Battery cell and battery stack

Abstract

A stack of rectangular planar electrochemical cell units (200), each cell unit (200) including at least one first fluid intermediate port (230, 235) disposed within or between one or more active cell chemistry regions (210) along a middle portion of a length of the cell unit and in fluid communication with a first fluid volume of the cell unit (200). The first fluid intermediate ports (230, 235) of respective ones of the cell units (200) are aligned to form at least one first fluid intermediate passage extending in a stacking direction. The stack is configured such that, in each first fluid volume, a first fluid flow path (405, 410) extends through the at least one first fluid intermediate port (230, 235) and one or more active cell chemistry regions (210) between each respective opposing cell end portion.

Description

[0001] This invention relates to a stack comprising multiple electrochemical cell units. More specifically, this invention relates to metal-supported cells, particularly oxidant-type (MS-SOFC) or electrolyzer-type (MS-SOEC) metal-supported solid oxide fuel cell units, and their stacks.

[0002] Some fuel cell units generate electricity through an electrochemical conversion process that oxidizes fuel to produce electricity. Some fuel cell units can also, or alternatively, operate as regenerative fuel cell (or reverse fuel cell) units, often referred to as solid oxide electrolyzer fuel cell units, for example, separating hydrogen and oxygen from water, or carbon monoxide and oxygen from carbon dioxide. They can be tubular or planar in configuration. Planar fuel cell units can be arranged in a stacked configuration, for example, 100-200 fuel cell units stacked together, with each fuel cell unit electrically connected in series.

[0003] Solid oxide fuel cells (SOFCs) that generate electricity are based on a solid oxide electrolyte that conducts negative oxygen ions from the cathode to the anode located on the opposite side of the electrolyte. For this purpose, fuel or reformed fuel is in contact with the anode (fuel electrode), while the oxidant (such as air or an oxygen-enriched fluid) is in contact with the cathode (air electrode). Conventional ceramic-supported (e.g., anode-supported) SOFCs have low mechanical strength and are prone to fracture. Therefore, metal-supported SOFCs have recently been developed, which have active fuel cell assembly layers supported on a metal substrate. In these cells, the ceramic layers are very thin because they only perform electrochemical functions: that is, the ceramic layers are not self-supporting but rather thin coatings / films laid on and supported by the metal substrate. Compared to ceramic-supported SOFCs, such metal-supported SOFC stacks are more robust, less expensive, have better thermal performance, and can be manufactured using conventional metal welding techniques.

[0004] The applicant's earlier patent application, WO2015 / 136295, discloses a metal-supported SOFC, wherein the electrochemical activation layer (or activated fuel cell assembly layer) comprises respective anode, electrolyte, and cathode layers, respectively deposited (e.g., as a thin coating / film) and supported thereon on a metal support plate 12 (e.g., a foil). The metal support plate has porous regions surrounded by non-porous regions, and the activation layer is deposited on the porous regions, allowing gas to pass through the pores from one side of the metal support plate to the opposite side, thereby entering the activation layer coated thereon. Figure 1As shown, the fuel cell unit 9 includes three plates or layers—a metal support plate 12, a separator plate 50, and a spacer plate 13 sandwiched between them. It also has fluid ports 20 and 88 (for oxidant or fuel), and the three plates are stacked on top of each other and welded (fused together) by the spacer plate 13 to form a single metal-supported solid oxide fuel cell unit, where the fluid volume is defined by a large space 14 provided in the spacer plate 13. The metal components of the stacked repeating layers of the fuel cell are in electrical contact with each other, and the electron flow between them is primarily through a fuse / weld path, thus avoiding surface-to-surface contact resistance losses.

[0005] As discussed in WO2015 / 136295, the porous region includes small orifices (holes drilled through the metal foil substrate) extending through the metal support plate 12, located on the anode (or cathode, depending on the polarity orientation of the electrochemically activated layer) below the metal support plate 12. These orifices are situated within a large space or orifice 14 defined by the spacer 13 to allow fluid volume to communicate with the electrochemically activated layer beneath the support plate 12 through the orifices.

[0006] In the separator 50, upper and lower corrugations 60 are provided to extend upward to the cathode (or anode, depending on the polarity orientation of the electrochemical activation layer) of the subsequent fuel cell unit stacked on the fuel cell unit, and downward to the metal support plate 12 of its own fuel cell unit. Thus, an electrical connection is formed between stacked adjacent fuel cell units so that the stacked electrochemical activation layers (typically one on each fuel cell unit) are connected in series with each other.

[0007] It is known to employ a single central port in a circular fuel cell unit (e.g., WO 2005 / 064725 A1 and US2011 / 123890 A1), where the electrochemical activation layer can be in the form of a toroidal segment surrounding the central port (e.g., WO2005 / 064725 A1) or a ring around the central port. Given its highly symmetrical nature, this architecture differs significantly from rectangular fuel cell units.

[0008] US 2013 / 0177829 A1 and US 2012 / 0295182 A1 incorporate a central manifold within a double-plate structure. The separator is paddle-shaped or H-shaped. Within the separator are a pair of elongated channels extending in opposite directions, at the distal ends of which a pair of corresponding self-supporting electrolyte electrode assemblies are positioned, separate from the central manifold.

[0009] WO 2008 / 123968 A1 relates to a battery cell stack with a central port having a self-supporting electrolyte electrode assembly.

[0010] JP 2013 / 187005 A relates to a battery cell having two self-supporting electrolyte electrode assemblies arranged on a separator having a central port for cooling air. The battery cells can be stacked and fastened using bolts passing through the central port.

[0011] Solid oxide electrolyzers (SOECs) can have the same structure as SOFCs, but are essentially operated in reverse or regenerative mode to electrolyze water and / or carbon dioxide using solid oxide electrolytes to produce hydrogen and / or carbon monoxide and oxygen.

[0012] This invention relates to a stack of repetitive solid oxide fuel cell units having a structure suitable for use as SOEC or SOFC. For convenience, SOEC or SOFC stacked cell units will be referred to as "cell units" (i.e., SOEC or SOFC stacked cell units) in the following text.

[0013] This invention seeks to improve the efficiency of fuel cell units while providing cost-effective cell units—reducing their manufacturing costs would have a significant benefit in lowering the entry cost of fuel cell energy production.

[0014] The present invention provides a rectangular planar electrochemical cell stack, each cell including at least one first fluid intermediate port disposed along the middle of its length within or between one or more activated cell chemical regions and in fluid communication with a first fluid volume of the cell, wherein the first fluid intermediate ports of each respective cell are aligned to form at least one first fluid intermediate passage extending along the stacking direction; and wherein the stack is configured such that in each first fluid volume, a first fluid flow path extends through one or more activated cell chemical regions between the at least one first fluid intermediate port and each respective opposite cell end.

[0015] In this way, the first fluid flow path can extend in opposite (e.g., longitudinal) directions through one or more activated battery chemistry regions between the at least one first fluid intermediate port and each corresponding opposite battery end. This flow path arrangement means that the one or more activated battery chemistry regions can be located between the intermediate port and each opposite battery end. Compared to a flow path extending longitudinally from one battery end to the opposite battery end throughout the entire battery chemistry region, having activated battery chemistry regions located on each side of the intermediate port means a lower pressure drop throughout the region and a shorter distance for fluid flow to serve the activated battery chemistry regions. Therefore, differences in temperature and fuel delivery / consumption can be reduced throughout the chemistry region.

[0016] The flow path is between the intermediate port and the corresponding opposite end; however, the fluid flow itself will fan out over the activated cell chemistry region between the intermediate port and the opposite cell end. Nevertheless, when the flow fans out, the (main) component of the fluid flow path extends (e.g., longitudinally) between the intermediate port and the corresponding cell end.

[0017] The activated cell chemistry regions can share the same intermediate port and be equidistant from it. This increases the power density of each cell by effectively reducing the number of ports required per unit area of ​​activated cell chemistry region. This results in more thermally ideal cell structures, increasing the proportion of cell area covered by the activated cell chemistry region, shortening fluid flow path lengths, and reducing the number of ports. Shorter fluid flow path lengths mean a reduced temperature gradient along the path length. The intermediate port can extend through the height of the stack along the stacking direction.

[0018] The stack is configured such that, in use, a first fluid flow path extends in opposite directions between the at least one first fluid intermediate port and each corresponding opposite cell end. The flow path may be symmetrical about the center of the rectangular cell. In practice, the port does not need to guide the fluid flow path, and the fluid flow from the port may be non-directional (there may not be a defined tortuous flow path within the cell). In other words, the flow path around (i.e., from or to) the intermediate port is substantially radial. That is, the flow path is not limited to a channel around (i.e., from or to) the intermediate port. The one or more activated cell chemical regions may substantially surround the intermediate port.

[0019] The intermediate port can be located in the middle along the length and width of the battery cell. A rectangular battery cell includes a square battery cell, wherein the length and width of the square battery cell are equal. The battery cell can be elongated, in which case the length of the battery cell is greater than its width, and vice versa. The rectangular battery cell can have rounded or semi-rounded corners located between two pairs of parallel edges.

[0020] A rectangular battery cell may have two pairs of substantially parallel sides. If the length of the first pair of sides is greater than the length of the second pair of sides, the fluid intermediate port may be located at the midpoint of the length of the first pair of sides.

[0021] The battery cell may include a metal support plate and a separator plate, with the first fluid volume defined and contained between them. In the stack, a second fluid volume may be defined between adjacent battery cells. The battery cell may include a metal-supported solid oxide fuel cell unit.

[0022] Each battery cell may include a separator and a metal support plate, the metal support plate carrying an activated battery chemical region disposed on a porous region on its first side, the separator and the metal support plate being stacked on top of each other to form the battery cell. At least one fluid port may be provided in each of the separator and the metal support plate, these ports being aligned to form a corresponding first fluid intermediate port and a first fluid passage.

[0023] Typically, each battery cell has at least two separate activated battery chemistry regions, each located between the central port and each opposite battery end.

[0024] The individual activated battery chemistry regions can be located on each side of the central port. Smaller, individual activated battery chemistry regions typically have lower stress than a single region of equivalent area, thus reducing the likelihood of stress-related failures.

[0025] Alternatively, each battery cell may contain a continuous activated battery chemical region, with its intermediate port located within or surrounded by the activated battery chemical region. The continuous activated battery chemical region may be a single region within each battery cell.

[0026] Typically, the dimension of the activated battery chemical region, which is parallel to the fluid flow path and between the intermediate port and one of the opposite ends of the battery cell, is less than or equal to its dimension perpendicular to the fluid flow path.

[0027] The size of the activated battery chemistry region, parallel to the fluid flow path and between the intermediate port and one of the opposite ends of the battery cell, can be considered as the shortest distance from the edge of the activated battery chemistry region near the intermediate port to the opposite edge of the activated battery chemistry region near the end of the battery cell.

[0028] The length of the battery cell can be referred to as the cell's dimension, which is typically parallel to the fluid flow path, and the width of the battery cell can be referred to as its overall dimension perpendicular to the fluid flow path. Typically, the length of the flow path through the activated battery chemistry region (between the middle port and corresponding ends of the battery cell) is approximately half the length of the battery cell, and more specifically, it is not less than 45% of the cell's length. When discussing the width of the battery chemistry (i.e., the overall dimension of the battery chemistry perpendicular to the flow path), it can generally be assumed that the width is greater than or equal to 90% of the width of the battery cell (the width of the battery cell is the overall dimension of the battery cell perpendicular to the flow path). Therefore, the proportion of the battery cell area covered by the activated battery chemistry region can be maximized. The activated battery chemistry region needs to be positioned as close as possible to the port and the battery perimeter because even a small increase in effective battery coverage can significantly affect power density during the manufacture and stacking of the battery cells. Therefore, the goal is to minimize the proportion of the battery area not coated with the activated battery chemistry region.

[0029] In some embodiments, the distance between the at least one first fluid intermediate passage and each battery end is less than the width of the battery cell (the width is generally perpendicular to the fluid flow path, i.e., the line between the intermediate passage and the battery end), but this is not always the case.

[0030] In some embodiments, the length of the battery cell is less than or equal to about 2.4 times the width of the battery cell; there may be embodiments where the length is actually less than the width. Preferably, the length of the battery cell is between 1.5 and 2.4 times the width of the battery cell. More preferably, the length of the battery cell is less than or equal to twice the width of the battery cell.

[0031] In a preferred embodiment, the fluid flow path spans a dimension of the activated battery chemical layer, which is the shorter of the length and width dimensions of the activated battery chemical layer. Therefore, the battery cell can have a low aspect ratio. The aspect ratio can be defined as the size of the activated battery chemical region parallel to the fluid flow path divided by the size of the activated battery chemical region perpendicular to the fluid flow path. A low aspect ratio means that the ratio between the width (the distance between the inlet and outlet ports of the activated battery chemical region) and the length of the activated battery chemical layer is less than 1.2, preferably between 0.3 and 1.2. Preferably, the aspect ratio is less than 1. More preferably, the aspect ratio is less than 0.8, and even more preferably, the aspect ratio is between 0.3 and 0.8. Very low aspect ratios (e.g., less than 0.3) are beneficial to battery performance, but manufacturing limitations restrict these.

[0032] A shorter fluid flow path can: a) improve heat distribution because the conduction path length from the hot inlet to the colder outlet is shortened (due to fluid entering or leaving the fluid volume midway along the length of the cell) and can b) reduce the pressure drop between the intermediate fluid passage and the cell end or end fluid passage, thereby increasing the net efficiency of the stack due to reduced parasitic losses from the fluid blower and / or pump. The improved heat distribution, i.e., the lower heat density gradient, may also lead to a reduction in the current density gradient.

[0033] Each battery cell may have only one first fluid intermediate port that is in fluid communication with the first fluid volume.

[0034] Each battery cell may have only one first fluid intermediate port, in which case the first fluid flow path is split and extends in two opposite directions between the at least one first fluid intermediate port and each corresponding battery end. Having only one first fluid intermediate port allows a larger proportion of the battery cells to be used for activating the battery chemistry layer, thereby allowing for a greater power density. Alternatively, there may be multiple first fluid intermediate ports, for example, arranged along a centerline between the ends of the battery cells (i.e., along either side of the middle of the length of the battery cell and / or between the activated battery chemistry regions).

[0035] Alternatively, there may be multiple first fluid intermediate ports, for example, arranged on either side of the respective short axis (i.e., either side of the middle of the length of the battery cell), such that all flow from one intermediate port tends to be directed only toward one corresponding battery end.

[0036] Typically, at least one first fluid end passage is provided at or near each opposing stack end, extending along the stacking direction. Thus, the stack can be configured such that the intermediate and end first fluid passages form inlet and outlet passages within the stack, respectively, or vice versa, for supplying a first fluid to a first fluid volume of each cell during use, such that the first fluid flow path extends through one or more activated cell chemistry regions between the intermediate port of each cell and the two opposing cell ends.

[0037] One or two first fluid end passages may form a manifold externally around the stack ends. However, typically, the first fluid end passages form a manifold internally by providing aligned first fluid end ports within the battery cell, extending through the stack in the stack (axial) direction, for example, with appropriate seals / gaskets between adjacent cells.

[0038] The first fluid volume can be either air or fuel fluid. Each battery may include at least one activated battery chemistry region comprising an electrolyte inserted between an air electrode and a fuel electrode. Each battery also includes an air / oxidant fluid volume and a fuel fluid volume communicating with each of the air and fuel electrodes. Therefore, the intermediate and end fluid passages can respectively form inlet and outlet passages for supplying fluid to the same corresponding fluid volume in each battery, which can be either an air fluid volume or a fuel fluid volume.

[0039] In one embodiment, each battery cell includes at least first and second first fluid end ports respectively disposed at or near each opposite battery end, the respective first fluid end ports being aligned to define respective first and second internal first fluid end passages extending along the stacking direction, whereby the intermediate and end first fluid passages respectively form inlet and outlet passages within the stack, or vice versa, for supplying first fluid to a first fluid volume of each battery cell.

[0040] The end ports provide an internal manifold for the first fluid. This facilitates the closure of the first fluid volume and means directly sealing the first fluid volume separately from the second fluid volume. The activated cell chemistry region and the intermediate port are positioned between the respective fluid end ports. Therefore, the fluid flow path between each end port and the intermediate port passes through the activated cell chemistry region and delivers and removes fluid therefrom (i.e., in SOFC operation, delivers fuel and removes emissions from the fuel volume, or delivers oxidant and removes emissions from the oxidant volume).

[0041] In one battery cell embodiment, the first fluid volume is defined by two planar components of the battery cell, and the first fluid volume is sealed between the two planar components and around their peripheries by a weld line, wherein a first fluid intermediate port is in fluid communication with the first fluid volume. There are no weld paths around any port in fluid communication with the first fluid volume. One or both of the planar components may include a flanged peripheral feature, and the battery cell is sealed around the flanged peripheral feature by a weld between the two planar components to form the first fluid volume. The two planar components are adjacent (i.e., in contact) to each other around the flanged peripheral feature. The flanged peripheral feature in the first planar component extends toward the other planar component (or vice versa if both components are provided with flanged peripheral features).

[0042] Alternatively, when using a battery cell with spacers, the welding lines around the periphery of the battery cell can pass through a gasket or spacer disposed between the two planar components.

[0043] In one battery cell embodiment, the first fluid volume is defined by two planar components (plates) of the battery cell, and a weld line between the two planar components surrounds a second fluid intermediate port (i.e., in fluid communication with the second fluid volume), such that the second fluid intermediate port is not in fluid communication with the first fluid volume. The weld line surrounding the port and located between the two planar components (e.g., a metal support plate and a separator plate) seals the port to prevent fluid communication with the (first) fluid volume between or defined by the two planar components. One or both of the planar components may include an annular feature surrounding the second fluid intermediate port and extending toward the other planar component, wherein the weld line surrounds the annular feature. The two planar components are adjacent (i.e., in contact) to each other around the annular feature. The annular feature in the first planar component extends toward the other planar component (or vice versa if both planar components are provided with annular features), thus the annular feature extends inward within the battery cell.

[0044] Alternatively, the welding wire around the port can pass through a gasket or spacer disposed between the two planar components.

[0045] In one embodiment, each battery cell further includes at least one second fluid intermediate port disposed along the middle of its length within or between one or more activated battery chemistry regions and in fluid communication with a second fluid volume of the battery cell, wherein the second fluid intermediate ports of the respective battery cells are aligned to form at least one second fluid intermediate passage extending along the stacking direction; and wherein the stacking is configured such that in each second fluid volume, a respective second fluid flow path extends through one or more activated battery chemistry regions between the at least one second fluid intermediate port and each respective opposite battery end.

[0046] The corresponding second fluid flow path may extend in opposite directions over one or more activated cell chemistry regions between the at least one second fluid intermediate port and each corresponding opposite cell end. As a result of the second fluid intermediate port, the second fluid volume benefits from similar advantages as those discussed above with respect to the first volume. The second fluid intermediate port may be located at the midpoint along the length of the cell and at the midpoint along the width of the cell. One or more of the first and second fluid intermediate ports may be offset from the midpoint along the width or length of the cell, and may be arranged symmetrically about a line at the midpoint along the width or length of the cell. The (one or more) second fluid intermediate ports are generally spaced apart from the first fluid intermediate port in a direction substantially parallel to the width of the cell.

[0047] In such a battery cell (having at least one second fluid intermediate port), the first fluid volume may be defined by two planar components, and the first fluid volume is sealed between the two planar components and around their periphery by a weld line; and the weld line between the two planar components surrounds the second fluid intermediate port. Therefore, the first fluid intermediate port is in fluid communication with the first fluid volume, and the weld line around the second fluid intermediate port separately seals the second fluid volume from the first fluid volume.

[0048] One or both planar components may include an annular feature extending around the second fluid intermediate port and toward the other planar component, wherein the weld line surrounds the annular feature. One or both planar components may include a flanged peripheral feature, and the battery cell is sealed around the flanged peripheral feature by welding between the two planar components to form a first fluid volume. In this case, the two planar components are adjacent (i.e., in contact) to each other around the annular feature and adjacent to each other around the flanged peripheral feature. The annular feature and the flanged peripheral feature in the first planar component extend toward the other planar component (or vice versa if both planar components are provided with an annular feature and a flanged peripheral feature), thus the annular feature extends inward within the battery cell.

[0049] Alternatively, the welding line around the second fluid intermediate port can pass through a gasket or spacer disposed between the two planar components.

[0050] The battery cell may include the two planar components defining a first fluid volume therebetween, while a second fluid volume is defined between adjacent battery cells. Each battery cell (in one or both of the planar components) may have an annular feature surrounding each first fluid port (a first fluid intermediate port and, if present, a first fluid end port), wherein the annular feature extends toward the adjacent battery cell and contacts the adjacent battery cell in the stack. The first fluid volume may be separately sealed from the second fluid volume by a weld line between adjacent battery cells surrounding the annular feature. The second fluid port (e.g., a second fluid intermediate port) is in fluid communication with the second fluid volume, and each second fluid port may have a raised port feature surrounding the fluid port and allowing fluid communication between the second fluid volume and the passage defined by the second fluid port. These raised port features are located in one or both of the planar components and protrude from the other planar component of the battery cell, thus protruding toward the adjacent battery cell.

[0051] Typically, the first fluid intermediate port is the inlet port. Preferably, the second fluid intermediate port (if present) is the inlet port. The first and / or second fluid intermediate passage may include an inlet or outlet passage. When used as an inlet passage for the first and / or second (respectively) fluid volumes (making the intermediate port a delivery or inlet port), using the intermediate port as the inlet port facilitates preheating of the stack, shortening the heat conduction path length from the inlet to the outlet for a given cell length, both in terms of preheating rate and in terms of reducing temperature changes across the entire cell, as hot fluid enters each cell near the center of the stack.

[0052] Preferably, each battery cell includes two first fluid intermediate ports, each first fluid intermediate port being in fluid communication with the first fluid volume, and a second fluid intermediate port being in fluid communication with the second fluid volume, and optionally, the second fluid intermediate port is disposed between the two first fluid intermediate ports.

[0053] Preferably, the flow in the two fluid volumes is symmetrical, resulting in improved heat and fluid distribution. The fluid intermediate ports may be aligned along a midline of the length of the battery cell, which may be within or between one or more activated battery chemical regions. The line may be substantially perpendicular to the length of the battery cell. The two first fluid intermediate ports (fluidly in communication with the first fluid volume) may be uniformly spaced from the one second fluid intermediate port (fluidly in communication with the second fluid volume) (preferably in the width direction).

[0054] Alternatively, there can be two second fluid intermediate ports, with one first fluid intermediate port positioned between them. This, too, creates a symmetrical fluid flow path.

[0055] Alternatively, for example, there may be multiple intermediate ports proportional to the width of the battery cell (a dimension perpendicular to the overall fluid flow path), the multiple intermediate ports being arranged symmetrically with respect to the midpoint across the width of the battery cell. If both first and second fluid intermediate ports are present, there may be multiple of each fluid intermediate port, and they alternate symmetrically with respect to the midpoint of the width of the battery cell, such that a first fluid intermediate port is adjacent to two second fluid intermediate ports, and vice versa. The multiple intermediate ports are arranged along a midline between the ends of the battery cell (i.e., along either side of the midpoint of the battery cell length and / or between regions of activated battery chemistry).

[0056] In the presence of at least one second fluid intermediate port, a first fluid end passage in fluid communication with the first fluid volume may be provided, extending along the stacking direction at or near each opposite stack end. These passages are internal manifold passages, defined by the first and second first fluid end ports within each aligned battery cell, respectively. Simultaneously, second fluid end passages in fluid communication with the second fluid volume are provided, extending along the stacking direction at or near each opposite stack end. These passages are external manifold passages extending beyond each battery cell.

[0057] For each of the first fluid volume and the second fluid volume, the stack can be configured such that intermediate and end fluid passages form inlet and outlet passages within the stack, respectively, or vice versa, for supplying a specific fluid to the fluid volume of each cell during use, such that the fluid flow path extends through one or more activated cell chemistry regions of each cell between the intermediate port of each cell and two opposing cell ends. One or both types of end passages can be internally formed manifolds, but to maximize the activated cell chemistry surface area, one type of fluid end passage is preferably an externally formed manifold.

[0058] Preferably, the aligned first and second first fluid end ports and the two first fluid intermediate ports form a rhombus arrangement. The first fluid intermediate ports may be located at the midpoint of the length of the battery cell and symmetrically facing the edge of the width of the battery cell, while the first fluid end ports are located at the midpoint of the width of the battery cell. Preferably, the rhombus arrangement of the ports is for the fuel port; preferably, the intermediate ports are inlet ports for the first fluid volume, and the end ports are outlet or discharge ports for the first fluid volume. In this case, the second fluid intermediate port is for the oxidant and is preferably the inlet port for the second fluid volume.

[0059] Typically, the first fluid volume is the fuel volume, while the second fluid volume is the oxidant volume. The pressure drop across the length of the activated battery chemical region is generally more significant for the oxidant; therefore, preferably, the second external manifold fluid is the oxidant, as the overall gap between adjacent battery cells is larger than the gap between the metal substrate and separator within the battery cell, defining the second fluid volume. This means that in this case, the first fluid volume for fuel is contained or sealed within the battery cell and is in fluid communication with the first fluid intermediate passage and the first fluid end passage (if any). Furthermore, if the first fluid volume (enclosed by the battery cell) is to be accommodating to air, the gap between the metal substrate and separator must be increased, requiring more material to create a larger gap, thus increasing stacking costs.

[0060] In an alternative arrangement of the battery cell ports, there may be two pairs of first fluid end ports arranged in a cross shape, with a single first fluid intermediate port. The single first fluid intermediate port may be positioned in the middle along the length and width axes of the battery cell, and each of the first fluid end ports may be positioned towards a corner of the (rectangular or square) battery cell. In this case, there may be two second fluid intermediate ports, with the first fluid intermediate ports positioned between them. The second fluid may have end passages, and these second fluid end passages, in fluid communication with the volume of the second fluid, are configured to extend along the stacking direction at or near each opposite stack end; these passages are external manifold passages extending beyond each battery cell. Preferably, in this arrangement, the first fluid is fuel and the second fluid is an oxidant.

[0061] Ideally, the one or more first fluid intermediate ports are symmetrically arranged within the battery cell about one or both axes. The intermediate ports may be oriented towards the center of one or both of the length and width axes of the battery cell. This symmetrical positioning of the intermediate ports facilitates symmetrical flow into or out of the ports, resulting in a symmetrical fluid distribution and a uniform temperature distribution across the battery cell. This uniform temperature distribution across the battery cell, particularly in the activated battery chemistry regions, contributes to the uniform degradation of these regions throughout their lifetime.

[0062] When present, the one or more second fluid intermediate ports are preferably arranged symmetrically within the battery cell about one or both axes of the battery cell.

[0063] In one arrangement, there may be two first fluid intermediate ports and two second fluid intermediate ports. The two first fluid intermediate ports and the two second fluid intermediate ports may each be located on either side of a centerline along the length of the battery cell, and each of the first and second fluid intermediate ports is positioned towards each edge of the width of the battery cell. Therefore, there may be multiple pairs of intermediate ports, each pair having a first fluid intermediate port and a second fluid intermediate port, each pair facing each edge of the width of the battery cell. The center of each pair is at the middle of the length of the battery cell. Preferably, in the first pair, the first fluid intermediate port faces a first end of the length of the battery cell, and the second fluid intermediate port faces a second end of the length of the battery cell (the first end opposite the second end); and in the second pair, the first fluid intermediate port faces the second end of the length of the battery cell, and the second fluid intermediate port faces the first end of the length of the battery cell.

[0064] Preferably, at least one of the intermediate or end ports of the battery cell surrounds the one or more activated battery chemical regions.

[0065] The fluid port enclosing the activated battery chemistry region may include one or more of the following: at least one first fluid intermediate port, at least one second fluid intermediate port, and any present battery end port. Being enclosed means that the activated battery chemistry region at least partially surrounds the port (e.g., approximately beyond 90 degrees, 180 degrees, or approximately 360 degrees of the port). The shape of the edge of the activated region may match or reflect the shape of the edge of the port, such that the activated region at least partially surrounds the port. If the port is circular, the edge of the enclosed activated battery chemistry region is arc-shaped. The edge of the activated region may be equidistant from the port surrounding the enclosed region. Alternatively or additionally, the edge of the enclosed activated region may not be equidistant from the port; in particular, the radius defining the edge of the activated region may increase with distance from the port enclosed by the activated region.

[0066] This encapsulation of the activated battery chemistry region maximizes the area within the battery cell available for the activated battery chemistry region, thereby maximizing the power density in the stack. In other words, when the battery cell is viewed along its length from one end to the other, a specific location along this length is simultaneously occupied by both the port and the battery chemistry region (because the chemistry region extends around the intermediate or end port in question), which achieves a higher utilization rate than a battery whose chemistry region is limited to areas outside the port area.

[0067] If the activated battery chemistry region is a single region, the activated region can completely surround the intermediate port. The activated battery chemistry region can be spaced apart from the port to allow space for gaskets and / or molding port features. A barrier layer (e.g., an extended electrolyte layer) can extend below the gasket, and the gasket can contact the barrier (e.g., electrolyte) layer, thereby enabling the activated battery chemistry region to tightly surround the port.

[0068] As an alternative to or addition to the enclosure, one or more of the ports may extend in the width direction of the battery cell. For example, one or more of the ports may be rectangular, allowing the rectangle to surround the rectangular port. In this case, it may be preferable that the middle port is rectangular, as this allows for an increase in the proportion of the battery cell region where the activated battery chemistry region is located, without having to enclose the activated battery chemistry region. The same applies to the end ports.

[0069] In a battery cell, one of the first or second fluid volumes is defined by a planar component having an elongated shape that extends at least partially around the periphery of the activated battery chemistry region to confine the fluid flow path within this region.

[0070] Preferably, the planar component is a metal component. The planar component may be an interconnect plate, current collector, separator, battery chemistry support substrate, etc. The elongated feature is used to guide and retain fluid within one or both of the fluid volumes. That is, the elongated feature significantly reduces air bypass around the sides of the battery cell (air bypass around the sides of the battery cell cannot participate in the chemical reactions of the activated battery chemistry region).

[0071] The elongated shape feature may include a feature in the planar component that forms a protruding rib on one side of the component and a channel on the other side of the component. This protruding rib on one side of the component can confine the flow path of the first or second fluid within the activated battery chemistry region, and extends as a channel on the other side to facilitate a flow path along the periphery of this region, thereby delivering fluid to the distal edge of the region. The elongated shape feature, including the feature of forming a protruding rib on one side of the component and a channel on the other side of the component, may be a pressed or molded feature.

[0072] The ribs protrude into a fluid volume and are used to contain a fluid (either fuel or oxidant) within the fluid volume (otherwise they would pass around the sides of the battery cell). The ribs may form recesses in a second fluid volume, which forms a supply channel to supply a second fluid, namely the other of the fuel and oxidant.

[0073] The ribs may be shaped or pressed features, in which case the ribs form recesses in a second fluid volume, which forms supply channels to supply a second fluid, namely, another of fuel and oxidant. The ribs may be shaped or pressed features on interconnect plates or separator plates and protrude toward adjacent battery cells in the stack.

[0074] Typically, the ribs or elongated features contact the electrolyte or cathode layer of the activated battery chemistry region or the electrolyte outside the adjacent battery region. Therefore, a fluid volume is formed between the interconnect or separator and the activated battery chemistry region of the adjacent battery cell. The protruding side of the ribs or elongated features serves to contain the fluid within the fluid volume formed between the interconnect or separator and the activated battery chemistry region of the adjacent battery cell, preventing fluid from leaving the battery to the side of the battery cell.

[0075] Preferably, the ribs or elongated features protrude into the fluid volume, which has an external manifold passage extending beyond the end of each battery cell. In this case, the ribs serve to confine and guide fluid between the respective end of the battery cell and the fluid intermediate port. More preferably, the ribs or elongated features protrude into the oxidant volume, and opposite sides of the ribs or elongated features form fuel supply channels in the relative fluid volume.

[0076] The ribs or elongated features may include a pair of such ribs or elongated features aligned with the edges of the porous region or activated battery chemistry region in the stack. Each rib or elongated feature is disposed on the edge of the porous region or activated battery chemistry region and is therefore substantially aligned with the edge of the battery cell.

[0077] Each rib or elongated feature may be continuous along the length of the battery cell. Alternatively, each rib or elongated feature may be discontinuous, with the discontinuity caused by a fluid intermediate port. The discontinuous ends of the ribs or elongated features may be close to a gasket or molded port feature that forms part of an intermediate fluid passage, such that the ribs or elongated features and the gasket or molded port feature cooperate to contain the fluid within the fluid volume.

[0078] Discontinuous ribs or elongated features may also bend towards the center of the battery cell at the ends of the ribs or elongated features near the intermediate ports. For example, the ribs or elongated features may bend to match a curve in the edge of the activated battery chemistry region, for example, to match a curve or the activated battery chemistry region around the port. In this case, the ribs or elongated features should be sized such that on their side as a channel, they deliver fluid (e.g., fuel) to the corner of the activated battery chemistry region at the end of the battery cell. This is particularly preferred when the battery cell includes two first fluid intermediate ports (arranged towards opposite edges of the battery cell), wherein at least one second fluid intermediate port is disposed between them, the intermediate ports being aligned along the middle of the length of the battery cell, and the first and second first fluid end ports are respectively disposed at or near each opposite battery end (i.e., similar to or identical to the “diamond” configuration described herein). In such a battery cell, the discontinuous ribs may bend towards the second fluid intermediate port in the region near the ends of the first fluid intermediate ports, and the ends of the ribs are close to a gasket in the second fluid volume. In this configuration, the ribs can form protrusions in the second fluid volume and depressions in the first fluid volume. Therefore, the curved ribs prevent the second fluid from bypassing the second fluid volume while providing a fluid delivery channel for the first fluid, improving regional supply to the battery chemistry region near the corners of the battery cell, thereby preventing fuel shortages in that region. This has proven to improve the uniformity of fuel supply to remote areas more effectively than initially anticipated.

[0079] In cases where one of the fluid volumes has multiple intermediate ports, partitioning by extending from specific intermediate ports—for example, through battery separator ribs or 3D-shaped structures (as soft barriers) or welded elements (as hard or absolute barriers)—can be used to ensure that fluid flows only to specific portions of the activated battery chemistry region. In cases with multiple chemistry regions, such partitioning can be used to ensure that the activated battery chemistry region has a dedicated intermediate port supply path, supplying fluid only to that specific chemistry region (e.g., a region on one half of the battery), while another intermediate port provides a dedicated supply path, supplying fluid only to the remaining activated battery chemistry regions. While this can be beneficial, it is not without risk, as a failure to supply fluid within a dedicated fluid path can lead to insufficient fuel in only the associated partitioned area, resulting in the failure of a portion of the battery / stack.

[0080] In one embodiment, the battery cell includes:

[0081] Divider; and

[0082] A metal support plate, on its first side, supports an activated battery chemical region disposed on a porous region;

[0083] The metal support plates are stacked on top of each other to form the battery cell;

[0084] in:

[0085] At least one of the partition plate and the metal support plate includes a flanged peripheral feature formed by pressing the plate into a concave configuration;

[0086] The partition plate and the metal support plate are directly abutted at the peripheral feature with flanges to form the first fluid volume therebetween, optionally by welding;

[0087] At least one fluid port is provided in each of the partition plate and the metal support plate, the ports being aligned to form the first fluid passage within the flanged peripheral feature, each port being either a first fluid intermediate port and / or a first fluid end port and communicating with the first fluid volume; and

[0088] At least one of the partition plate and the metal support plate is provided with a shaped port feature formed by pressing around the at least one fluid port, the shaped port feature extending toward the other plate, and the elements of the shaped port feature being spaced apart from each other to define a fluid path between the elements from the port so that fluid can flow from the at least one first fluid port to the first fluid volume.

[0089] The battery cell may consist of only two layers / components, namely a metal support plate and a separator, instead of a metal support plate, spacers, and separators, while ultimately operating in essentially the same manner, with each battery cell having essentially the same output per square centimeter of electrochemically activated layer. This simplifies the number of components that need to be supplied and processed (e.g., coated), simplifies assembly, and directly reduces the amount of material required, thereby reducing the material cost and weight of each fuel cell cell.

[0090] The concave configuration allows the associated plate to have the appearance of a framed tray, with a correspondingly convex external shape (relative to the exterior of the fuel cell unit) and typically a planar base, thus defining (e.g., partially) the fluid volume within the assembled battery unit. In this concave configuration, the flanged peripheral features extend beyond the plane of the original sheet of the separator and / or the metal support plate, toward the corresponding opposing surface of the other of the separator and the metal support plate. Therefore, the fluid volume is defined by the shaped flanged peripheral features, which are formed by pressing, such as by using molding, hydroforming, or stamping. These processes are simple processes for forming a central protrusion in the fluid volume, as also found in separators in the prior art, for supporting and electrically connecting adjacent fuel cells via the electrochemically activated layer. Therefore, such centrally inward and outward protrusions can also be pressed from the original sheet for the separator before or after the flanged peripheral features and the shaped features, but more preferably simultaneously.

[0091] In some embodiments, the porous region is formed by holes drilled into the metal support plate—typically laser-drilled holes.

[0092] In some embodiments, the (activated) fuel cell chemistry layer takes the form of an electrochemically activated layer, which includes an anode, electrolyte, and cathode formed (e.g., coated or deposited) on a metal support plate disposed within the porous region. This arrangement of a (non-self-supporting, thin) chemistry layer directly disposed on the metal support plate requires a minimal number of components. Therefore, the metal support plate performs a dual function of supporting the battery chemistry region and defining the fluid volume (together with the separator). Furthermore, it should be understood that both the metal support plate and the separator have a side exposed to the oxidant and a side exposed to the fuel, and are therefore components subjected to harsh dual atmospheric conditions.

[0093] In other embodiments, the porous region is disposed on a separate plate (e.g., a metal foil) on which the fuel cell chemistry layer is formed (e.g., coated or deposited), and the separate plate (carrying the fuel cell chemistry layer) is disposed above a window (e.g., a frame) on the metal support plate.

[0094] The fuel cell chemistry layer can have multiple regions. For example, the metal support plate can have multiple regions of small holes, each covered by a separate electrochemical activation layer. Alternatively, the metal support plate can have multiple windows, and multiple separate plates of activated cell (fuel cell) chemistry layer formed on (above) these windows.

[0095] The individual plates, or each individual plate, can be welded to the metal support plate above the window in the metal support plate.

[0096] In the stack, at least one additional fluid port may be provided in each of the partition plate and the metal support plate. These ports are aligned to form a second fluid passage within the flanged peripheral feature. Each port is a second fluid intermediate port and / or a second fluid end port and communicates with a second fluid volume on a second side of the metal support plate. The second fluid passage is separately sealed from the first fluid volume. Optionally, this is achieved by providing a weld around the second fluid port. The port may also optionally be provided with an annular flange, which is formed by pressing an annular region around the port in at least one of the partition plate and the metal support plate.

[0097] In a preferred embodiment, the first and second fluid flow paths are arranged in a co-flow configuration within the activated battery chemistry region. The fluids can flow in a co-flow configuration, whereby both the first and second fluid flow paths originate from the respective ends of the battery cell to the center of the battery cell, and vice versa. That is, from the end fluid passage to the middle passage, and vice versa.

[0098] Alternatively, the fluids can be arranged in a counterflow pattern, whereby the first fluid flow path is from each end of the battery cell to the center of the battery cell, and the second fluid flow path is from the center of the battery cell to each end of the battery cell, and vice versa. That is, the first fluid flow path is from the central passage to the end passage, and the second fluid flow path is from the end fluid passage to the central passage, and vice versa.

[0099] Alternatively, the fluids can be arranged in a co-counter-flow configuration, whereby the first fluid flow path extends from the corresponding end of the battery cell to the center of the battery cell (or vice versa), while the second fluid flow path extends from one end of the battery cell to the other end. In other words, the first fluid flow path extends from the intermediate passage to the end passage (or vice versa), while the second fluid flow path extends from the end fluid passage to the intermediate passage.

[0100] Alternatively, the fluids can be arranged in a cross-flow configuration, whereby the first fluid flow path extends from each end of the battery cell to the center of the battery cell (or vice versa), and the second fluid flow path is substantially perpendicular to the first fluid flow path, extending from one long side of the battery cell to the opposite long side of the battery cell. That is, the first fluid flow path extends from the central passage to the end passage (or vice versa), and the second fluid flow paths originate from and flow towards the internal or external manifold-side fluid passages, which are respectively located at or near the long side of each opposite battery cell.

[0101] The co-current arrangement is preferred because it causes the hottest portion of the battery cell region to face towards the ends of the battery cell, whereas in the counter-current arrangement, the hottest portion of the battery cell faces towards the center of the activated battery chemistry region (midway between the middle port and the ends of the battery cell). Therefore, for counter-current, the measured discharge fluid temperature better reflects the hottest temperature of the stack, an important parameter as excessive heat can lead to battery cell failure. Furthermore, in counter-current, the hottest temperature is typically higher than in co-current (all other parameters being equal), thus requiring a higher cooling fluid flow rate (typically using an oxidant flow) in the counter-current arrangement, thereby increasing parasitic losses of the fan or pump in the co-current arrangement.

[0102] In an alternative arrangement, there may be two first fluid intermediate ports and two second fluid intermediate ports. Each of the two first fluid intermediate ports and the two second fluid intermediate ports is located on either side of the length of the battery cell, and each of the first and second fluid intermediate ports is positioned towards each edge of the width of the battery cell. Therefore, there are multiple pairs of intermediate ports, each pair having a first fluid intermediate port and a second fluid intermediate port, each pair facing each edge of the width of the battery cell. The center of each pair is located at the middle of the length of the battery cell: in the first pair, the first fluid intermediate port is positioned from the middle towards a first end of the battery cell, while in the second pair, the first fluid port is positioned from the middle towards a second end of the battery cell, with the first end opposite the second end.

[0103] In an alternative arrangement, there may be a first fluid intermediate port and a second fluid intermediate port. The first fluid intermediate port faces a first edge of the width of the battery cell, and the pair of first fluid end ports are respectively located at each end of the length of the battery cell and facing a second edge of the width of the battery cell. The second fluid intermediate port is located facing a second edge of the width of the battery cell, and the pair of second fluid end ports are respectively located at each end of the length of the battery cell and facing a first edge of the width of the battery cell. Therefore, there are V-shaped arrangements for the first fluid port and V-shaped arrangements for the second fluid port.

[0104] In a preferred arrangement, the first fluid is a fuel and the second fluid is an oxidant, and the stack comprises rectangular (including elongated and square) planar electrochemical cell units, each cell including two first fluid intermediate ports disposed along its length at the midpoint of one or more activated cell chemical regions and in fluid communication with a first fluid volume of the cell, wherein the stack is configured such that, in each first fluid volume, a first fluid flow path extends (in opposite directions) through one or more activated cell chemical regions between the at least one first fluid intermediate port and each corresponding opposite cell end. In this arrangement, the stack may further include a second fluid intermediate port disposed along the midpoint of the length of the cell within one or more activated cell chemical regions and in fluid communication with a second fluid volume of the cell, wherein the second fluid intermediate port is disposed between the two first fluid intermediate ports, wherein the stack is configured such that, in each second fluid volume, a corresponding second fluid flow path extends (in opposite directions) through one or more activated cell chemical regions between the at least one second fluid intermediate port and each corresponding opposite cell end.

[0105] In this arrangement, the stack may further include first fluid end passages in fluid communication with the first fluid volume, extending in the stacking direction at or near each opposite stack end and along the midpoint of the width of the battery cell. These passages are internal manifold passages defined by first and second first fluid end ports aligned within each battery cell. The stack may also include second fluid end passages in fluid communication with the second fluid volume, extending in the stacking direction at or near each opposite stack end. These passages are external manifold passages extending beyond each battery cell.

[0106] Preferably, the first fluid intermediate ports of each corresponding battery cell are aligned to form at least one first fluid intermediate passage extending along the stacking direction. Preferably, the second fluid intermediate ports of each corresponding battery cell are aligned to form at least one second fluid intermediate passage extending along the stacking direction.

[0107] The battery cell may be a rectangular (e.g., elongated or square) fuel or electrolytic battery cell having at least one fuel intermediate port and one oxidant intermediate port. The intermediate port may be located in the middle along the length of the battery cell, thereby dividing the activated battery region into two halves, and at least one of a pair of fuel end ports is respectively located at each end of the length of the battery cell; and / or at least one pair of oxidant end ports is respectively located at each end of the length of the battery cell; such that the battery is configured to have a fuel flow path and an oxidant flow path, each flow path extending in opposite directions from the respective intermediate port to a respective corresponding opposite end port or a respective battery cell end, thereby forming an external manifold. The battery cell may include two planar members, each providing a port. The two planar members define or surround a first fluid volume therebetween. One of the intermediate ports may be provided with a port feature in the form of an annular protrusion protruding from one or both of the planar members toward the other planar member (i.e., within and through the first fluid volume), such that the port feature in one planar member abuts or contacts the other planar member. A weld line can be provided around the raised port feature to seal the port and prevent fluid communication with the first fluid volume. The port in fluid communication with the first fluid volume (e.g., the first fluid intermediate port) can be provided with a raised port feature surrounding the port, extending from one or both of the planar components into the first fluid volume to contact another planar component in the planar components, resisting stacking compressive forces while allowing fluid communication between the port and the fluid volume. These ports can also be provided with annular raised features in one or both of the planar components, extending away from another planar component in the battery cell. These raised features are adapted to contact adjacent battery cells in the stack to seal the port (with the weld line surrounding the raised feature) to prevent fluid communication between the port and the fluid volume defined between the port and the adjacent battery cell.

[0108] The battery stack can be an electrochemical battery stack comprising a plurality of planar batteries stacked on top of each other, wherein each battery: has a length greater than its width; includes at least one intermediate battery port disposed along the middle of the length of the stack; includes at least first and second end battery ports respectively disposed at or near each opposite end of the length of the battery; includes at least one activated battery chemical region comprising an electrolyte disposed between an air electrode and a fuel electrode; and includes an air fluid volume and a fuel fluid volume respectively communicating with each of the air electrode and the fuel electrode. The respective intermediate battery ports can be aligned to form an internal fluid intermediate passage extending along the stack direction and connected to the respective air fluid volume or the respective fuel fluid volume of the battery. The respective first and second end battery ports can be aligned to form respective first and second internal fluid end passages, each extending along the stack direction and connected to the same fluid volume. The intermediate passage and the end passage can respectively form an inlet passage and an outlet passage for the fluid volume, or vice versa, to define opposing flow paths within the volume extending through each battery between each intermediate battery port and its respective corresponding end port.

[0109] In one example, the battery cell includes an inherent shape feature (e.g., a flanged peripheral feature) that creates a fluid volume within the battery cell. The battery cell may include the flanged peripheral feature, and the battery cell may be sealed around the flanged peripheral feature to form a first fluid volume. Sealing can be achieved by welding around the flanged peripheral feature. Welds can also be used around the intermediate and end ports to seal the first fluid volume separately from the second fluid volume. The battery may include a metal substrate and spacers, at least one of which has the flanged peripheral feature. This reduces the number of components because spacers are not required, thus reducing material waste. It also facilitates the electrical connection of the two metal plates.

[0110] The fluid ports are configured to pass through the opening of each of the battery cells (i.e., through each of the metal substrate and separator of each battery cell), with the respective fluid ports aligned with each other along the stacking direction to form a fluid passage that communicates with the respective fluid volume.

[0111] Preferably, the battery cell (i.e., at least one of the metal substrate and the separator) is provided with a molded port feature formed by a port extending inwardly around the battery cell, the elements of the molded port feature being laterally spaced from each other to define a fluid passage between the elements of the port, allowing fluid to flow from the port to a fluid volume enclosed by the battery cell. The molded port feature is also preferably formed by pressing.

[0112] At least one of the metal substrate and the separator may be provided with shaped port features formed around its port and extending outward away from the fluid volume surrounded by the battery cells. When multiple such battery cells are stacked adjacent to each other, such features can be used to laterally position sealing gaskets disposed between the battery cells, or such features can be connected to adjacent plates (metal substrate and separator) to form rigid stops to limit compression of gaskets disposed between or within the battery cells, or can form surfaces on which sealant or the like can be formed in situ. Within the battery stack, the metal substrate can be electrically connected to adjacent separators, so these shaped port features can be welded to adjacent metal substrates or separators, conveniently providing electrical connection and achieving port / manifold sealing.

[0113] A support structure can be provided within the fluid volume surrounded by the battery cells to help maintain the spacing between the metal substrate and the separator. The support structure can be permeable and only needs to be exposed to a fluid environment that is uniform across its surface area. This reduces the thermal and chemical requirements of the support structure. The innermost electrode (closest to the supporting metal substrate) can be electrically connected via the metal substrate, while the outermost electrode can be electrically connected via a current collector structure. The current collector structure can be a permeable support structure and only needs to be exposed to a fluid environment that is uniform across its surface area. This reduces the thermal and chemical requirements of the current collector structure.

[0114] Alternatively, the separator may include recesses formed or pressed therein, extending toward and / or away from the activated battery chemistry region of the battery cell. These recesses help maintain the spacing between the metal substrate and the separator, and collect current from the activated battery chemistry region.

[0115] For example, when the fluid volume is a fuel volume, a catalyst may be provided within the support structure or partition plate facing the activated battery chemistry region within the fluid volume surrounded by the battery cell to promote internal reforming. Alternatively, when the fluid volume is a fuel volume, if no support structure is provided within the fluid volume, such a catalyst may be provided on the surface of the metal substrate.

[0116] These and other features of the invention will now be described in further detail, with reference to the accompanying drawings (which are not drawn to scale and whose height dimensions are exaggerated for clarity), through various embodiments and by way of example only, in which:

[0117] Figure 1 An exploded view of a prior art fuel cell unit is shown;

[0118] Figures 2a to 2c A battery cell including spacers according to the present invention is shown;

[0119] Figures 2d to 2f An alternative spacerless battery cell according to the present invention is shown;

[0120] Figure 2g Another spacerless battery cell according to the present invention is shown;

[0121] Figure 3a and Figure 3b A perspective view and a cross-sectional view of a fluid port with shaped port features and a flange are shown respectively.

[0122] Figure 4a and Figure 4b The plan view and cross-sectional view of the battery cell in Figure 2 are shown respectively, which illustrate the fluid flow path between the fluid ports. Figure 4c Figure e shows Figure 4a Different fluid flow directions in the battery cells. Figure 4f A plan view of a battery cell with curved ribs is shown.

[0123] Figure 5 A plan view of a battery cell with a wrapped electrochemical activation layer is shown.

[0124] Figure 6 A plan view of a battery cell with a port having a rectangular cross-section is shown.

[0125] Figure 7 A plan view of a battery cell similar to that in Figure 4 is shown, in which a second fluid forms a manifold inside.

[0126] Figure 8a and Figure 8b A plan view of a battery cell with a single electrochemically activated layer region is shown.

[0127] Figures 9a to 9c A plan view of a battery cell with a single electrochemically activated layer region and a co-current arrangement for the first and second fluids is shown.

[0128] Figure 10a andFigure 10b A plan view of a battery cell with a single electrochemically activated layer region is shown, wherein the first fluid and the second fluid are arranged in an alternating flow pattern.

[0129] Figures 11a to 11c A plan view of a battery cell with a first fluid end port arranged toward each corner of the battery cell is shown.

[0130] Figures 12a to 12c A plan view of a battery cell with two first fluid intermediate ports and two second fluid intermediate ports is shown.

[0131] Figures 13a to 13c A plan view of a battery cell is shown, comprising a first fluid end port, two first fluid intermediate ports, and two second fluid intermediate ports arranged at each corner of the battery cell; and, Figures 14a to 14c A plan view of the battery cell, including two metal support plates, is shown.

[0132] Figure 2a A first example of a battery cell 200 is shown, which, like batteries in the prior art, is a sample including spacers (i.e., three component layers).

[0133] The battery cell 200 has a substrate in the form of a rectangular metal support plate 205, on which two separate activated battery chemical regions, namely electrochemical activation layers 210, are deposited. The two electrochemical activation layers 210 are arranged side by side.

[0134] Figure 2b It is along Figure 2a A longitudinal side section view of the battery cell 200. Figure 2b The electrochemical activation layer 210 is shown in more detail. Each cell 200 includes battery chemical layers 211, 212, and 213 deposited or coated on a metal support plate 205 to form the electrochemical activation layer 210. The anode layer 213, electrolyte layer 212, and cathode layer 211 are sequentially deposited on the porous region 214. However, in some cell arrangements, this order may be reversed (so that the cathode layer is closest to the substrate).

[0135] The metal support plate 205 is a metal (e.g., ferritic stainless steel) foil. The porous region 214 includes an array of through holes formed by drilling (or other means, such as etching), which extends from a first side 225 of the metal support plate 205 to the opposite side (second side 226) of the metal support plate 205 and is surrounded by the porous region.

[0136] The anode layer 213, electrolyte layer 212, and cathode layer 211 can be formed by deposition, for example, by chemical vapor deposition, electrostatic deposition, spray deposition, spin coating deposition, powder deposition, etc., on a metal substrate 205. This process can be a two-stage process, first depositing powder or particulate material, followed by sintering or other treatments to form each layer of the solid oxide battery. Each layer is thin, therefore none is self-supporting; that is, a metal substrate is needed to support the solid oxide chemical layers. Other barrier layers can also be provided, such as an extended electrolyte layer 215.

[0137] The electrochemically activated layers 210 can be formed directly on the metal substrate 205, or they can be formed on a separate porous metal substrate, which can be attached to the window frame substrate. In the latter case, the two separate electrochemically activated layers shown in FIG. 2 can be formed on two separate porous metal supports. However, this requires more components and more manufacturing steps.

[0138] Return to Figure 2a The battery cell has two first fluid intermediate ports 230a and 230b for supplying or removing first fluid into or from a first fluid volume, and a single second fluid intermediate port 235 for supplying or removing second fluid into or from a second fluid volume. The first fluid intermediate ports 230a and 230b and the second fluid intermediate port 235 are disposed between two electrochemical activation layers (or regions) 210 and are located in the middle of the length of the battery cell.

[0139] The second fluid intermediate port 235 is substantially centered along the first (longer) axis of the metal support plate 205 because it lies between the two electrochemically activated layers 210. The single second fluid intermediate port 235 is also substantially centered along the second (shorter) axis of the metal support plate 205 because it lies between the two first fluid intermediate ports 230a and 230b. Therefore, the second fluid intermediate port 235 is substantially centered within the metal support plate 205.

[0140] The first fluid intermediate ports 230a and 230b are substantially centrally located along the first (longer) axis of the metal support plate 205 because they are situated between two electrochemically activated layers 210 equidistant from the ends of the two cells. The first fluid intermediate ports 230a and 230b are disposed on either side of the second fluid intermediate port 235 away from the center of the second (shorter) axis; the first fluid intermediate port 230a is disposed toward the first (longer) edge of the metal support plate 205, and the first fluid intermediate port 230b is disposed toward the second (longer) edge of the metal support plate 205.

[0141] Sufficient distance is provided between intermediate ports 230a, 230b, and 235, and between intermediate ports 230a, 230b, and 235 and the electrochemical activation layer 210, to allow for positioning of gaskets or molding of port features around the ports. However, the gaskets may contact and be located on the barrier layer (e.g., an extended electrolyte layer (not shown) extending beyond the electrochemical activation layer 210).

[0142] The battery cell 200 also includes a pair of first fluid end ports 240a and 240b, one of which is disposed at each end of the first (long) axis of the battery cell 200. The first fluid end ports are used to supply or remove first fluid from the battery cell. The first fluid end ports 240a and 240b are closer to the ends of the first (long) axis of the battery cell 200 than the electrochemical activation layer 210. Therefore, the ports 230 and 240 for the first fluid are arranged in a diamond shape.

[0143] The external manifold 245 represents the volume between the end of the battery cell 200 (i.e., the end of the metal support plate 205) and the inner edge of the housing, the inner edge of which includes a stack of multiple battery cells 200. A second fluid can be supplied to or removed from the battery cell 200 through the external manifold 245.

[0144] Figure 2a The diagram also shows some dimensions of the electrochemical activation layer 210 and the extent of the battery cell. Each electrochemical activation layer is characterized by a minimum length x1 spanning the electrochemical activation layer between the opposite edges of the electrochemical activation layer near the middle port and the end port. The minimum length x1 may generally be parallel to the two edges of the electrochemical activation layer and / or generally perpendicular to the other two edges of the electrochemical activation layer. The length x1 is parallel to the main component of the fluid flow path between the middle port and the end of the battery cell (see further in Figure 4). Each electrochemical activation layer is also characterized by a minimum width y1 across the electrochemical activation layer, which is perpendicular to the length x1 and perpendicular to the main component of the fluid flow path. The length x1 and the width y1 together define the aspect ratio of the electrochemical activation layer as aspect ratio = x1 / y1. In one example, the aspect ratio is less than or equal to 1.2.

[0145] The battery cell is characterized by its length x2, which is generally parallel to the main component of the fluid flow path (i.e., parallel to the line from the middle port 235 of the battery cell to the end). The battery cell is also characterized by its width y2, which is generally perpendicular to the main component of the fluid flow path (i.e., parallel to the line from the middle port 235 of the battery cell to the end). In one example, the ratio x2 / y2 is less than or equal to 2.4.

[0146] Figure 2b It is alongFigure 2a A side cross-sectional view of line AA of the battery cell 200. The battery cell 200 is a sample or repeatable cell, including a metal support plate 205 on which an electrochemically activated layer 210 is deposited or coated, and a separator plate 255 separated from a second side (i.e., the side not carrying the electrochemically activated layer 210) of the metal support plate 205 by a spacer or gasket 260, thereby giving the sample a closed first fluid volume 280. The spacer or gasket 260 may be similar to Figure 1 The existing spacer 13 is a frame-like component. The separation is also maintained by a molded port feature or gasket 261. If the molded port feature or gasket 261 is a molded port feature, it is a continuous raised annular structure welded or otherwise sealed (e.g., using a gasket or sealant) to seal the passage in question. The molded port feature will be described further with reference to FIG3. The spacer or gasket 260 and the molded port feature or gasket 261 seal the first fluid (in the first fluid passage and supplied to the first fluid volume 280 through the first fluid ports 240a, 240b) separately from the second fluid (in the second fluid passage and supplied to the second fluid volume 285 through the second fluid port 235), thereby preventing mixing. This seal can be achieved by welding or brazing through the specimen (i.e., through all the metal support plates 205, spacers or gaskets 260 and 261, and the separator 255) – such a weld line will be similar to the one described later. Figure 2d (Those weld lines shown in the variant). See also the later sections. Figure 4b It shows a gasket 262 sealing the end ports 240a, 240b in a second fluid volume 285 surrounding the first fluid end passages 240a, 240b.

[0147] A fluid passage for the first fluid is formed by a first fluid port in the metal support plate 205, a corresponding hole through the partition plate 255, and an associated gasket or separator. A first fluid intermediate passage is formed by a first fluid intermediate port 230a and a corresponding hole through the partition plate 255 and an associated gasket or separator. A second fluid intermediate passage is formed by a second fluid intermediate port 235 and a corresponding hole through the partition plate 255 and an associated gasket or separator 261. A first fluid end passage is formed in the region of the metal support plate 205 by a first fluid end port 240a, a corresponding hole through the partition plate 255 and an associated gasket or separator 260, and a gasket 262. Figure 4b ).

[0148] Spacers or gaskets 260 and 261 can be conductive, thereby providing an electrical interconnection between the metal support plate 205 and the partition plate 255 of the specimen or repeating unit. Conductivity can be improved by specimen welding or brazing.

[0149] The partition between the metal support plate 205 and the partition plate 255 defines a first fluid volume 280. Figure 2b In the arrangement shown, the anode layer is closest to the metal support plate 205, the first fluid volume is the fuel volume, and the second volume is the oxidant volume (when operating in SOFC mode).

[0150] The separation between the metal support plate 205 and the partition plate 255 can also be maintained by the support structure 265. Elements of the support structure 265 may be integral with the partition plate 255 (corrugated or pressed interconnects / bipolar plates with pressed features such as channels or pits, as is well known in the art) and may appear as multiple domes, but may have other cross-sectional shapes such as pyramids, flat-topped pyramids, cones, domes, or protrusions. Elements of the integral support structure 265 protrude from the partition plate 255 toward the metal support plate 205 of the sample and contact a second side of the metal support plate 205 (the side where the electrochemical activation layer 210 is not deposited or coated). Alternatively, the support structure 265 may be a separate component, in which case it may include mesh, expanded metal, or a combination thereof.

[0151] The support structure 265 can be a conductive support structure for electrically interconnecting the metal support plate 205 and the partition plate 255, which can eliminate the need to use spacers or gaskets 260 and 261 to electrically interconnect the metal support plate 205 and the partition plate 255.

[0152] An integral second support structure 266 protrudes from the metal support plate 205 of the separator 255 away from the specimen. Elements of the support structure 266 are shown as multiple domes, but may have other cross-sectional shapes, such as pyramids, flat-topped pyramids, cones, domes, or protrusions. Alternatively, the second support structure 266 may be a component separate from the separator 255, in which case it may include mesh, expanded metal, or a combination thereof.

[0153] The second support structure 266 is typically a conductive support structure to enable interconnection between adjacent samples.

[0154] An integral support structure 265 and support structure 266 can be formed in the partition plate 255 by pressing or shaping the support structure 265 along a first direction and by pressing or shaping the support structure 266 along a second direction. The first direction faces the second side of the metal support plate 205 (the side where the electrochemical activation layer 210 is not deposited or coated), and the second direction is opposite to the first direction, i.e., the second direction faces the electrochemical activation layer 210 of the adjacent sample. The shaping or pressing process refers to the presence of a recess (not shown) on the side of the partition plate 255 opposite to the protrusion that serves as the support structure 265 or the second support structure 266.

[0155] Figure 2c It shows Figure 2a Battery cell 200 along Figure 2a The cross-sectional view of line BB. Therefore, Figure 2c The cross-sectional view is perpendicular to Figure 2b The cross-sectional view shown is shown. However, only one additional battery cell 200b is shown in this view to illustrate how the battery cells are interfaced along the stacking direction.

[0156] A pair of ribs 270a and 270b in Figure 2c The ribs 270a and 270b are elongated protrusions that extend from the separator 255 away from the metal support plate 205 of the battery cell or sample 200 (i.e., toward the electrochemical activation layer 210 of the adjacent battery cell), thus projecting in the same direction as the second support structure 266. The ribs 270a and 270b are shown as having a pyramidal cross-section, but may have other cross-sectional shapes, such as domes, and may have flat or rounded tops. The ribs are elongated compared to the support structure 265 and the second support structure 266. The ribs extend along the long axis of the battery cell 200 (in and out). Figure 2c The plane), and its size and position are set to contact the electrochemical activation layer of the adjacent battery cell or sample 200 (which will be further described with reference to FIG4).

[0157] Rib 270 is integrally formed with partition plate 255 and is formed by pressing partition plate 255 or molding partition plate 255. Therefore, rib is a protrusion away from metal support plate 205 and also a channel on the side of partition plate 255 facing metal support plate 205. Therefore, it is important that rib forms a channel in the first fluid volume 280 and a protrusion in the second fluid volume (which will be further described with reference to FIG4).

[0158] The distal end or peak of the rib 270 of the first battery cell 200a is arranged to contact the electrochemically activated layer 210 of the adjacent battery cell 200b, and to make contact at or near the edge of the electrochemically activated layer 210. If the rib contacts the cathode layer 211, it is used to collect current from the battery cell (together with the conductive second support structure 266). Alternatively, the rib 270 may only contact the electrolyte layer 212 (because the cathode layer 211 typically has a smaller extent than the electrolyte layer 212). Because the rib 270 contacts the electrochemically activated layer 210, it is not necessary to deposit a non-conductive coating (or provide a non-conductive layer), which would be necessary if the rib contacted the metal support plate 205.

[0159] Figures 2d to 2fAlternative battery cells or specimens 201a and 201b are shown, comprising only two component layers, namely plates, namely a metal support plate 205 and a separator plate 255. Any separator plates are omitted, and the first fluid volume 280 (e.g., fuel volume) is generated by using flange features and shaped port features, which will be described below.

[0160] Figure 2d It is a floor plan, and Figure 2e and Figure 2f Cross-sectional views of stacked, spacerless battery cells or samples 201a and 201b are shown. Figure 2b and Figure 2c As shown, each battery cell 201a, 201b includes a metal support plate 205 deposited or coated with an electrochemical activation layer 210, a separator plate 255, and a support structure 265 integral with or separate from the separator plate 255, and a second support structure 266. Ribs 270a, 270b are similar to those in the reference section. Figure 2c The ribs are described. It is clear that the ribs 270a and 270b are in contact with the electrochemically activated layer 210 near the edge of the layer.

[0161] like Figure 2e and Figure 2f As shown, the peaks or ends of the second support structure 266 and the ribs 270 of the battery cell 201a contact the electrochemical activation layer 210 of the adjacent battery cell 201b to separate the battery cell 201a from the adjacent battery cell 201b. This creates a second fluid volume 285. As described above, the elements of the second support structure 266 are dome-shaped, pyramidal, or conical (or similar shapes), thus not restricting the movement of the second fluid within the second fluid volume 285. However, the ribs are elongated, thus restricting the flow of the second fluid (e.g., an oxidant) from the second fluid volume along a direction perpendicular to the long axis of the ribs.

[0162] Battery cells 201a and 201b are further shown having a flanged peripheral feature 275 surrounding their periphery. The flanged peripheral feature 275 extends out of the main plane of the separator 255 and the metal support plate 205, as found in the central fluid volume region, to form concave surfaces (and convex surfaces on the outer surfaces) in the separator 255 and the metal support plate 205. The concave surfaces form a first fluid volume 280 within the fuel cell cell during fuel cell cell assembly and allow the battery cell to be formed as a spacer-free specimen, thereby reducing the number of components.

[0163] The flanged peripheral feature 275 can be formed by pressing or molding, and it can be formed simultaneously with the support structure 265 and the second support structure 266. The flanged peripheral feature 275 is shown in the metal support plate 205 and the partition plate 255, but it can also be formed in either the metal support plate 205 or the partition plate 255. Since it is difficult to coat the molded metal support plate with battery chemicals, it is more convenient to omit the flanged peripheral feature.

[0164] Figure 2d A weld line 239 is shown around the flanged perimeter, sealing the first fluid volume of the specimen. (The weld is shown as a dashed line in the plan view and as a triangle for a pile weld in the cross-section). A weld line 237 is also provided around the second fluid intermediate port 235 to seal the first fluid volume 280 separately from the second fluid volume 285.

[0165] exist Figure 2e In the first fluid end ports 240a, 240b, convex hard stop features 253 extending toward adjacent battery cells are provided. Such port features formed around these end ports require an insulating layer between battery cells: an insulating, compressible sealing gasket (e.g., located within the annular hard stop 253) can be provided, or a sealant can be applied to the hard stop and cured in situ to form an insulating layer.

[0166] The flanged peripheral feature 275 is used to make Figure 2b , Figure 2c The spacer or gasket 260 becomes redundant. Gaskets or spacers (such as...) Figure 2b The gasket or spacer 261 can be held around the port. Or, as Figures 2d to 2f As shown, the molded port feature 238 can also be formed around each port to replace the spacer, and in some examples, the gasket can also be replaced by the molded port feature.

[0167] In the following text, Figure 3a and Figure 3b How can the molding port features be provided around Figure 2a and Figure 2dThe details and examples of any or all of the ports shown illustrate how an intermediate port can have a structure that allows fluid communication with one fluid volume but seals it separately from another, and how the 3D structure ensures the transmission of sealing load / force along the stacking direction. It will be apparent that in some cases, shaped port features such as recesses allow fluid communication between the fluid conduit and the fluid volume, while in others, shaped port features prevent fluid communication between the fluid conduit and the fluid volume. Gaskets positioned around the fluid conduit (and, in some cases, positioned by shaped port features) can additionally or alternatively prevent fluid communication between the conduit and the fluid volume.

[0168] Figure 2g Another spacerless variant of the specimen is shown, wherein the metal support plate 205 is conveniently flat, and the flanged peripheral feature 275 and the (larger) molded port feature 238 are disposed only in the metal spacer plate 255. In this variant, the end ports 240a, 240b are sealed by conventional compressible insulating gaskets 251, which define a fluid passage extending through the end ports (first) of the stack. Such gaskets 251 can be positioned during stack assembly using known alignment assembly methods; since the battery cells are arranged in series, the gaskets need to be insulated between adjacent battery cells. The second fluid intermediate port passage is defined and sealed separately from the first fluid volume by a pressed flanged annular region disposed in the metal spacer plate 255 around the second fluid intermediate port 235, this region being studded by an annular weld around the entire port.

[0169] at last, Figure 2h It shows that it can be used, for example, Figure 2a The middle portion of two alternative frame spacers in the spacer specimen, where battery chemical regions 210 are shown on either side of the middle port line. In each case, (dashed) weld lines are shown around the peripheral and central second fluid intermediate ports. The left-hand spacer can be a single continuous spacer frame, which avoids positioning the central spacer but means that the first fluid can only flow out from each port through the throat. Furthermore, this version shows a single first fluid intermediate port dedicated to / only supplying one battery region. The right-hand version shows each second fluid intermediate port supplying both chemical regions; however, in this version, a separate central spacer 261 needs to be secured in place by a weld that seals the second fluid passage; additional anchoring spacer components 261 can be provided if additional throats are required. It should be understood that battery cells with internal spacers near the intermediate ports should have a spacer structure that transmits force to seal the passage along the stacking direction, while having a throat that allows fluid to exit the port into the internal fluid volume of the specimen.

[0170] In the three corresponding battery cell variants of Figure 2 (i.e., with spacers and without spacers), it is desirable to use the first fluid volume as the fuel volume, and this volume is sealed around the entire periphery of the battery by peripheral welds through all the corresponding plate components of the battery cell, and sealed by welds around the second fluid intermediate port (or more generally, the second fluid port passage of any internal manifold).

[0171] For example, Figure 3a and Figure 3b The diagram illustrates how the port feature shown in the perspective and cross-sectional views can be formed. This port is shown as being located at a curved corner of the battery cell, but the shaped port feature described with reference to FIG3 can similarly be arranged around any port described herein.

[0172] Figure 3 shows a fluid port 322 surrounded by a molded port feature 324 and a gasket 334, the gasket 334 being configured to cover a recess formed by the molded port feature 324 during assembly. The molded port feature 324 is disposed within a partition plate 255. The molded port features 324 extend downward to contact a metal support plate 205, their lowermost surfaces lying in a first plane (the same plane as the flanged peripheral feature 275), while their uppermost surfaces and the remainder of the partition plate 255 lie in a second plane spaced apart from the metal support plate 205, in order to define a fluid volume 320. The fluid volume 320 is one of a first fluid volume 280 and a second fluid volume 285.

[0173] The shaped port feature 324 has grooves in its innermost region that open to the fluid port 322. Then there are two staggered circular recessed rings, followed by a final ring of alternating grooves and circular recesses, the length of which is approximately twice the diameter of the circular recesses. In this embodiment, these grooves are radially aligned with the inner circular recesses of the two staggered rings and are staggered relative to the grooves in the innermost region. The circular recess of the final ring is radially aligned with the second circular recess in the staggered ring of two circular recesses. This arrangement forms a pathway for allowing fluid to flow between the recesses within the fuel cell unit (from the fluid port to the interior of the fuel cell unit, or in the opposite direction, if discharged).

[0174] In addition to the recesses and / or grooves forming the molded port feature 324, protrusions 320 are also provided. These protrusions 320 are located in a ring outside the outer periphery of the washer 334 and provide two functions:

[0175] First, they provide guidance for the position of the gasket 334, as the gasket can be fitted inside the ring of the protrusion 320, thus being in the correct position relative to the fluid port 322 during the assembly of the battery cell stack, i.e., centered relative to the fluid port 322.

[0176] Secondly, such as Figure 3b As shown, the height h of the protruding member 320 is less than or preferably between 75% and 99% of the thickness t of the gasket 334, or more preferably between 75% and 85% (e.g., 78-82%) of the thickness t. The ratio of height h to thickness t can be customized according to the compression requirements of the specific gasket used. Although such a large height h is not necessary to provide the first function, and therefore it can be less (e.g., h can be between 5% and 75% of the gasket thickness t), it is preferably larger to provide the second function of providing hard stop during assembly and stacking. This hard stop function is helpful in the manufacturing process of fuel cell stacks because the gasket is compressible and thus able to seal recesses in the outer surface of the fuel cell unit during compression. Therefore, there is a possibility of over-compression during assembly, which could cause the electrochemically activated layer on the metal support plate to crack or be damaged, since the support structures 265, 266 also come into contact with those electrochemical layers during gasket compression. By setting hard stops, the degree of compression can be limited, thereby resisting excessive compression and preventing accidental rupture of the electrochemically activated layer on the metal support plate (and thus allowing for better tolerance of the bonding pressure between the central protrusion and the electrochemically activated layer within the fuel cell).

[0177] In an alternative, the protruding member 320 may be a continuous annular protruding member. The forming port feature used herein refers to one or both of the protruding member 320 and the forming port feature 324.

[0178] However, it is important that these protruding members 320 not exceed the thickness t of the gasket 334; otherwise, the gasket cannot be compressed during stacking, and similarly, the electrical connection between the electrochemical activation layer and the central protrusion may fail, thus hindering efficient stacking operation and potentially introducing hot spots. However, the actual height h of the protruding members 320 can be varied or set appropriately to achieve the required gasket compression during assembly, thereby ensuring proper connection between the electrochemical activation layer and the central protrusion, ensuring proper sealing of the recesses in the outer surface of the fuel cell unit via the gasket, and ensuring proper electrical connection across the entire set of central protrusions 330. An electrically insulating coating or paste layer can be applied to one or both adjacent surfaces (hard stop surfaces, formed by the protruding members 320 and the metal substrates of the adjacent fuel cell units) of adjacent fuel cell units to prevent electrical contact between adjacent fuel cell units through the adjacent surfaces.

[0179] In this variation, the washer may have a shape or hole therein to accommodate the protrusion 320, rather than the protrusion surrounding the outer periphery of the washer 334, thereby again providing the washer with a fixed position relative to the protrusion 320, and a potential fixed orientation of the washer relative to it (or a fixed orientation if the washer can be fitted in more than one fixed orientation).

[0180] In this variation, a protruding member 320 surrounding the outer periphery of the gasket is formed on the metal support plate 205, extending toward the partition plate 255 of the adjacent fuel cell unit. In another variation, protruding members are formed on both the metal support plate 205 and the partition plate 255, and these protruding members may be spaced apart from each other. Furthermore, the protruding members on the metal support plate 205 and the partition plate 255 may have an intermediate height and be arranged such that their protruding features are adjacent to each other to form an interface protruding member with the same height as the protruding members on the partition plate 255 or the metal support plate 205, or spaced apart from each other on both the partition plate 255 and the metal support plate 205.

[0181] Figure 4 shows Figures 2a to 2c The battery cell 200 is illustrated, with example fluid flow paths extending between ports within the battery cell 200. Shaded arrow 405 represents the fluid flow path of a first fluid, while blank arrow 410 represents the fluid flow path of a second fluid. Typically, when operating in SOFC mode, the first fluid can be fuel and the second fluid can be an oxidant (or air). Generally, the middle port is the fluid inlet port. Therefore, the fluid input to the battery cell, i.e., the hot fluid, is directed towards the center of the battery cell. This reduces the preheating time of the stack and promotes uniform heat distribution. However, if the middle port is the outlet port (and therefore fluid enters the fluid volume at each corresponding opposite end), a symmetrical flow path towards the middle port would promote uniform heat distribution.

[0182] Figure 4a The fluid flow paths between the various channels are shown in a plan view, while Figure 4b Along Figure 4a The cross-sectional view taken by line AA shows the fluid flow path. Figure 4a In the diagram, arrows 405 and 410, representing the flow paths of the first and second fluids, should be understood as representing the flow paths on the second and first sides of the metal support plate 205, respectively (i.e., the flow 405 depicted by the arrows would obviously be invisible in the plan view because it appears below the metal support plate 205; i.e., those arrows could instead be shown as dashed arrows). This is in Figure 4b It is evident that the second fluid flow path 410 is within the second fluid volume 285 and above the first side of the metal support plate 205 (coated with the activating chemical substance), i.e., above the cathode layer 213 of the electrochemical activation layer 210. Similarly, as... Figure 4b As shown, the first fluid flow path 405 is in the first fluid volume 280 and above the second side of the metal support plate (fluidly connected to the anode layer 211 through the porous region 214).

[0183] The first fluid flow path 405 is located between the first fluid intermediate ports 230a and 230b and a pair of first fluid end ports 240a and 240b. The arrows indicate the direction of the first fluid flow path; in this case, the first fluid intermediate ports 230a and 230b are inlet ports to allow fluid to enter the first fluid volume 280, and the first fluid end ports are outlet or discharge ports to allow fluid to flow out of the first fluid volume 280. The first fluid (e.g., fuel) is entirely internally manifolded.

[0184] The second fluid flow path 410 is located between the second fluid intermediate port 235 and the external manifold 245. The direction of the arrow indicates the direction of the second fluid flow path; the second fluid intermediate port 235 is the inlet port that allows fluid to enter the second fluid volume 285, and the external manifold allows fluid to flow out of the second fluid volume 285. The external manifold may simply be a gap or space between the battery and the outer sheath or housing. The second fluid intermediate passage is formed by the second fluid intermediate port 235 and is sealed separately from the first fluid volume by forming an annular port feature (see Figure 3) or a gasket 415. If the latter is a conductive gasket or spacer, or if it is an annular port feature, the intermediate passage can be sealed by welding or brazing around the intermediate port and through the conductive gasket or the formed port feature.

[0185] Therefore, the first and second fluid flow paths extend from their respective intermediate ports and are symmetrical about the intermediate ports. It will be understood that the flow paths are schematically indicated by arrows to represent the general direction of flow, and in fact, the flow typically radiates or fans out from each port through the battery chemistry, as it is unrestricted as it flows out or spreads over the battery chemistry. Specifically, there is no three-dimensional channel that forces the flow through a particular tortuous flow path; rather, the flow is unrestrained except at or near the periphery of the electrochemical activation layer 210. Thus, although the arrows are shown to represent, for example, a flow path from the first fluid intermediate port 230a to the first fluid end port 240a, the arrows represent multiple flow paths between said ports, ensuring that each portion of the electrochemical activation layer 210 is supplied with the first fluid and that the discharged fluid is removed from each portion of the electrochemical activation layer 210. However, each of the multiple flow paths between the ports indicated by the arrows has a major component in the length direction of the battery cell, i.e., between the opposite edges of the electrochemical activation layer 210 near the middle port 230a and near the end port 240a (which is also parallel to the length of the battery cell). The same is true for all other fluid flow paths described herein.

[0186] Furthermore, referring to Figure 3, it can be understood that the flow into and out of each port is radial (at least in the vicinity of the port); that is, the shaped port features do not direct the flow in any particular direction (the inlet port is non-directional or isotropic).

[0187] The raised port features (as described with reference to FIG3, not shown in FIG4) and / or interconnecting recesses 265 can allow the intermediate port to avoid collapse. The raised port features described with reference to FIG3 provide a method for sealing the intermediate port passage and for supplying fluid volume from the passage.

[0188] Figure 4a The diagram also shows the positions of a gasket 415 surrounding the first fluid intermediate port 230 and a gasket 262 surrounding the first fluid end port 240. Gaskets 415 and 262 contact the first side of the metal support plate 205 (which is also the side supporting the electrochemical activation layer 210). In the stacking of battery cells, as... Figure 4b As shown, gaskets 415 and 262 are disposed between the metal support plate 205 and the separator plate 255 of the next battery cell, and separate the first fluid volume 280 and the second fluid volume 285.

[0189] Figure 4aThe diagram also shows a region 420 where the rib 270 contacts the electrochemically activated layer 210. The rib 270 is parallel to the length of the battery cell and contacts the electrochemically activated layer 210 along its edge. Therefore, the rib 270 serves to contain a second fluid (e.g., air) within a second fluid volume 285. Figure 4a The second fluid flow path 410 is shown in the diagram.

[0190] like Figure 4a As shown, the ribs extend beyond the edge of the electrochemical activation layer 210, but in this extended region, the ribs 270 contact or are positioned above the insulating electrolyte layer, which extends beyond... Figure 4a The edge of the electrochemically activated layer 210 shown.

[0191] Rib 270 (represented in the figure by region 420 contacted by rib 270) extends toward the outer edge of gasket 415 at intermediate port 230 and may contact the outer diameter of gasket 415. Therefore, gasket 415 (containing the first fluid) and rib 270 cooperate (to form a continuous barrier) to guide the second fluid by restricting its exit from the second fluid volume 285 in a direction perpendicular to the length of the battery. That is, gasket 415 and rib 270 restrict the second fluid and guide the second fluid flow path 410 from the second fluid intermediate port 235 to above the electrochemical activation layer 210 and to the outer manifold 245. Gasket 262 surrounding the first fluid end port 240 also restricts the flow of the second fluid flow path 410 around gasket 262.

[0192] Therefore, the first fluid enters the first fluid volume 280 along the middle of the length of the battery cell 200 and exits near the end of the battery cell. Similarly, the second fluid enters the second fluid volume 285 along the middle of the length of the battery cell 200 and exits near the end of the battery cell. This allows for improved thermal management. This also allows for a low aspect ratio arrangement for the first and second fluid volumes, wherein the first fluid flow path 405 and the second fluid flow path 410 cross the short side of the electrochemical activation layer 210 (approximately half the length of the battery), rather than the long side of the electrochemical activation layer 210 (approximately the width of the battery). Low aspect ratio refers to the width of the activated battery chemical layer (the distance between the inlet and outlet ports) (in... Figure 2a (marked as x1) and length (in) Figure 2a The ratio between x1 and y1 is less than or equal to 1.2 (i.e., x1 / y1 ≤ 1.2). In one example, the aspect ratio is less than 1; in another, it is less than 0.8; and in yet another, it is between 0.3 and 0.8. An arrangement with a low aspect ratio reduces the pressure drop between the volume inlet and outlet, and also reduces the thermal gradient between them.

[0193] Rib 270 is located near the central port of the first fluid and is recessed when viewed from the first fluid volume 280, thus forming a delivery channel for conveying the first fluid (e.g., fuel) to the first fluid volume 280, whereby the first fluid can flow out of the rib along its length. This encourages fluid flow toward the outermost corner of the activated chemical region (and stack), thereby promoting uniform flow in this region even with only a single central end port 240 of the first fluid.

[0194] exist Figure 4a and Figure 4b In the diagram, the directions of the first and second fluid flow paths from the center of the battery cell 200 to the end of the battery cell 200 are shown (by the direction of the arrows). Regarding... Figure 4c , Figure 4d as well as Figure 4e Various alternatives are described. Figure 4c , Figure 4d as well as Figure 4e In each of these, the port is positioned and referenced within the battery cell 200. Figure 2a -d、 Figure 4a as well as Figure 4b Similar to what is described.

[0195] Figure 4c A counter-current arrangement is shown, in which the direction of the first fluid flow path is generally opposite to the direction of the second fluid flow path. The direction of the second fluid flow path 410 remains from the center to the edge of the battery, but the direction of the first fluid flow path 406 is arranged from the end of the battery cell to the center of the battery cell. That is, the first fluid flows from the first fluid end port 240 to the first fluid middle port 230.

[0196] Figure 4d A second counter-current arrangement is shown. In this case, the direction of the first fluid flow path 405 is from the center of the battery cell to the end of the battery, while the direction of the second fluid flow path 411 is arranged from the end of the battery cell to the center of the battery cell. That is, the second fluid flows from the external manifold 245 to the second fluid intermediate port 235.

[0197] Figure 4e This illustrates a co-current arrangement in which the first and second fluid flow paths are generally in the same direction (in this sense, it is similar to...). Figure 4a and Figure 4b(In a downstream arrangement). In this case, the direction of the first fluid flow path 406 is arranged from the end of the battery cell to the center of the battery cell. That is, the first fluid flows from the first fluid end port 240 to the first fluid middle port 230. The direction of the second fluid flow path 411 is arranged from the end of the battery cell to the center of the battery cell. That is, the second fluid flows from the external manifold 245 to the second fluid middle port 235.

[0198] Figure 4f It shows Figure 4a The battery cell 200 has an alternative rib arrangement. Similarly, discontinuous ribs 270 in the separator (represented in the figure by the area 420 contacted by ribs 270) extend toward the outer edge of the gasket 415 at the central port 230, but the ends of the ribs curve toward the port (hockey stick shape) to minimize any gaps between the ribs and the gasket. For clarity, the flow path of the second fluid (air / oxidant) is not shown in the figure, but will be similar. Figure 4a Those shown. Some air escapes from between the rib end and the gasket, but the bending minimizes this distance (and therefore the escape) (an example of a battery with a continuous cell chemistry region and a single continuous rib is shown in Figure 8).

[0199] The ribs improve fuel distribution to the battery corners by providing a fuel fluid delivery channel within the first fluid (fuel) volume, from which an additional fuel flow path 406 can branch off. In one test, the ribs resulted in an increase of over 10% in fuel flow downwards along the ribs.

[0200] Figure 5 A variation is shown in which the electrochemically activated layer 510 wraps around the first fluid end port 240, i.e., the electrochemically activated layer extends at least partially around the port, preferably having a corresponding contour edge of the electrochemically activated layer. Extending at least partially around the port means that the corresponding contour can be >90 degrees, or >180 degrees, or 360 degrees (e.g., Figure 8a In other respects, the electrochemical activation layer 510 is similar to the previously described electrochemical activation layer 210. The edge of the electrochemical activation layer 510 near the first fluid end port 240 is deposited in a semi-circular or arc shape to follow the circular shape of the port 240. The annular gap between the end port 240 and the electrochemical activation layer 510 allows for the positioning of a gasket around the end port 240 (e.g., regarding...). Figure 4aThe described gasket 262), an annular gap, means that the gasket does not contact the cathode of the electrochemical activation layer 510. The gasket may contact and lie on the extended electrolyte layer. Alternatively or additionally, the annular gap provides space for the formed port features around the port. The enclosed electrochemical activation layer 510 allows the edges of the electrochemical activation layer 510 to be closer to the ends of the metal substrate 205 (e.g., flush with the center of the end port 240), thereby allowing the electrochemical activation layer 510 to cover a larger proportion of the metal substrate 205 (compared to not having an enclosed electrochemical activation layer).

[0201] The electrochemical activation layer 510 may additionally or alternatively wrap around any other port of the battery cell, for example, around the first and / or second fluid intermediate port, similar to the way it is wrapped around the first fluid end port 240.

[0202] Figure 6 A variation is shown in which the first and second fluid ports are non-circular; otherwise, the ports resemble those previously described. Each port is shown as rectangular, but they can also be elliptical or square. Similarly, the electrochemical activation layer 510 is shown as wrapping around the first fluid end port 640. Circular or elliptical ports require more wrapping than rectangular or square ports, which occupy less space in the metal support plate 205. Furthermore, by using intermediate ports that extend along the centerline (such that the length of the intermediate ports in the minor axis direction of the cell is greater than their width in the major axis direction of the cell), the intermediate ports 630, 635 substantially occupy all areas of the metal support plate 205 between the electrochemical activation layers 510, thereby allowing the electrochemical activation layer 510 to cover a larger proportion of the metal substrate 205.

[0203] Regarding the previous discussion of ideal dimensions, for illustrative purposes, a minimum length x1 and a minimum width y1 of the electrochemically activated layer have been added in this case (similarly, these can be added to...). Figure 5 Width y1 and Figure 2a Similar to the previous example. Length x1 is the minimum value passing through the electrochemical activation layer between the edge of the electrochemical activation layer near the middle port and the edge of the electrochemical activation layer near the end port. Length x1 is parallel to the edge of the electrochemical activation layer and the edge of the battery cell (e.g., its length).

[0204] Encapsulating the activated regions can lead to fuel shortages in the outermost corner chemical regions. Therefore, it is preferable to combine battery chemical encapsulation with shaped delivery channels / ribs to provide delivery pathways, allowing fuel to reach those outermost corners of the battery chemical regions. In this way, a metal support plate with an increased coverage ratio of electrochemical activation layer can be achieved, resulting in high energy density.

[0205] Figure 7A variant battery cell is shown in which the second fluid is also in the internal manifold; otherwise, the battery cell is similar to the cell described above. The battery cell is provided with a pair of biased second fluid end ports 745a and 745b, one each facing each end of the first (long) axis of the battery cell 200. The second fluid end ports are used to supply or remove the second fluid from the battery cell. The second fluid end ports 745a and 745b are closer to the ends of the first (long) axis of the battery cell 200 than the electrochemical activation layer 210. The second fluid end ports replace the external manifold 245 in the previous figure and form end fluid passages for the second fluid in the stack. Because the second fluid is entirely internally manifolded (using the intermediate port 235 and end port 745), the ends of the battery cell can be positioned closer to the inner end of the housing on which the stack is placed.

[0206] A second fluid end port is shown at each end of the battery cell, but more can be provided. For example, there could be two second fluid end ports at each end of the battery cell, with a first fluid end port positioned between them. This would maintain the symmetry of uniform flow.

[0207] Figure 7 The fluid flow path and direction are also shown in a plan view (indicated by arrows). The first fluid flow path 405 and flow direction are shown in reference. Figure 4a and Figure 4b As described. The second fluid flow path 785 is between the second fluid intermediate port 235 and the second fluid end ports 745a, 745b. The directions of both the first fluid (on the first fluid flow path 405) and the second fluid (on the second fluid flow path 785) are shown as from the center or intermediate port of the battery cell to the end of the battery cell. That is, the directions of the first and second fluid flow paths are in a generally co-current arrangement, similar to the arrangement regarding... Figure 4a and Figure 4b The described arrangement. Similarly, either the first or second fluid flow path direction can be reversed to provide a counter-current arrangement, similar to the arrangement described above. Figure 4c and Figure 4d The described arrangement, or the directions of the first and second fluid flow paths, can be reversed to provide a co-current arrangement, similar to the arrangement described above. Figure 4e The described arrangement. Furthermore, it should be understood that any other variations previously or subsequently described may have the following characteristics: Figure 7 The second fluid volume is in a manner that completely fills the internal manifold.

[0208] Figure 8a and Figure 8bAnother variant of the battery cell is shown, in which a single electrochemical activation layer 810 exists, compared to the two separate activation layers 210 described previously. In other respects, this variant is similar to the battery cell described above. The single electrochemical activation layer 810 surrounds the first and second fluid intermediate ports 230, 235. That is, a portion of the electrochemical activation region 810 is disposed between the intermediate ports 230, 235 and the long edge of the battery cell, meaning the electrochemical activation layer is a continuous region. Therefore, the single electrochemical activation layer 810 can cover a larger proportion of the metal support plate 205 compared to the case of two electrochemical activation layers 210.

[0209] Figure 8b It shows Figure 8a The battery cell, exemplified by fluid flow paths extending between ports within the battery cell. The first fluid flow path 405 and the second fluid flow path 410 are similar to those in the reference design. Figure 4a and Figure 4b The fluid flow path described, and with Figures 4c to 4e Similar to those described in the text, one or both of which can be reversed.

[0210] Figure 8b The diagram also shows a region 820 that contacts a continuous rib 270 disposed in a separator plate of adjacent battery cells in the stack. Region 820 and the associated rib are similar to... Figure 4a The battery cell has two regions 420 and two ribs along each long edge, except in this variation, the region 820 contacted by the ribs and associated ribs is continuous along the length of the battery cell to eliminate any air bypass between the gasket and the rib ends. As previously described, the ribs are ribs along the length of the separator between adjacent battery cells, and this rib contacts the first battery cell when the first and adjacent battery cells are in a stack. That is, the region 820 contacted by the ribs is along the electrochemical activation layer 810 arranged on either side of the intermediate port and along the portion of the electrochemical activation layer 810 between the intermediate port and the long edge of the battery cell. Thus, the ribs of the contact region 810 are used to contain a second fluid in a second fluid volume. The ribs are close to the intermediate port of the first fluid and are recessed when viewed from the first fluid volume, thus forming a delivery channel for conveying the first fluid into the first fluid volume, whereby the first fluid can flow out along the length of the ribs.

[0211] Figures 9a to 9c A variant is shown in which a single first fluid intermediate port is present, but no second fluid intermediate port is present; otherwise, this variant is similar to those previously described. The first fluid intermediate port 930 is located at the center of the battery cell. The first fluid end port is positioned towards the corner of the battery cell. Thus, the first fluid port forms an "X"-shaped cross.

[0212] The second fluid is an external manifold, represented by an external manifold 245a disposed at the first end of the battery cell and an external manifold 245b disposed at the second end of the battery cell. External manifolds 245a and 245b are similar to the previously described external manifold 245 and can each extend along the stacking direction.

[0213] The electrochemical activation layer 810 surrounds the first fluid intermediate port 930 in a manner similar to that described with reference to FIG8. Alternatively, the electrochemical activation layer may comprise a separate electrochemical activation layer, similar to the electrochemical activation layer 210 described above. Still alternatively, there may be more than one first fluid intermediate port disposed along the center of the length of the battery cell, similar to the two fluid intermediate ports previously described with respect to FIG2 and FIG4.

[0214] Figure 9b It shows the use of Figure 9a The modified battery cell has a first fluid flow path 905 and a second fluid flow path 910. The first fluid flow path 905 is in the form of a cross or an "X".

[0215] The second fluid flow path is located between the external manifold 245a at the first end of the battery cell and the external manifold 245b at the second end of the battery cell. The second fluid flow path 910 is contained within the second fluid volume by a rib (protruding from the separator of the adjacent battery cell) that contacts the electrochemical activation layer 810 at region 820. The second fluid flow path 910 surrounds the first fluid intermediate port 930 and a gasket (not shown) surrounding the first fluid intermediate port 930 to separate the first fluid volume and the second fluid volume.

[0216] The direction of the first fluid flow path is shown as from the intermediate port 930 to the end port 940. The direction of the second fluid flow path is shown as from the external manifold 245a at the first end of the battery cell to the external manifold 245b at the second end of the battery cell. Therefore, the flow through one half of the battery cell is forward, while the flow through the other half is backward. Similarly, the direction of the first fluid flow path can be reversed, such that the first fluid flows from the first fluid end port 940 to the first fluid intermediate port 930. In this case, the flow is again forward through one half of the battery cell and backward through the other half. This forward and backward flow through the other half of the battery cell leads to an asymmetrical heat distribution, which is disadvantageous.

[0217] Figure 9c It shows Figure 9a , Figure 9bA variation of the arrangement is provided, wherein the second fluid is internally formed into a manifold using second fluid end ports 745a and 745b. Second fluid end port 745a is positioned toward the first end of the battery cell, while second fluid end port 745b is positioned toward the second end of the battery cell. The second fluid end ports 745 at each end of the battery cell are located midway along the end of the battery cell and between first fluid end ports 940 (one first fluid end port 940 is positioned toward each corner of the battery cell). The first fluid flow path 905 and the first fluid flow direction are related to... Figure 9b Similar to what is described. Similarly, the second fluid flow path 910 and the second fluid flow direction are related to... Figure 9b The descriptions are similar.

[0218] Figure 10a , Figure 10b Another variant of the battery cell is shown, in which the first fluid and the second fluid are arranged in a cross-flow configuration. A single intermediate port 930 for the first fluid is present, but there is no intermediate port for the second fluid. Furthermore, there is no end port for the first fluid; instead, the first fluid forms an external manifold, represented by external manifolds 1040a and 1040b respectively located at the first and second ends of the battery cell. The external manifold 1040 is located outside the area covered by the metal support plate 205 and forms an end fluid passage for the first fluid.

[0219] Fluid-side ports 1041 and 1046, in fluid communication with the second fluid volume, are provided for the delivery and discharge of the second fluid. The side ports are located along the long edge of the metal support plate 205, extending beyond the electrochemical activation layer 810. Figure 10a As shown, two fluid-side ports 1041 are disposed along the first edge of the metal support plate 205, and two other side ports 1046 are disposed along the second edge of the metal support plate 205, with the first and second edges facing each other, and the electrochemical activation layer 810 located therebetween.

[0220] Figure 10b It shows the use of Figure 10a The first fluid flow path 1005 and the second fluid flow path 1010 of the modified battery cell.

[0221] A first fluid flow path 1005 is located between the first fluid intermediate port 930 and the external manifolds 1040a and 1040b. A second fluid flow path 1010 is located between the fluid-side port 1041 at the first edge of the battery cell and the fluid-side port 1046 at the second edge of the battery cell. The second fluid flow path 1010 passes around the first fluid intermediate port 930 and a gasket (not shown) around the first fluid intermediate port 930 to separate the first fluid volume and the second fluid volume.

[0222] The direction of the first fluid flow path 1005 is shown as from the intermediate port 930 to the external manifolds 1040a and 1040b. The direction of the second fluid flow path 1010 is shown as from the fluid-side port 1041 at the first edge of the battery cell to the fluid-side port 1046 at the second edge of the battery cell. Therefore, the flow is an alternating flow arrangement through the battery cells. Similarly, the direction of the first fluid flow path can be reversed, such that the first fluid flows from the external manifolds 1040a and 1040b to the first fluid intermediate port 930. In this case, the flow is also an alternating flow through the battery cells.

[0223] For example, in the case where the battery repeating unit is a sealed unit with a sealed fluid volume, both the battery end port and the battery middle port are provided with internal manifolds, and other fluids can then be supplied through external manifolds for inlet and / or outlet purposes.

[0224] Figures 11a to 11c Another variant of the battery cell is shown, comprising four first fluid end ports and two second fluid intermediate ports. The two second fluid intermediate ports 1135a and 1135b are located midway along the length of the battery cell, and an electrochemical activation layer is coated or deposited between the second fluid intermediate ports 1135a and 1135b and the ends of the battery cell. A first fluid intermediate port 1130 is located midway along the length of the battery cell and between the two second fluid intermediate ports 1135a and 1135b.

[0225] A first fluid end port 940 is provided at each corner facing the battery cell. The first fluid end port 940 is located away from the midpoint of the width of the battery cell. The first fluid end port 940 and the first fluid intermediate port 1135 are in fluid communication with each other. Therefore, the first fluid end port 940 and the first fluid intermediate port 1130 form a cross or "X" shape, wherein the first fluid intermediate port 1130 is located at the center of the cross. The external manifold 245 is in fluid communication with the second fluid intermediate ports 1135a and 1135b.

[0226] Figure 11b It shows the use of Figure 11aThe modified battery cell has a first fluid flow path 1105 and a second fluid flow path 1110. The first fluid flow path 1105 is between a first fluid intermediate port 1130 and a first fluid end port 940. The second fluid flow path is between the second fluid intermediate ports 1135a and 1135b and the external manifold 245. The direction of the first fluid flow path 1105 is shown as from the intermediate port 1130 to the first fluid end port 940. The direction of the second fluid flow path 1110 is shown as from the fluid intermediate port to the external manifold 245 at the end of the battery cell. Therefore, the flow is symmetrical about the two axes of the battery cell. The flow is arranged in a forward flow through the battery cell. The direction of the first fluid flow path can be reversed, such that the first fluid flows from the first fluid end port 940 to the first fluid intermediate port 1130, in which case the flow is countercurrent through the battery cell. Similarly, the flow direction of the second fluid flow path 1110 can be reversed, such that the second fluid flows from the external manifold 245 to the second fluid intermediate port 1135, in which case the flow is countercurrent through the battery cell. If the flow direction of the first fluid and the flow direction of the second fluid are both reversed (relative to...) Figure 11b (As indicated by the arrow in the image), the two fluids flow in a co-current arrangement toward the center of the battery cell.

[0227] Figure 11c It shows Figure 11a , Figure 11b A variation of the arrangement is provided, wherein the second fluid is internally formed into a manifold using second fluid end ports 745a and 745b. Second fluid end port 745a is positioned toward the first end of the battery cell, while second fluid end port 745b is positioned toward the second end of the battery cell. The second fluid end ports 745 at each end of the battery cell are located midway along the end of the battery cell and between first fluid end ports 940 (one first fluid end port 940 is positioned toward each corner of the battery cell). The first fluid flow path 1105 and the first fluid flow direction are related to... Figure 11b The description is similar. Similarly, the second fluid flow path 1110 and the second fluid flow direction are similar to those described above. Figure 11b The descriptions are similar.

[0228] Figures 12a to 12cAnother variant of the battery cell is shown, comprising two first fluid intermediate ports and two second fluid intermediate ports. The fluid intermediate ports are positioned along the length of the battery cell and facing the sides of the battery cell (i.e., they are spaced apart from the centerline in the width direction of the battery cell). A first fluid intermediate port 1230a and a second fluid intermediate port 1235a are located on the first side of the battery cell, their centers aligned on an axis parallel to the length direction of the battery cell. The first fluid intermediate port 1230a is further away from the external manifold 245a (located at the left end of the battery cell) than the second fluid intermediate port 1235a. A first fluid intermediate port 1230b and a second fluid intermediate port 1235b are located on the second side of the battery cell, their centers aligned on an axis parallel to the length direction of the battery cell. The axis aligning the intermediate ports 1230b and 1235b is symmetrically arranged with respect to the axis containing the intermediate ports 1230a and 1235a about the centerline in the width direction of the battery. The second fluid intermediate port 1235b is further away from the external manifold 245a (located at the left end of the battery cell) than the first fluid intermediate port 1230b. An electrochemical activation layer is coated or deposited between the intermediate ports 1230a, 1230b and 1235a, 1235b and the end of the battery cell. The first fluid end port 240 is positioned towards the end of the battery cell, and the external manifold 245 is located outside the battery cell, as previously described. Therefore, the first fluid port is configured in a diamond shape.

[0229] Figure 12b It shows the use of Figure 12a The first fluid flow path 1205 and the second fluid flow path 1210 of the modified battery cell.

[0230] The first fluid flow path 1205 is between the first fluid intermediate ports 1230a and 1230b and the first fluid end port 240. The second fluid flow path 1210 is between the second fluid intermediate ports 1235a and 1235b and the external manifold 245.

[0231] The direction of the first fluid flow path 1205 is indicated as from the first fluid intermediate ports 1230a and 1230b to the first fluid end port 240. Since the flow from each port is isotropic, fluid from the first fluid intermediate port 1230a flows around the second fluid intermediate port 1235a (and the accompanying gasket or molded port feature) to reach the first fluid end port 240a (a portion of the electrochemically activated layer and the second fluid intermediate port 1235a are located between the first fluid intermediate port 1230a and the first fluid end port 240a). Similarly, fluid from the first fluid intermediate port 1230b flows around the second fluid intermediate port 1235b to reach the first fluid end port 240b.

[0232] The direction of the second fluid flow path 1210 is shown as from the second fluid intermediate ports 1235a, 1235b to the external manifold 245 at the end of the battery cell. Fluid from the second fluid intermediate port 1235a flows around the first fluid intermediate port 1230a (and the accompanying gasket or molded port feature) to reach the external manifold 245b (a portion of the electrochemical activation layer and the first fluid intermediate port 1235a are located between the second fluid intermediate port 1235a and the external manifold 245b). Similarly, fluid from the second fluid intermediate port 1235b flows around the first fluid intermediate port 1230b to reach the external manifold 245b.

[0233] Therefore, the flow is typically symmetrical about the two axes of the battery cell. The flow is arranged in a forward direction through the battery cell. The direction of the first fluid flow path can be reversed, such that the first fluid flows from the first fluid end port 240 to the first fluid middle port 1230; in this case, the flow is counter-current through the battery cell. Similarly, the flow direction of the second fluid flow path 1210 can be reversed, such that the second fluid flows from the external manifold 245 to the second fluid middle port 1235; in this case, the flow is counter-current through the battery cell. If both the first and second fluid flow directions are reversed (relative to...) Figure 12b (As indicated by the arrow in the image), the two fluids flow in a co-current arrangement toward the center of the battery cell.

[0234] Figure 12c It shows Figure 12a , Figure 12b A variation of the arrangement, wherein the second fluid forms a manifold internally using second fluid end ports 745a and 745b. Second fluid end port 745a is positioned towards the first end of the battery cell, while second fluid end port 745b is positioned towards the second end of the battery cell. The second fluid end ports 745 at each end of the battery cell are substantially located in the middle along the end of the battery cell, but may be positioned on one side of the middle, such that the first fluid end port 240 and the second fluid end port 745 are offset in opposite directions from the midpoint of the end of the battery cell. The first fluid flow path 1205 and the first fluid flow direction are related to... Figure 12b The descriptions are similar. Similarly, the second fluid flow path 1210 and the second fluid flow direction are similar to those described about... Figure 12b The descriptions are similar.

[0235] Figures 13a to 13c Another variant of the battery cell is shown, having two first fluid intermediate ports 230 and one second fluid intermediate port 235, similar to those described with reference to FIG2. First fluid end ports 940, respectively disposed toward each corner of the battery cell, are also shown, similar to those described with reference to FIG9.

[0236] Figure 13b It shows the use of Figure 13a The first fluid flow path 1305 and the second fluid flow path 1310 of the modified battery cell.

[0237] The first fluid flow path 1305 is between the first fluid intermediate ports 230a and 230b and the first fluid end port 940. The second fluid flow path 1310 is between the second fluid intermediate port 235a and the external manifold 245.

[0238] The direction of the first fluid flow path 1305 is indicated from the first fluid intermediate ports 230a and 230b to the first fluid end port 240. The direction of the second fluid flow path 1310 is indicated from the second fluid intermediate port 235 to the external manifold 245 located at the end of the battery cell.

[0239] Therefore, the flow is symmetrical about the two axes of the battery cell. The flow is arranged in the forward direction through the battery cell. The direction of the first fluid flow path 1305 can be reversed, so that the first fluid flows from the first fluid end port 940 to the first fluid middle port 230. In this case, the flow is counter-current through the battery cell. Similarly, the flow direction of the second fluid flow path 1310 can be reversed, so that the second fluid flows from the external manifold 245 to the second fluid middle port 235. In this case, the flow is counter-current through the battery cell. If both the first fluid flow direction and the second fluid flow direction are reversed (relative to...) Figure 13b (As indicated by the arrow in the image), the two fluids flow in a co-current arrangement toward the center of the battery cell.

[0240] Figure 13c It shows Figure 13a , Figure 13b A variation of the arrangement, wherein the second fluid uses second fluid end ports 745a and 745b to form a manifold internally. The second fluid end ports 745a and 745b are similar to those previously referenced. Figure 7 Those described. The first fluid flow path 1305 and the first fluid flow direction are similar to those described above. Figure 13b Those described. Similarly, the second fluid flow path 1310 and the second fluid flow direction are similar to those described above. Figure 13b Those described.

[0241] Figures 14a to 14cAnother variant of the battery cell is shown, in which separators, partitions, or baffles can be provided to separate a first or second fluid volume by providing a degree of flow obstruction, thereby allowing the respective intermediate ports to primarily direct their fluid to specific battery chemical regions, such that each electrochemically activated layer has an associated fluid volume. Separators can also fluidly isolate the fluid volume into two volumes, but this requires peripheral sealing, such as welding.

[0242] As previously described with reference to FIG2, there is a single second fluid intermediate port 235 disposed at the midpoint of the length and width of the battery cell. The second fluid intermediate port is in fluid communication with the external manifold 245. Two first fluid intermediate ports 230a and 230b are disposed at the midpoint along the length of the battery cell, positioned on each side of the second fluid intermediate port 235, and the first fluid end ports are disposed toward each corner of the battery cell.

[0243] A separator 1490 is disposed on or in contact with the second side of the metal support plate 205, dividing the fluid volume on that side of the metal support plate into two volumes. The separator 1490 is shown as existing in the first fluid volume on the second side of the metal support plate 205. The separator separates the volumes such that the first fluid intermediate port 230a is in fluid communication with the first fluid end ports 940c, 940d and the electrochemical activation layer 210b facing the second end of the battery cell, and the separator separates the volumes such that the first fluid intermediate port 230b is in fluid communication with the first fluid end ports 940a, 940b and the electrochemical activation layer 210a facing the first end of the battery cell.

[0244] The separator 1490 may be a feature formed or pressed into the metal support plate 205 or the separator 255, similar to a formed port feature, and may be formed in the same manufacturing steps as forming or pressing a port feature.

[0245] Figure 14b It shows the use of Figure 14aThe modified battery cell has a first fluid flow path 1405 and a second fluid flow path 1410. The second fluid flow path 1410 is between the second fluid intermediate port 235a and the external manifold 245. The first fluid flow path 1405 is between the first fluid intermediate ports 230a and 230b and the first fluid end port 940. The first fluid flow path 1405 includes a first sub-path 1405a and a second sub-path 1405b, which are separated by a separator 1490. The first sub-path 1405a is between the first fluid intermediate port 230b and the first fluid end ports 940a and 940b, and is in fluid communication with the electrochemical activation layer 210a. The second sub-path 1405b is between the first fluid intermediate port 230a and the first fluid end ports 940c and 940d, and is in fluid communication with the electrochemical activation layer 210b.

[0246] The direction of the first fluid flow path 1405 is indicated as being from the first fluid intermediate ports 230a and 230b to the first fluid end ports 940c, 940d and 940a, 940b, respectively. The direction of the second fluid flow path 1410 is indicated as being from the second fluid intermediate port 235 to the external manifold 245 at the end of the battery cell.

[0247] The flow is arranged in a forward direction through the battery cells. The direction of the first fluid flow path 1405 can be reversed, so that the first fluid flows from the first fluid end port 940 to the first fluid middle port 230. In this case, the flow is counter-current through the battery cells. Similarly, the flow direction of the second fluid flow path 1410 can be reversed, so that the second fluid flows from the external manifold 245 to the second fluid middle port 235. In this case, the flow is counter-current through the battery cells. If both the first fluid flow direction and the second fluid flow direction are reversed (relative to...) Figure 14b (As indicated by the arrow in the image), the two fluids flow in a co-current arrangement toward the center of the battery cell.

[0248] Figure 14c It shows Figure 14a , Figure 14b A variation of the arrangement, wherein the second fluid uses second fluid end ports 745a and 745b to form a manifold internally. The second fluid end ports 745a and 745b are similar to those previously referenced. Figure 7 Those described. The first fluid flow path 1405 and the first fluid flow direction are similar to the reference. Figure 14b Those described. Similarly, the second fluid flow path 1410 and the second fluid flow direction are similar to those described above. Figure 14b Those described.

[0249] The battery in Figure 14 can be formed from a single continuous metal substrate plate supporting two battery chemical regions, which can be incorporated into a battery cell with or without spacers.

[0250] However, if multiple smaller coated substrates, for example for manufacturing reasons, are beneficial, then multiple metal substrates, each carrying a corresponding battery chemical region, can be used to form a single battery cell. In the case of two coated battery substrates, these can be joined together, for example by butt welding at their adjacent edges to form a single metal substrate with multiple battery regions, and then incorporated into the sample in the same manner as described above.

[0251] Alternatively, multiple coated battery substrates do not need to be directly bonded together, but can be attached, for example, by piling or supporting, to spacers and interconnects, or simply have interconnects with 3D features that provide fluid volume, and then form a battery cell, for example, a battery cell having a dedicated sealed fluid volume for each individual corresponding battery chemistry region.

[0252] These and other features of the invention have been described above by way of example only. Detailed modifications can be made to the invention within the scope of the claims, particularly regarding the shape of the fuel cell unit, the electrochemical activation layer, and the arrangement of the ports for the first and second fluids.

Claims

1. A rectangular planar electrochemical cell stack, each cell including at least one first fluid intermediate port, the first fluid intermediate port being disposed along the middle of the length of the cell within one or more activated cell chemical regions and in fluid communication with a first fluid volume of the cell. Its features are, The first fluid intermediate ports of each corresponding battery cell are aligned to form at least one first fluid intermediate passage extending along the stacking direction; and, The stack is configured such that in each first fluid volume, a first fluid flow path extends through one or more activated cell chemistry regions between the at least one first fluid intermediate port and each corresponding opposite cell end. Each battery cell also includes at least one second fluid intermediate port, which is disposed along the middle of the length of the battery cell within one or more activated battery chemical regions and is in fluid communication with a second fluid volume of the battery cell; Wherein, the second fluid intermediate ports of the corresponding battery cells are aligned to form at least one second fluid intermediate passage extending along the stacking direction; and, The stack is configured such that in each second fluid volume, a corresponding second fluid flow path extends through one or more activated cell chemistry regions between the at least one second fluid intermediate port and each corresponding opposite cell end. The second fluid volume is defined by a planar component having an elongated shape feature that extends at least partially around the periphery of the activated cell chemical region to confine the fluid flow path within the region; the elongated shape feature includes features in the planar component that form protruding ribs on one side of the planar component and channels on the other side of the planar component.

2. The stacking according to claim 1, characterized in that, Each cell has at least two separate activated cell chemistry regions, each located between the middle port and each opposite cell end.

3. The stacking according to claim 1 or 2, characterized in that, The dimension of the activated battery chemical region, parallel to the fluid flow path and between the intermediate port and one of the opposite ends of the battery cell, is less than or equal to its dimension perpendicular to the fluid flow path.

4. The stack according to claim 1, characterized in that, Each battery cell has only one first fluid intermediate port that is in fluid communication with the first fluid volume.

5. The stack according to claim 1, characterized in that, Each battery cell includes at least first and second first fluid end ports respectively disposed at or near each opposite battery end, the respective first fluid end ports being aligned to define respective first and second internal first fluid end passages extending along the stacking direction, whereby the intermediate first fluid passage and the end first fluid passage respectively form an inlet passage and an outlet passage within the stack, or vice versa, for supplying first fluid to a first fluid volume of each battery cell.

6. The stack according to claim 1, characterized in that, Each battery cell includes two first fluid intermediate ports, each first fluid intermediate port being in fluid communication with a first fluid volume, and a second fluid intermediate port being in fluid communication with a second fluid volume, wherein the second fluid intermediate port is disposed between the two first fluid intermediate ports.

7. The stack according to claim 1, characterized in that, A first fluid end passage is provided in fluid communication with the first fluid volume, the first fluid end passage extending along the stacking direction at or near the end of each opposite stack, these passages being internal manifold passages defined by aligned first and second first fluid end ports within each battery cell, respectively. Simultaneously, a second fluid end passage is provided in fluid communication with the second fluid volume, the second fluid end passage extending along the stacking direction at or near the end of each opposite stack, these passages being external manifold passages extending beyond each battery cell.

8. The stack according to any one of claims 6 to 7, characterized in that, The first fluid volume is the fuel volume, and the second fluid volume is the oxidant volume.

9. The stacking according to claim 1, characterized in that, The first fluid intermediate port is the inlet port.

10. The stack according to claim 1, characterized in that, At least one of any intermediate or end ports provided in the battery cell surrounds the one or more activated battery chemical regions.

11. The stack according to claim 1, characterized in that, One of the first or second fluid volumes is defined by a planar component having an elongated shape that extends at least partially around the periphery of the activated cell chemical region to confine the fluid flow path within the region.

12. The stack according to claim 11, characterized in that, The elongated shape feature includes features in the planar component that form a protruding rib on one side of the planar component and a channel on the other side of the planar component, wherein the elongated shape feature is a pressing or molding feature.

13. The stacking according to claim 1, characterized in that, The battery cell includes: Divider; and A metal support plate supports the activated battery chemical region disposed on a porous region on its first side; The separator and the metal support plate are stacked on top of each other to form the battery cell; in: At least one of the partition plate and the metal support plate includes a flanged peripheral feature formed by pressing the plate into a concave configuration; The partition plate and the metal support plate are directly adjacent at the peripheral feature with flanges to form the first fluid volume therebetween; At least one fluid port is provided in each of the partition plate and the metal support plate, the ports being aligned to form the first fluid passage within the flanged peripheral feature, each port being either a first fluid intermediate port and / or a first fluid end port, and communicating with the first fluid volume; and At least one of the partition plate and the metal support plate is provided with a shaped port feature formed by pressing around the at least one fluid port, the shaped port feature extending toward the other plate, and the elements of the shaped port feature being spaced apart from each other to define a fluid path between the elements from the port so that fluid can flow from the at least one first fluid port to the first fluid volume.

14. The stack according to claim 13, characterized in that, The partition plate and the metal support plate are directly adjacent to each other at the peripheral features with flanges to form the first fluid volume therebetween.

15. The stack according to claim 13, characterized in that, At least one additional fluid port is provided in each of the partition plate and the metal support plate, these ports being aligned to form a second fluid passage within the flanged peripheral feature, each port being a second fluid intermediate port and / or a second fluid end port, and communicating with a second fluid volume on a second side of the metal support plate, wherein the second fluid passage is sealed separately from the first fluid volume.

16. The stack according to claim 15, characterized in that, The second fluid passage is sealed separately from the first fluid volume by a weldment disposed around the second fluid port.

17. The stack according to claim 15, characterized in that, The port is provided with an annular flange, which is formed by pressing an annular region around the port in at least one of the partition plate and the metal support plate.

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