solid ceramic support structure for the device. First and second input passages extend within the respective electrodes, within the electrolyte layer, and/or at the surfaces that form the interface between the respective electrodes and the electrolyte layer. First and second exhaust passages are spaced apart from the input passages, and extend within the respective electrodes and/or at a surface thereof opposite the interface surface with the electrolyte layer. Gases are adapted to flow through the respective input passages, then through the pores of the porous electrodes, and then through the respective exhaust passages.
Abstract:
A monolithic or essentially monolithic single layer capacitor with high structural strength and capacitance, a printed circuit board having the capacitor mounted thereon, and a method of making. Sheets of green-state ceramic dielectric material and glass/metal composite material are laminated together, diced into individual chips, and fired to sinter the glass and the ceramic together. The composite material contains an amount of metal sufficient to render the composite conductive whereby the composite may be used for one or both electrodes and for mounting the capacitor to the printed circuit board. Vertically-oriented surface mountable capacitors and hybrid capacitors are provided.
Abstract:
The invention provides solid oxide fuel cell devices and a fuel cell system incorporating a plurality of the fuel devices, each device including an elongate substrate having a reaction zone for heating to an operating reaction temperature, and at least one cold zone that remains at a low temperature below the operating reaction temperature when the reaction zone is heated. An electrolyte is disposed between anodes and cathodes in the reaction zone, and the anode and cathode each have an electrical pathway extending to an exterior surface in a cold zone for electrical connection at low temperature. In one embodiment, the device is a multi-layer anode-cathode structure, and in another embodiment, the device is an electrode-supported device. The system further includes the devices positioned with their reaction zones in a hot zone chamber and their cold zones extending outside the hot zone chamber. A heat source is coupled to the hot zone chamber to heat the reaction zones to the operating reaction temperature, and fuel and air supplies are coupled to the substrates in the cold zones.
Abstract:
A method of fabricating a ceramic tube with electrodes thereon suitable for use as a tubular reaction chamber for a fuel cell. In one embodiment, the method includes wrapping a first electrode material around a mandrel, then wrapping a green ceramic material over the first electrode material, and then wrapping a second electrode material over the green ceramic material. The wrapped layers are laminated together, and then removed from the mandrel and sintered, in either sequence, to produce the laminated ceramic tube having an inner first electrode and an outer second electrode. Alternatively, a first electrode tube is provided in place of the mandrel and around which the green ceramic material is wrapped. The outer second electrode may be produced by wrapping a second electrode material around the green ceramic material, before or after laminating, or by printing the electrode material onto the sintered ceramic tube. The present invention further provides a method of making a ceramic tube in which a sacrificial organic material is first wrapped around the mandrel to a desired thickness prior to wrapping the green ceramic material to increase the green material thickness. During sintering, the organic material is burned away leaving only a laminated ceramic tube, optionally with electrodes thereon.
Abstract:
A fuel cell device is provided having an active central portion with an anode, a cathode, and an electrolyte therebetween. At least three elongate portions extend from the active central portion, each having a length substantially greater than a width transverse thereto such that the elongate portions each have a coefficient of thermal expansion having a dominant axis that is coextensive with its length. A fuel passage extends from a fuel inlet in a first elongate portion into the active central portion in association with the anode, and an oxidizer passage extends from an oxidizer inlet in a second elongate portion into the active central portion in association with the cathode. A gas passage extends between an opening in the third elongate portion and the active central portion. For example, the passage in the third elongate portion may be an exhaust passage for the spent fuel and/or oxidizer gasses.
Abstract:
A fuel cell device is provided having an active structure with an anode and cathode in opposing relation with an electrolyte therebetween, a fuel passage adjacent the anode for supplying fuel to the active structure, and an air passage adjacent the cathode for supplying air to the active structure. A porous ceramic layer is positioned between each of the anode and fuel passage and the cathode and air passage, the porous ceramic layers having a porosity configured to permit transport of fuel and air from the respective fuel and air passage to the respective anode and cathode. An inactive surrounding support structure is provided that is monolithic with the electrolyte and the porous ceramic layers, wherein the inactive surrounding support structure lacks the anode and cathode in opposing relation and the active structure resides within the inactive surrounding support structure.