High-performance fuel cells

Abstract

A fuel cell unit includes a support structure having a plurality of flow channels and an active layer membrane coupled to the support structure, the active layer membrane including at least one electrode layer. Each of the plurality of flow channels is configured to direct one of air and fuel through the at least one electrode layer of the active layer membrane to generate an electric current. Each of the plurality of flow channels includes at least one enhancement feature configured to disrupt the formation of a boundary layer near the surface of the active layer membrane where the reaction occurs. The plurality of flow channels can be positioned in a zigzag configuration to increase the power density of the fuel cell unit.

Description

Technical Field

[0001] The present disclosure relates to high-performance fuel cells and combustion systems including such fuel cells. In particular, the present disclosure relates to fuel cell units including flow channels that each include enhanced features configured to disrupt the formation of a boundary layer near the surface of a reactive active layer membrane. The present disclosure also relates to fuel cell units including flow channels that alternate in a zigzag or seesaw configuration, thereby increasing the power density of the fuel cell unit. Background Art

[0002] Fuel cells are electrochemical energy conversion devices that have demonstrated the potential for relatively high efficiency and low pollution in power generation. Fuel cells typically provide direct current (dc), which can be converted into alternating current (ac) via, for example, an inverter. DC or ac voltage can be used to power motors, lamps, communications equipment, and any number of electrical devices and systems. Fuel cells can operate in stationary, semi-stationary, or portable applications. Some fuel cells (such as solid oxide fuel cells (SOFCs)) can operate in large-scale power systems that provide electricity to meet industrial and municipal needs. Others may be suitable for smaller portable applications, such as powering cars.

[0003] Fuel cells generate electricity by electrochemically combining a fuel and an oxidant across an ion-conducting layer. The ion-conducting layer (also known as the electrolyte of the fuel cell) can be liquid or solid. Common fuel cell types include phosphoric acid (PAFC), molten carbonate (MCFC), proton exchange membrane (PEMFC), and solid oxide (SOFC), which are often named after their electrolytes. In practice, fuel cells are usually assembled in a fuel cell assembly in an electrically series manner to generate electricity at a useful voltage or current. Typically, the components of a fuel cell include an electrolyte and two electrodes. The reaction that generates electricity usually occurs at the electrodes, and a catalyst is usually provided on the electrodes to accelerate the reaction. The electrodes can be configured as channels, porous layers, etc. to increase the surface area for chemical reactions to occur. The electrolyte transports charged particles from one electrode to the other and is essentially impermeable to the fuel and oxidant. Summary of the Invention

[0004] According to an embodiment, a fuel cell unit is provided that includes a support structure having a plurality of flow channels and an active layer membrane coupled to the support structure, the active layer membrane including at least one electrode layer. Each of the plurality of flow channels is configured to channel one of air and fuel across the at least one electrode layer of the active layer membrane to generate an electric current, and each of the plurality of flow channels includes at least one enhancement feature configured to disrupt the formation of a boundary layer near a surface of the active layer membrane where a reaction occurs.

[0005] According to an embodiment, a fuel cell is provided that includes a plurality of fuel cell units. Each of the plurality of fuel cell units includes a support structure having a plurality of flow channels and an active layer membrane coupled to the support structure, the active layer membrane including at least one electrode layer. Each of the plurality of flow channels is configured to channel one of air and fuel across the at least one electrode layer of the active layer membrane to generate an electric current, and each of the plurality of flow channels includes at least one enhancement feature configured to disrupt the formation of a boundary layer near a surface of the active layer membrane where a reaction occurs.

[0006] According to an embodiment, a method is provided, which includes directing fuel into a fuel inlet of a fuel cell in a fuel cell stack extending from an inlet end to a combustion outlet end, the fuel inlet being positioned near the inlet end of the fuel cell stack; directing air into an air inlet of the fuel cell, the air inlet being positioned near the inlet end of the fuel cell stack; generating electrical energy by directing air and fuel across opposite sides of an active layer membrane including an anode layer, an electrolyte layer, and a cathode layer; directing at least some of the fuel and at least some of the air through a flow channel of the fuel cell toward a combustion outlet of the fuel cell near the combustion outlet end of the fuel cell stack; and burning at least some of the fuel and at least some of the air near the combustion outlet end as output combustion from the fuel cell.

[0007] Additional features, advantages, and embodiments of the present disclosure are set forth or apparent by considering the following detailed description, drawings, and claims. In addition, it should be understood that the foregoing summary and the following detailed description of the present disclosure are exemplary and intended to provide further explanation without limiting the scope of the present disclosure as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The foregoing and other features and advantages will become apparent from the following more particular description of various exemplary embodiments as illustrated in the accompanying drawings, in which like reference numerals generally indicate identical, functionally similar, and / or structurally similar elements.

[0009] Figure 1 A perspective view of a fuel cell unit according to an embodiment of the present disclosure is shown.

[0010] Figure 2 Shown along Figure 1 The line 2-2 shown in Figure 1 Cross-sectional side view of a fuel cell unit.

[0011] Figure 3 The embodiment according to the present disclosure is shown Figure 1 and Figure 2 A cross-sectional side view of a stack of several fuel cell units is shown in FIG.

[0012] Figure 4 The embodiment according to the present disclosure is shown Figure 1 A top view of the catalyst side of a fuel cell unit.

[0013] Figure 5A A perspective view of a fuel cell unit according to an embodiment of the present disclosure is shown.

[0014] Figure 5B The embodiment according to the present disclosure is shown Figure 5A An enlarged view of one flow channel of a fuel cell unit.

[0015] Figure 6A The embodiment according to the present disclosure is shown Figure 1 Side view of a fuel cell unit.

[0016] Figure 6B The embodiment according to the present disclosure is shown Figure 5A Side view of a fuel cell unit.

[0017] Figure 7A The embodiment according to the present disclosure is shown Figure 1 A top view of the catalyst side of a fuel cell unit.

[0018] Figure 7B The embodiment according to the present disclosure is shown Figure 5A A top view of the catalyst side of a fuel cell unit.

[0019] Figure 8A A side view of a fuel cell unit according to an embodiment of the present disclosure is shown.

[0020] Figure 8B Shown along Figure 8A The line 8B-8B shown in FIG. Figure 8A Cross-sectional view of a fuel cell unit.

[0021] Figure 8C The embodiment according to the present disclosure is shown Figure 8B An enlarged partial view of a flow channel of a fuel cell unit.

[0022] Figure 9A The embodiment according to the present disclosure is shown Figure 8B The line bb shown in Figure 8A and Figure 8B A cross-sectional top view of one flow channel of a fuel cell unit.

[0023] Figure 9B Another embodiment according to the present disclosure is shown along Figure 8B The line bb shown in Figure 8A and Figure 8B A cross-sectional top view of one flow channel of a fuel cell unit.

[0024] Figure 9C Another embodiment according to the present disclosure is shown. Figure 8B The line bb shown in Figure 8A and Figure 8B A cross-sectional top view of one flow channel of a fuel cell unit.

[0025] Figure 9D Another embodiment according to the present disclosure is shown. Figure 8B The line bb shown in Figure 8A and Figure 8B A cross-sectional top view of one flow channel of a fuel cell unit.

[0026] Figure 10 An integrated fuel cell and combustion system according to one embodiment of the present disclosure is shown.

[0027] Figure 11 It shows that according to one embodiment of the present disclosure, Figure 10 Diagram of an integrated fuel cell and combustion system in which one or more portions provide power and / or propulsion for a vehicle system.

[0028] Figure 12 A flow chart illustrating one embodiment of a method for generating electrical energy and combustion from a fuel cell stack is shown. DETAILED DESCRIPTION

[0029] Various embodiments are discussed in detail below. Although specific embodiments are discussed, this is for illustrative purposes only. Those skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the present disclosure.

[0030] Improved fuel cell performance is needed. More particularly, there remains a need for fuel cells with improved performance and power density. Accordingly, the present disclosure relates to high performance fuel cells and combustion systems including such fuel cells. According to embodiments of the present disclosure, high performance fuel cells can be provided by using additive flow boundary layer disruption and pressurization geometries according to the principles of the present disclosure. For example, fuel cell performance may be limited by conventional manufacturing and / or boundary layers formed near the surfaces of electrodes and / or membranes where reactions occur. Fuel cells according to the principles of the present disclosure provide improved performance and power density through optimized design and / or features of the formation of swirling or disrupting boundary layers. According to the principles of the present disclosure, the size, volume and / or weight of the fuel cell can be reduced, which allows for a more compact structure and reduced cost. With a more compact structure and / or smaller volume, the fuel cell can be installed on, for example, a jet engine (e.g., a gas turbine engine) and can reduce emissions by at least 70%, with a potential lower heating value (LHV) efficiency of at least over 58%.

[0031] In one aspect, a fuel cell unit can include a flow channel that includes reinforcement features to disrupt the formation of a boundary layer near a surface of an active layer membrane where reactions occur.

[0032] A fuel cell unit may include a support structure having flow channels and an active layer membrane including electrode layers. The flow channels direct air and / or fuel across the electrode layers of the active layer membrane to generate an electric current. The flow channels may include reinforcement features to disrupt the formation of a boundary layer near the surface of the active layer membrane where the reaction occurs.

[0033] Figure 1 and Figure 2 FIG. 1 shows a fuel cell unit 100 according to an embodiment of the present disclosure. Figure 1 and 2 As shown, the fuel cell unit 100 includes a support structure 110 extending from a first side 114 to a second side 116, the support structure 110 having a plurality of elongated flow channels or passages shown as flow channels 120A, 120B. According to one embodiment, the support structure 110 is included in the stack (see, e.g., Figure 3 ) provides a metal support and / or ceramic support for current conduction between the fuel cells. The support structure 110 may also be referred to as a conductive support structure.

[0034] According to one embodiment, the support structure 110 includes a solid plate 112, and protrusions 130A, 130B extend away from the solid plate 112 in opposite directions (e.g., toward a side / surface 122 of the fuel cell unit 100 having an active layer membrane 115 (described in more detail below), and toward an opposite side / surface 124 of the fuel cell unit 100 (or an open side 124 because that side is not bounded or surrounded by any active layer membrane (e.g., active layer membrane 115))). The protrusions 130A, 130B extend the length of the plate 112, and therefore, the protrusions are elongated in the same direction as each flow channel 120A, 120B extends. These protrusions 130A, 130B and the plate 112 form a plurality of flow channels 120A, 120B, which, as shown, are elongated and located within the interior of the support structure 110. For example, the plurality of flow channels 120A, 120B extend into the interior of the support structure 110. The plurality of flow channels 120A, 120B can be less than one millimeter tall (e.g., in the direction in which the plurality of flow channels 120A, 120B extend into the support structure 110), for example, 25 mils (0.635 mm) tall. The plurality of flow channels 120A, 120B can be approximately 3 mm wide, for example, 3.176 mm wide. Alternatively, the plurality of flow channels 120A, 120B can be taller or shorter, wider or narrower.

[0035] In each fuel cell unit 100, the flow channels 120A on one side (e.g., side 122) of the plate 112 may be fuel channels or passages through which fuel flows through the fuel cell unit 100, while the flow channels 120B on the opposite side (e.g., side 124) of the plate 112 may be air channels or passages through which air flows through the fuel cell unit 100. Alternatively, the flow channels 120A on one side (e.g., side 122) of the plate 112 may be air channels or passages through which air flows through the fuel cell unit 100, while the flow channels 120B on the opposite side (e.g., side 124) of the plate 112 may be fuel channels or passages through which fuel flows through the fuel cell unit 100.

[0036] Flow channels 120A are each bounded or enclosed by an active layer membrane 115 (described in further detail below), two protrusions 130A, and plate 112. These flow channels 120A can be referred to as closed channels or passages. In contrast, flow channels 120B can be referred to as open channels or passages because these flow channels 120B are bounded on three sides by plate 112 and protrusions 130B, but are not bounded or enclosed by any active layer membrane (e.g., active layer membrane 115), and thus flow channels 120B are open along side 124 of support structure 110.

[0037] Figure 1 and 2The size of the support structure 110 can be relatively small. For example, the support structure 110 can have a length of, for example, eight centimeters (800 mm) long (e.g., in Figure 1 The support structure 110 may have a width of, for example, 2.5 centimeters (250 mm) long (e.g., in FIG. 1 ). Figure 1 The support structure 110 may also have a thickness of, for example, 2.2 mm (e.g., in FIG. Figure 1 Dimensions vertically or from top to bottom in the perspective view of the aircraft engine). The active layer membrane 115 (which will be described in more detail below) can have a footprint, or extend over a surface area, of, for example, ten square centimeters. Alternatively, the length and / or width of the support structure 110 and / or the dimensions of the active layer membrane 115 can be less than or greater than these dimensions. Although the support structure 110 is shown as a flat plate, the support structure 110 can optionally have a non-planar shape. For example, the support structure 110 can be formed as a curved plate around the central axis of the aircraft engine. Alternatively, the support structure 110 can have another shape. Although other components of the fuel cell unit 100 are shown as planar bodies or plates, these other components can also optionally have non-planar shapes, such as the support structure 110.

[0038] Figure 1 and 2 The fuel cell unit 100 further includes an active layer membrane 115. According to one embodiment, the active layer membrane 115 may include multiple layers. For example, Figure 2As shown in the embodiment of the present invention, the active layer membrane 115 can be disposed on the support structure 110 and separated from the support structure 110 by a porous support layer 140. The porous support layer 140 can be formed of one or more materials that form pores to allow fuel and air to flow through the porous support layer 140. In one embodiment, the support structure 110 and the porous support layer 140 can each be formed of the same type of material. Alternatively, depending on the embodiment, the support structure 110 can be formed to be non-porous (e.g., the fluid cannot pass through the support structure 110), while the porous support layer 140 can be formed to include pores through which one or more fluids can pass through the porous support layer 140. Examples of materials that can be used to produce the support structure 110 and / or the porous support layer 140 include, for example, conductive ceramic materials (e.g., for the porous support layer 140, a foam made of a ceramic-metal hybrid material), metals, metal alloys, etc. The porous support layer 140 may be formed by, for example, thermally spraying a material for forming the porous support layer 140 on the support structure 110, by forming a foam as the porous support layer 140 on the support structure 110 while brazing the support structure 110 (and optionally adding a sintering aid to the foam), by additively manufacturing the porous support layer 140 on the support structure 110, by casting the porous support layer 140 using a slurry, by heat treating the foam to form the porous support layer 140 in an inert gas environment, by using a metal structure (such as a mesh or net), etc. In all cases, the porous support layer 140 is bonded to the support structure 110 in some manner, for example.

[0039] Figure 2 The active layer membrane 115 also includes an anode layer 150, which is deposited or otherwise formed on the porous support layer 140. The anode layer 150 is generally formed of a material that serves as an anode of a fuel cell formed by a combination of two fuel cell units 100. The active layer membrane 115 also includes an electrolyte layer 160 deposited or otherwise formed on the anode layer 150. The electrolyte layer 160 is generally formed of a material that serves as an electrolyte of a fuel cell (e.g., a solid oxide fuel cell (SOFC)) formed by a combination of two fuel cell units 100. The active layer membrane 115 also includes a cathode layer 170 deposited or otherwise formed on the electrolyte layer 160. The cathode layer 170 is generally formed of a material that serves as a cathode of a fuel cell formed by a combination of two fuel cell units 100. Alternatively, the cathode layer 170 may be on and in contact with the porous support layer 140 instead of the anode layer 150, where the anode layer 150 is located Figure 2 The location of cathode layer 170 is shown. The two-dimensional area or footprint of layers (including, for example, anode layer 150, electrolyte layer 160, and cathode layer 170, with or without porous support layer 140) that overlie one another in whole or in part defines the active layer membrane 115 of fuel cell unit 100.

[0040] According to one embodiment, the electrodes of the fuel cell unit 100 (e.g., Figure 2 The anode layer 150, electrolyte layer 160 and / or cathode layer 170 may be deposited on a porous support (e.g., Figure 2 The porous supporting layer 140 may have pores large enough to allow the fuel (eg, gaseous fuel) flowing in the flow channel 120A to diffuse through the porous supporting layer 140 to the electrodes (eg, Figure 2 anode layer 150, electrolyte layer 160 and / or cathode layer 170). However, the pores may be small enough to prevent the formation of electrodes (e.g., Figure 2 The porous support layer 140 may be provided with a plurality of porous support layers 140. ... Figure 2 The size of the particles of the anode layer 150, electrolyte layer 160 and / or cathode layer 170 can be smaller or larger. Figure 2 The material layers of the anode layer 150, the electrolyte layer 160 and / or the cathode layer 170) may be deposited using thermal spraying or other deposition techniques.

[0041] The fuel cell unit 100 can be relatively thin. For example, the support structure 110 can be, for example, approximately 2.2 millimeters thick. According to one embodiment, the support structure 110 can be within 3% of 2.2 millimeters. The active layer membrane 115 can be, for example, approximately 200 microns thick. According to one embodiment, the active layer membrane 115 can be within 3% of 200 microns. The cathode layer 170 can be, for example, 50 to 100 microns thick, the electrolyte layer 160 can be, for example, 5 to 30 microns thick, and the anode layer 150 can be, for example, 50 to 100 microns thick. Alternatively, one or more of these layers can be thicker or thinner than these example dimensions.

[0042] The support structure 110 (eg, conductive support structure) and the electrodes (eg, Figure 2 The anode layer 150, electrolyte layer 160 and / or cathode layer 170 of the fuel cell unit 100 may be formed of one or more corrosion-resistant metals to slow down the degradation of the fuel cell unit 100 (relative to using non-corrosion-resistant metals). Examples of metals that may be used include, but are not limited to SS430 series stainless steel (such as SS430, SS431, etc.), JETHETE M152TM , CROFER 22APU and alloys, nickel and nickel-chromium alloys, etc. The metal may have a large chromium content (eg, greater than 8-10% by weight of the metal support structure 110 and / or porous support layer 140, for example) to impart greater conductivity to the support.

[0043] In one embodiment, a thin protective coating (e.g., a coating thinner than the cathode layer 170 and / or the anode layer 150) may be provided on the support structure 110 on the cathode or anode side of the fuel cell unit 100 to increase the conductivity of the oxide scale or to prevent chromium evaporation and electrode (e.g., Figure 2 The protective coating may be formed of materials such as cobalt, manganese, a combination of cobalt and manganese, an electronically conductive ceramic, etc.

[0044] Figure 3 Shown Figure 1 and Figure 2 FIG. 1 is an embodiment of a cross-sectional view of a stack 200 of several fuel cell units 100 shown in FIG. The number of fuel cell units 100 in the stack 200 is provided as an example. A greater or lesser number of fuel cell units 100 may be included in the stack 200. The stack 200 is connected to the stack 200 by Figure 2 The stack 200 is shown in cross-section in the same plane as that shown for a single fuel cell unit 100. The stack 200 extends from an inlet end 202 to an opposite end 204. Air and / or fuel flows in the flow channels 120A, 120B of each fuel cell unit 100 in a direction extending into the support structure 110 of each fuel cell unit 100.

[0045] The fuel cell units 100 can be placed in contact with each other so that some fuel cell units 100 have an open side 124 of the support structure 110 in contact with the active layer membrane 115 of another fuel cell unit 100. This can close the flow channel 120B between the plate 112 of one fuel cell unit 100, the two protrusions 130B of the same fuel cell unit 100, and the active layer membrane 115 of another fuel cell unit 100, as shown in FIG. Figure 3 This stacking of fuel cell units 100 forms a plurality of fuel cells 206, each of which is formed by a portion but not all of two fuel cell units 100. The end fuel cell units 100 (e.g., Figure 3 The fuel cell unit 100A in FIG. 1 may not have the protrusion 130B or the flow channel 120B on one side of the plate 112 of the fuel cell unit 100A. The other end fuel cell unit 100 (e.g., Figure 3The fuel cell unit 100B in FIG. 1 may be connected to the end cap support structure 208. The end cap support structure 208 may be the portion of the support structure 110 that includes the plate 112 and the protrusions 130B (and corresponding channels 120B), but does not include the protrusions 130A (or corresponding channels 120A).

[0046] like Figure 3 As shown, fuel cell units 100 are stacked on top of each other to form a plurality of fuel cells 206. The number of fuel cells 206 in each stack 200 can be increased by including more fuel cell units 100 in the stack 200. Within each fuel cell 206, fuel flows on one side of the active layer membrane 115 in the flow channel 120A of one fuel cell unit 100, while air flows on the other side of the same active layer membrane 115 in the flow channel 120B of another fuel cell unit 100. At least some of the fuel can pass through the porous support layer 140 to reach the anode layer 150, and the air can contact the cathode layer 170, allowing the fuel cell 206 to generate current. Alternatively, air can flow on one side of the active layer membrane 115 in the flow channel 120A of one fuel cell unit 100 in the fuel cell 206, while fuel flows on the other side of the same active layer membrane 115 in the flow channel 120B of another fuel cell unit 100. At least some air can pass through the porous support layer 140 to the cathode layer 170 on the porous support layer 140, and the fuel can contact the anode layer 150 on the opposite side of the active layer membrane 115 so that the fuel cell 206 can generate electrical current.

[0047] The fuel cells 206 can be connected in series with each other so that the currents generated in the fuel cells 206 are additively combined. The current generated by each fuel cell 206 can be conducted through the support structure 110 to a conductor (e.g., bus, wire, etc.) connected to several fuel cells 206. Alternatively, two or more fuel cells 206 can be connected in parallel with each other. The current can be transferred from the stack 200 and the housing (see, for example, FIG. 1 ) via one or more conductors (e.g., one or more buses, wires, cables, etc.). Figure 10 The housing 2010 shown in FIG. 2 is conducted out.

[0048] Figure 4 A view of one embodiment of a catalyst side 300 of a fuel cell unit 100 is shown. The fuel cell unit 100 represents a portion of one or more fuel cells included in a stack (e.g., Figure 3 of the fuel cell 206 of the stack 200) and / or the housing (see e.g. Figure 10The fuel cell unit 100 extends from the inlet end 304 to the opposite outlet end (or combustion end) 306 along a first direction, and extends from the catalyst side 300 to the opposite open side (or combustion end) along a second direction orthogonal to the first direction. Figure 4 Not visible in Figure 2 ), and extends from one edge 308 to an opposite edge 310 along a third direction orthogonal to the first and second directions. As described above, the first direction can be referred to as a flow direction because this is the direction in which air and fuel flow in the flow channels (e.g., flow channels 120A, 120B) of the fuel cell unit 100. As described above, the second direction can be referred to as a thickness direction or a cross direction because the thickness of the fuel cell unit 100 is measured along this second direction, and the fuel or air crosses and exits the flow channels to the catalyst stack or active layer membrane in this direction. The third direction can be referred to as a width direction of the fuel cell unit 100. The outlet end 306 of the fuel cell unit 100 can be located at the outlet side of the housing or extend together with the outlet side of the housing (see, for example Figure 10 The inlet port 304 may be located at or within a side of the housing (see, e.g., Figure 10 2016 of the housing 2010), the edge 308 may be located at or within a side of the housing (see, e.g., Figure 10 2015 of the housing 2010), and the opposing edges 310 may be located at or within opposing sides of the housing (see, e.g., Figure 10 side 2014 of the housing 2010).

[0049] Several fuel cell units 100 may be stacked together or sandwiched within a housing (see e.g. Figure 3 A stack of 200 and / or Figure 10 For example, several fuel cell units 100 may be placed in contact with each other so that the catalyst side 300 of the fuel cell units 100 faces the inlet side of the housing (see, e.g., Figure 10 20). The catalyst side 300 represents a side of the fuel cell unit 100 having several catalyst layers in the active layer membrane 115 of the fuel cell unit 100. As described above, these layers include an anode layer, a cathode layer, and an electrolyte layer (e.g., a solid oxide layer) disposed between the anode layer and the cathode layer (see, e.g., Figure 2 The fuel cell unit 100 includes a fuel inlet 312 and an air inlet 314 to respectively provide fuel and air to the flow channels 120A and / or 120B of the fuel cell unit 100. The fuel inlet 312 can be connected to the fuel inlet of the housing (see, for example, Figure 10The fuel inlet 2050 of the housing 2010 is aligned with or otherwise fluidly coupled thereto, and the air inlet 314 can be aligned with the air inlet of the housing (see, e.g., Figure 10 The air inlet 2060 of the housing 2010 is aligned with or otherwise fluidly coupled to the housing 2010. When the fuel cell units 100 are stacked on each other (see, e.g., FIG. Figure 3 The fuel inlet 312 may be aligned with or otherwise fluidly coupled to the fuel inlet so that the flow channel 120A or 120B of the fuel cell unit 100 receives fuel from the fuel inlet (see, e.g., FIG. Figure 10 The air inlet 314 can be aligned with or otherwise fluidly coupled to the air inlet so that the flow channel 120A or 120B of the fuel cell unit 100 receives fuel injected into the housing via the air inlet (see, e.g., Figure 10 The air is injected into the housing through the air inlet 2060 of the housing 2010.

[0050] According to the principles of the present disclosure, flow channels can be constructed in a compact arrangement. By creating flow channels in a compact arrangement, the size, volume and / or weight of the fuel cell unit can be reduced, which allows for a more compact structure and reduced costs. This can also provide increased power density. Reference Figure 5A , an exemplary configuration is shown and described. In particular, Figure 5A FIG. 4 shows a fuel cell unit 400 according to another embodiment. Figure 5A As shown, the fuel cell unit 400 includes a support structure 410 and an active layer membrane 415. The active layer membrane 415 may include, for example, a porous support layer, an anode layer, an electrolyte layer, and / or a cathode layer (see, for example, Figure 2 The porous support layer 140, the anode layer 150, the electrolyte layer 160 and the cathode layer 170). Figure 5A In one embodiment, the support structure 410 extends from a first side 414 to a second side 416, wherein the support structure 410 has a plurality of flow channels 420A, 420B. According to one embodiment, the flow channels 420A on one side (e.g., side 422) of the support structure 410 can be fuel channels or passages through which fuel flows through the fuel cell units 400, while the flow channels 420B on the opposite side (e.g., side 424) of the support structure 410 can be air channels or passages through which air flows through the fuel cell units 400. Alternatively, the flow channels 420A on one side (e.g., side 422) of the support structure 410 can be air channels or passages through which air flows through the fuel cell units 400, and the flow channels 420B on the opposite side (e.g., side 424) of the support structure 410 can be fuel channels or passages through which fuel flows through the fuel cell units 400.

[0051] like Figure 5A and 5B As further shown in the embodiment of FIG, the flow channels 420A, 420B are positioned in an alternating or zigzag and / or seesaw configuration such that the flow channels 420A on one side (e.g., side 422) of the support structure 410 including the active layer membrane 415 alternate in a zigzag configuration with the flow channels 420B on the opposite side (e.g., side 424) of the support structure 410. According to one embodiment, the walls of each of the flow channels 420A, 420B (see, e.g., FIG) are arranged such that the flow channels 420A, 420B are arranged in an alternating or zigzag configuration. Figure 5B The walls 421A, 421B) are positioned at 45 to 90 degrees to each other so that one wall of the flow channels 420A, 420B (see e.g. Figure 5B The wall 421A) can be positioned perpendicular to another wall of the same flow channel 420A, 420B (see e.g. Figure 5B wall 421B). Therefore, Figure 1 and Figure 2 Compared with the embodiment, Figure 5A The support structure 410 does not include a plate with a plurality of protrusions forming flow channels on each side of the plate (see e.g. Figure 1 and 2 plate 112 with protrusions 130A, 130B and channels 120A and 120B). Figure 5A This alternating or zigzag configuration of embodiments creates flow channels 420A, 420B, which can reduce the size, volume, and / or weight of the fuel cell unit 400, allowing for a more compact structure and reduced costs. For example, according to one embodiment, the height of the support structure 410 (i.e., the height from side (or surface) 422 to side (or surface) 424 of the support structure 410) can be reduced to approximately 2 mm, compared to a typical height of approximately 5 mm. Figure 1 and Figure 2 The height of the support structure 110 of the fuel cell unit 100 (ie, the height from a side (or surface) 122 to an opposite side (or surface) 124 of the support structure 110 ) is greatly reduced compared to that of the fuel cell unit 100 .

[0052] In addition, through Figure 5A The alternating or zigzag configuration of the embodiment generates flow channels 420A, 420B, and the fuel cell unit 400 can further have an increased power density. Figure 5B As shown, this zigzag configuration of the flow channels 420A, 420B creates a swirl channel 450 (or swirl geometry) in one or both of the flow channels 420A, 420B, which can more effectively separate the reacted and unreacted gases. This swirl channel 450 (or swirl geometry) can also help prevent and / or damage to the electrodes of the active layer membrane 415 where the reaction occurs (see, for example, Figure 2According to one embodiment, a boundary layer is formed near the surface of the anode layer 150, the electrolyte layer 160 and / or the cathode layer 170. Figure 5A This alternating or zigzag configuration of the flow channels 420A, 420B of embodiments may result in a disruption to the formation of a boundary layer, which may result in a reduction in mass transfer unit polarization, which in turn may result in higher cell output power (eg, power density).

[0053] Relative to Figure 1 and Figure 2 The fuel cell unit 100, Figure 5A The advantages of the fuel cell unit 400 are Figure 6A 、 6B , 7A and 7B. For example, Figure 6A and 6B As shown, which are drawn to scale relative to each other, the size and / or height of the fuel cell unit 400 can be greatly reduced relative to the size and / or height of the fuel cell unit 100 while maintaining the same channel dimensions in the flow channels 420A, 420B. According to one embodiment, the channel height can be optimized by adjusting the channel height and / or width to maximize the battery volume and weight power density. Although reducing the channel size may result in flow rate backpressure, various parameters can be optimized to maximize battery power while maintaining a desired backpressure for, for example, an engine. As described above, according to one embodiment, the height of the support structure 410 (i.e., from Figure 5A The height of the support structure 410 from side (or surface) 422 to side (or surface) 424 can be reduced to about 2 mm, which is generally about 5 mm. Figure 1 and Figure 2 The height of the support structure 110 of the fuel cell unit 100 (i.e., from Figure 2 The height of the fuel cell unit 400 is greatly reduced compared to the side (or surface) 122 of the support structure 110 to the opposite side (or surface) 124. This reduction in size and / or height of the fuel cell unit 400 is at least related to the removal of the plate 112 of the support structure 110 of the fuel cell unit 100 and the alternating or zigzag configuration of the flow channels 420A, 420B of the fuel cell unit 400. According to one embodiment, this configuration of the fuel cell unit 400 and the reduction in size thereof can be achieved by producing the fuel cell unit 400 via additive manufacturing. Additive manufacturing can involve joining or solidifying materials under computer control to produce a three-dimensional object, for example, by adding liquid molecules or melting powder particles to each other. Examples of additive manufacturing include three-dimensional (3D) printing, rapid prototyping (RP), direct digital manufacturing (DDM), selective laser melting (SLM), electron beam melting (EBM), direct metal laser melting (DMLM), etc. Alternatively, the fuel cell unit 400 can be formed in another way.

[0054] According to another embodiment, Figure 5A The alternating or zigzag configuration of the flow channels 420A, 420B of the fuel cell unit 400 results in an increase in the area of ​​the active layer membrane 415 or the cathode active area. This increase in the active area of ​​the active layer membrane 415 can occur, for example, by minimizing the width of the outer wall of the fuel cell unit (e.g., fuel cell unit 100). For example, as drawn to scale relative to each other Figure 7A and 7B As shown, Figure 1 and 2 The fuel cell unit 100 of the embodiment of the present invention includes a catalyst side 300, which represents a side of the fuel cell unit 100 having several catalyst layers in the active layer membrane 115 of the fuel cell unit 100. As described above, these layers include an anode layer, a cathode layer, and an electrolyte layer (e.g., a solid oxide layer) disposed between the anode layer and the cathode layer (see, e.g., FIG. Figure 2 The fuel cell unit 100 further includes a fuel inlet 312 and an air inlet 314. Figure 7B As shown in the embodiment, Figure 5A The fuel cell unit 400 of the embodiment of the present invention also includes a catalyst side 500, which represents a side of the fuel cell unit 400 having several catalyst layers in the active layer membrane 415 of the fuel cell unit 400. Again, as described above, these layers include an anode layer, a cathode layer, and an electrolyte layer (e.g., a solid oxide layer) disposed between the anode layer and the cathode layer (see, e.g., FIG. Figure 2 The fuel cell unit 400 further includes a fuel inlet 512 and an air inlet 514. Figure 7B As shown in the embodiment of Figure 7A Compared to the active layer membrane 115 or cathode active area of ​​the fuel cell unit 100, the size of the active layer membrane 415 or cathode active area of ​​the fuel cell unit 400 can be increased due to, for example, the alternating or zigzag configuration of the flow channels 420A, 420B of the fuel cell unit 400, which can result in an increase in the performance and / or power density of the fuel cell unit 400.

[0055] Figures 8A-8C FIG. 1 shows a fuel cell unit 100 ′ according to an embodiment. Figure 8A As shown, the fuel cell unit 100' includes a support structure 110 and an active layer membrane 115. The active layer membrane 115 may include, for example, a porous support layer, an anode layer, an electrolyte layer and / or a cathode layer (see, for example Figure 2 The porous support layer 140, the anode layer 150, the electrolyte layer 160 and the cathode layer 170 are similar to Figure 1 and Figure 2In an embodiment of the fuel cell unit 100, Figure 8A In the embodiment of FIG. 1 , the support structure 110 includes a plate 112 having protrusions that create a plurality of flow channels 120A, 120B (see, e.g., FIG. 2 ). Figure 2 According to one embodiment, flow channel 120A may be a fuel channel or passage through which fuel flows through fuel cell unit 100', and flow channel 120B may be an air channel or passage through which air flows through fuel cell unit 100'. Alternatively, flow channel 120A may be an air channel or passage through which air flows through fuel cell unit 100', and flow channel 120B may be a fuel channel or passage through which fuel flows through fuel cell unit 100'.

[0056] According to one embodiment, Figures 8A-8C One or both of the flow channels 120A, 120B of the fuel cell unit 100' further include one or more reinforcing features configured to prevent and / or disrupt the flow of the active layer membrane 115 near the surface where the reaction occurs (e.g., at the electrode of the active layer membrane 115 where the reaction occurs (see, e.g., Figure 2 The formation of a boundary layer near the surface of the anode layer 150, the electrolyte layer 160 and / or the cathode layer 170). Figure 8B and 8C In an embodiment, the flow channel 120A may include a webbing material 600 made of, for example, a metal wire and attached to the surface of each of the plurality of flow channels 120A, wherein the webbing material 600 is configured to disrupt the formation of a boundary layer near the surface of the active layer membrane 115 (e.g., one or more electrode layers discussed above) where the reaction occurs. According to another embodiment, the webbing material 600 may also improve the ability of the flow channel 120A and / or the fuel cell unit 100' to handle high pressure operations. Although Figures 8A-8C The embodiment shows only the webbing material 600 being attached to one set of flow channels 120A of the support structure 110 , but the webbing material 600 may also or alternatively be attached to another set of flow channels 120B of the support structure 110 .

[0057] According to another embodiment, Figure 8A The flow channel 120A of the support structure 110 of the fuel cell unit 100' may include one or more enhancement features in the form of a plurality of internal three-dimensional features. These features may be Figure 8C 600 of webbing material or Figure 8C An alternative to the webbing material 600. For example, Figure 9AAs shown, the one or more enhancement features may include a plurality of internal bumps 700 disposed along the length of one or more sidewalls of the flow channel 120A. According to one embodiment, the internal bumps 700 are disposed along the inner surface of one or more sidewalls of the flow channel 120A (see, e.g., Figure 9A According to another embodiment, the inner bump 700 is formed along the porous support layer (see for example Figure 2 The internal bumps 700 are provided on the underside of the porous support layer 140 (e.g., the surface of the porous support layer facing the flow channel 120A). These internal bumps 700 are configured to, for example, generate turbulence in the flow in the flow channel 120A and thereby reset the formation of a potential boundary layer at each bump 700. Figure 9B Another embodiment is shown in which the one or more reinforcing features may include a plurality of internal ridges 800 disposed along the length of one or more sidewalls of the flow channel 120A, wherein each internal ridge 800 includes a raised portion 800A (or convex portion) extending into the flow channel 120A and a recessed portion 800B (or concave portion) extending away from the flow channel 120A. These internal ridges 800 are configured, for example, to reset the formation of a potential boundary layer at each ridge 800. Figure 9C Another embodiment is shown in which one or more enhancement features are in the form of a spiral shape 900 disposed along the flow channel 120A. According to one embodiment, the spiral shape 900 may be formed inside the flow channel 120A and traverse the length of the respective flow channel 120A. According to another embodiment, the spiral shape 900 may be formed by creating a mesh that forms a turbulator within the flow channel 120A. Such a spiral or swirl shape 900 is configured to cause the air and / or gas flow through the flow channel 120A to rotate, and / or move in a vertical motion along the length of the flow channel 120A, thereby disrupting the formation of any boundary layer along the length of the flow channel 120A. While Figures 9A-9C The embodiment only shows the various enhancement features (700, 800, 900) being arranged along one set of flow channels 120A of the support structure 110, but the various enhancement features (700, 800, 900) may also or alternatively be arranged along another set of flow channels 120B of the support structure 110.

[0058] According to each of the various embodiments of the enhancement features discussed above, the enhancement features are configured to disrupt the formation of a boundary layer near the surface of the active layer membrane 115 (e.g., one or more electrode layers discussed above) where the reaction occurs. For example, according to one embodiment, each enhancement feature is configured to generate turbulence and / or rotation of the air and / or fuel as the air and / or fuel flows in the direction F along the flow channel 120A (see, e.g., FIG. 1 ). Figures 9A-9C)). The creation of turbulence and / or rotation in this flow helps prevent and / or disrupt the formation of a boundary layer near the surface of the active layer membrane 115 (eg, one or more electrode layers discussed above) where the reaction occurs.

[0059] According to one embodiment, a plurality of internal pillars may be positioned within each of the plurality of flow channels, wherein the plurality of internal pillars are configured to allow for pressurization of the fuel cell unit. Figure 9D As shown, a plurality of internal posts 1000 are disposed along the length of one or more side walls of the flow channel 120A. According to this embodiment, the plurality of internal posts 1000 can support pressures that may arise in the fuel cell unit and / or the fuel cell itself, which allows for additional pressurization of the fuel cell unit. For example, according to one embodiment, the internal posts 1000 extend across the width and / or height of the flow channel 120A at multiple locations such that the internal posts 1000 can act as an internal support structure, which improves tolerance to high internal pressures, including, for example, if the internal posts 1000 are attached to a porous support layer at multiple points (see, e.g., FIG. Figure 2 porous supporting layer 140). Although Figure 9D The embodiment only shows that the plurality of internal columns 1000 are arranged along one set of flow channels 120A of the support structure 110 , but the plurality of internal columns 1000 may also or may alternatively be arranged along another set of flow channels 120B of the support structure 110 .

[0060] According to one embodiment, the above-mentioned webbing material (e.g., Figure 8C The webbing material 600), the various reinforcement features (700, 800, 900) and / or the plurality of internal posts 1000 may be additively manufactured. Additive manufacturing may involve joining or solidifying materials under computer control to produce a three-dimensional object, for example, by adding liquid molecules or melting powder particles to one another. Examples of additive manufacturing include three-dimensional (3D) printing, rapid prototyping (RP), direct digital manufacturing (DDM), selective laser melting (SLM), electron beam melting (EBM), direct metal laser melting (DMLM), and the like. Alternatively, the webbing material (e.g., Figure 8C The webbing material 600 ), the various reinforcing features ( 700 , 800 , 900 ), and / or the plurality of interior posts 1000 may be formed in another manner.

[0061] Figure 10 An embodiment of an integrated fuel cell and combustion system 2000 is shown. The system 2000 includes a housing 2010 having a combustion outlet side 2012 and an opposite side 2016, a fuel and air inlet side 2022 and an opposite side 2024, and opposite sides 2014, 2015. Sides 2016, 2014, and 2024 are Figure 10The shape of the housing 2010 may be different from Figure 10 For example, in another embodiment, the housing 2010 need not have a rectangular or cubic shape.

[0062] The outlet side 2012 includes a number of combustion outlets 2080 from which combustion 2088 is directed out of the housing 2010. As described herein, the combustion 2088 may be directed out of the housing 2010 using a fuel cell stack (see, e.g., FIG. Figure 3 ) is produced by fuel and air consumed by a fuel cell in a combustion chamber. This combustion 2088 can be used to generate propulsion or thrust for a vehicle (such as a manned or unmanned aircraft).

[0063] The inlet side 2022 includes one or more fuel inlets 2050 and one or more air inlets 2060. Optionally, one or more of the inlets 2050, 2060 can be located on the other side of the housing 2010. The fuel inlet 2050 is fluidically coupled to a fuel source (e.g., one or more pressurized containers containing hydrogen gas) of the fuel cell. Alternatively, a fuel of another type or source can be used. The air inlet 2060 is fluidically coupled to an air source (e.g., one or more pressurized oxygen containers) for the fuel cell. Alternatively, another air source can be provided. The inlets 2050, 2060 receive fuel and air from external fuel and air sources, respectively, and guide the fuel and air into the fuel cell, respectively.

[0064] In one embodiment, the inlet side 2022 and the outlet side 2012 can be the only sides of the housing 2010 that are not sealed. For example, the housing 2010 can be sealed to prevent fluids (gas and / or liquids) from entering or exiting the housing 2010, except for the fuel and air inlets 2050, 2060 and the combustion outlet 2080. The air and fuel introduced into the housing 2010 via the inlets 2050, 2060 can be completely or substantially consumed (e.g., at least 98% of the volume or mass is consumed) by the fuel cell within the housing 2010 and / or producing the combustion 2088. This can allow the housing 2010 to have no other outlets through which fuel or air flows, other than the combustion outlet 2080 through which the combustion 2088 exits the housing 2010.

[0065] In one embodiment, system 2000 can be formed from one hundred fuel cells stacked side by side from end 2022 to end 2024. Alternatively, system 2000 can include fewer or more fuel cells stacked side by side. According to one embodiment, system 2000 can be 8 centimeters tall, 2.5 centimeters wide, and 24 centimeters long. Alternatively, system 2000 can be taller or shorter, wider or narrower, and / or longer or shorter than these example dimensions.

[0066] Figure 1 and 2 The fuel cell unit 100 and Figures 5A-9D The fuel cell units 400 and 100' shown in the embodiments of the present invention may represent the fuel cell units 400 and 100' included in the embodiment of the present invention. Figure 10 A portion of one or more fuel cells in the housing 2010 is shown. Additionally, as described above, Figure 4 、 Figure 7A and Figure 7B Shown respectively Figure 1 and Figure 5A 100, 400 of the fuel cell unit 300, 500 of the catalyst side of the view of an embodiment. According to one embodiment, the outlet end 306, 506 of the fuel cell unit 100, 400 can be located on the outlet side 2012 of the housing 2010 (eg, Figure 10 ) or coextensive with the outlet side 2012 of the housing 2010. For example, Figure 10 The outlet 2080 shown in FIG. 1 may be the outlet end 306, 506 ( FIG. 2 ) of a stack of fuel cell units 100, 400. Figure 7A and 7B ). Inlet ports 304, 504 ( Figure 7A and 7B ) can be located at or within side 2016 of the shell 2010, the edges 308, 508 can be located at or within side 2015 of the shell 2010, and the relative edges 310, 510 can be located at or within the opposite side 2014 of the shell 2010.

[0067] Several fuel cell units (e.g., fuel cell units 100, 400, and / or 100') can be stacked together or sandwiched within the housing 2010. For example, several fuel cell units (e.g., fuel cell units 100, 400, and / or 100') can be placed in contact with each other such that the catalyst side (e.g., catalyst side 300 and / or 500) of the respective fuel cell units (e.g., fuel cell units 100, 400, and / or 100') faces the inlet side 2022 of the housing 2010. The fuel inlet (e.g., fuel inlet 312 and / or 512) can be aligned with or otherwise fluidly coupled to the fuel inlet 2050 of the housing 2010, and the air inlet (e.g., air inlet 314 and / or 514) can be aligned with or otherwise fluidly coupled to the air inlet 2060 of the housing 2010. When the fuel cell units (e.g., fuel cell units 100, 400, and / or 100') are stacked on one another, the fuel inlet (e.g., fuel inlet 312 and / or 512) can be aligned with or otherwise fluidly coupled to the fuel inlet 2050 so that the fuel cell units (e.g., fuel cell units 100, 400, and / or 100') receive fuel injected into the housing 2010 via the fuel inlet 2050. The air inlet (e.g., air inlet 314 and / or 514) can be aligned with or otherwise fluidly coupled to the air inlet 2060 so that the fuel cell units (e.g., fuel cell units 100, 400, and / or 100') receive air injected into the housing 2010 via the air inlet 2060.

[0068] Figure 11 An embodiment of a vehicle system 3000 is shown, which may be at least partially comprised of Figure 10 One or more of the integrated fuel cell and combustion systems 2000 shown in provide power and / or propulsion. Vehicle system 3000 may alternatively be referred to as a vehicle. Vehicle system 3000 is shown as an aircraft (e.g., an unmanned aerial vehicle), but may alternatively be a manned aircraft, a ship, or a land-based vehicle (e.g., a car, a rail vehicle, a mining vehicle, etc.). Vehicle system 3000 includes one or more integrated fuel cell and combustion systems 2000 that generate combustion 2088 to propel or assist in propulsion of vehicle system 3000. For example, combustion 2088 may provide thrust to vehicle system 3000 to help move vehicle system 3000.

[0069] The vehicle system 3000 may include one or more power systems 3005, 3010 that receive electrical current generated by the integrated fuel cell and combustion system 2000 to perform work. For example, the power systems 3005, 3010 may be fuel cells (e.g., fuel cell units 100, 400, and / or 100') that are at least partially powered by stacked fuel cell units (e.g., fuel cell units 100, 400, and / or 100') in the integrated fuel cell and combustion system 2000. Figure 3 Examples of power systems 3005, 3010 may be control circuits that control movement, thrust, throttle setting, direction of movement, etc., of vehicle system 3000, weapons, navigation systems, motors (e.g., rim motors), etc. of vehicle system 3000. Power systems 3005, 3010 may be conductively coupled to system 2000 to receive power from fuel cells (e.g., fuel cell units 100, 400, and / or 100') of stacked fuel cell units. Figure 3 The fuel cell 206) receives the current.

[0070] Figure 12 A flow chart of one embodiment of a method 4000 for generating electrical energy and combustion from a fuel cell stack is shown. The method 4000 may describe the fuel cell units (100, 400, 100') described herein, the fuel cells (see, e.g., Figure 3 The operation of one or more embodiments of the fuel cell 206 and / or integrated fuel cell and combustion system 2000 may be controlled automatically by one or more processors, pumps, valves, motors, etc. to automatically control the fuel cells in the system 2000 to simultaneously or synchronously generate electrical current for propulsion and combustion.

[0071] At 4002, air and fuel are directed into separate flow channels of a fuel cell unit (100, 400, 100') and / or fuel cell having at least one enhancement feature (as described above) to disrupt the fuel cell stack of the system (see e.g. Figure 3 For example, oxygen can be introduced into the air inlet 2060 of the housing 2010 of the system 2000, and gas can be introduced into the fuel inlet 2050 of the housing 2010 of the system 2000. These inlets are respectively connected to the air channels and fuel channels in different fuel cells.

[0072] At 4004, a catalyst layer stack (or active layer membrane) in a fuel cell is used to pass through or otherwise contact the catalyst layer stack (or active layer membrane) in the fuel cell (see, e.g., Figure 1 and Figure 2 Active layer membrane 115 and / or Figure 5AAt least some of the fuel and air in the active layer membrane 415 of the fuel cell generates current. For example, the fuel channel may extend on one side of the catalyst layer stack in each fuel cell, and the air channel may extend on the opposite side of the catalyst layer stack in the same fuel cell. The fuel and air respectively contact the cathode layer and the anode layer in the catalyst layer stack of each fuel cell to generate current (see, for example, Figure 1 and 2 The current can flow through the fuel cell support structure (see e.g. Figure 1 and 2 The support structure 110 and / or Figure 5A support structure 410) to one or more external loads.

[0073] Air and fuel that are not consumed during the generation of electrical current continue to flow through the elongated fuel and air channels at 4006. The air and fuel may remain separated within the fuel cell while the air and fuel flow toward the open ends of the air and fuel channels within the fuel cell.

[0074] At 4008, air and fuel that were not consumed during the generation of current and that flowed to the open ends of the flow channels of the fuel cell are combusted. This combustion can occur just outside the open ends of the channels, outside the fuel cell. At 4010, the current generated by the fuel cell is optionally used to power one or more loads (e.g., one or more electronic components of the aircraft). The combustion generated by the fuel cell can be used to propel the aircraft or assist in propulsion of the aircraft.

[0075] Although various dimensions are provided herein for the system 2000 and fuel cell units (100, 400, 100'), these dimensions may be varied as needed. For example, the dimensions of the components may be varied to increase combustion and / or electrical current generation, to accommodate continuous and uniform flow of air and fuel, and so forth, while the aircraft engine is being operated at reduced or increased thrust.

[0076] As mentioned above, fuel cell performance may be limited due to the formation of a boundary layer near the surface of the active layer membrane where the reaction occurs. In addition, pressurization has been found to be a power density enhancement factor for fuel cells. Therefore, according to the principles of the present disclosure, various geometries can be created via three-dimensional (3D) printing of, for example, fuel cell metal and / or ceramic support structures, which are generally impossible in traditional manufacturing. In addition, these support structures and / or enhancement features can be produced in a single manufacturing process (e.g., 3D printing). In addition, it has been found that these geometries can produce excellent performance, including, for example, higher performance density.

[0077] For example, current machined metal supports have limited geometry and / or flexibility, which can lead to over-design of the fuel cell and / or reduced power density. However, according to the principles of the present disclosure, metal supports with desired geometries can be manufactured on demand, and 2D / 3D structures are expected to produce at least a 2x to 3x increase in power density.

[0078] Furthermore, current fuel cells exhibit the formation of boundary layers near the surface of the active layer membrane where the reaction occurs, which results in a reduction in reaction rates, particularly at downstream locations. However, according to the principles of the present disclosure, enhancement features can be created and / or 3D printed into the flow field of the flow channel to swirl and / or disrupt such boundary layers by creating, for example, steps, trip wires, rotating features, fins, heat transfer enhancing dimples and / or valleys, and combinations thereof.

[0079] Furthermore, a current problem with SOFCs (and similar fuel cells) is that they are not optimized for pressurization. However, according to the principles of the present disclosure, novel 3D designs and / or structures can be created that can manage high pressures with minimal support, thereby enabling such 3D designs and / or structures to maintain pressure without adding too much weight to the actual fuel cell structure.

[0080] Furthermore, current SOFCs (and similar fuel cells) are typically assembled in a complex manner that includes arranging several manifolds. However, according to the principles of the present disclosure, 3D designs and / or structures can be created in a manner that allows for ease of assembly and / or new manifold geometries.

[0081] Thus, according to the principles of the present disclosure, flow channels can be created, for example, by 3D printing of materials made of various alloys (including, for example, SS441 or other compatible SOFC alloys) to promote boundary layer disruption geometries (e.g., zigzag configurations, swirl geometries, internal 3D features, internal fins, herringbone flow disruption fins, boundary layer stroke features, and / or other 3D geometries). Furthermore, these features, as well as support columns, can be added to allow the SOFC to be pressurized. According to the principles of the present disclosure, these effects are expected to increase power density by up to 5x. A 5x increase in the power density of such compact SOFCs will allow these SOFCs to be commercialized at a lower cost, smaller size (e.g., a SOFC that can be adapted, for example, in a jet engine) and reduced weight.

[0082] Further aspects of the disclosure are provided by the subject matter of the following clauses.

[0083] 1. A fuel cell unit comprising: a support structure having a plurality of flow channels; and an active layer membrane coupled to the support structure, the active layer membrane comprising at least one electrode layer, wherein each of the plurality of flow channels is configured to direct one of air and fuel across at least one electrode layer of the active layer membrane to generate an electric current, and wherein each of the plurality of flow channels comprises at least one enhancement feature configured to disrupt formation of a boundary layer near a surface of the active layer membrane where a reaction occurs.

[0084] 2. The fuel cell unit of any preceding clause, wherein the at least one electrode layer comprises a first electrode layer and a second electrode layer.

[0085] 3. A fuel cell unit according to any preceding clause, wherein the first electrode layer is an anode layer and the second electrode layer is a cathode layer.

[0086] 4. A fuel cell unit according to any preceding clause, wherein the active layer membrane further comprises a porous layer disposed between the support structure and the at least one electrode layer.

[0087] 5. A fuel cell unit according to any preceding clause, wherein the active layer membrane is deposited onto the support structure.

[0088] 6. A fuel cell unit according to any preceding clause, further comprising a bonding layer for bonding the active layer membrane to the support structure.

[0089] 7. A fuel cell unit according to any preceding clause, wherein the at least one enhancement feature comprises a webbing material attached to a surface of each of the plurality of flow channels, wherein the webbing material is configured to disrupt the formation of a boundary layer near a surface of the active layer membrane where the reaction occurs.

[0090] 8. A fuel cell unit according to any preceding clause, wherein the at least one enhancement feature comprises (i) multiple internal three-dimensional features, (ii) multiple internal fins, (iii) multiple chevron flow disruption fins, (iv) multiple boundary layer travel features, and (v) combinations thereof.

[0091] 9. The fuel cell unit of any preceding clause, wherein the plurality of internal three-dimensional features comprises one or more of (i) a plurality of internal bumps, (ii) a plurality of internal ridges, and (iii) a spiral shape.

[0092] 10. The fuel cell unit of any preceding clause, further comprising a plurality of internal posts positioned within each of the plurality of flow channels, wherein the plurality of internal posts are configured to allow pressurization of the fuel cell unit.

[0093] 11. A fuel cell unit according to any preceding clause, wherein the support structure comprises plates disposed between different groups of flow channels.

[0094] 12. A fuel cell unit according to any preceding clause, wherein a first set of said flow channels directing air flow is located on one side of said plate and a second set of said flow channels directing fuel flow is located on an opposite side of said plate.

[0095] 13. A fuel cell unit according to any preceding clause, wherein (i) a first group of flow channels of the plurality of flow channels for directing air flow is located on one side of the support structure, and (ii) a second group of flow channels of the plurality of flow channels for directing fuel flow is located on an opposite side of the support structure.

[0096] 14. The fuel cell unit of any preceding clause, wherein the first set of flow channels and the second set of flow channels are arranged in a zigzag configuration.

[0097] 15. The fuel cell unit according to any preceding clause, wherein the zigzag configuration creates a cyclonic flow channel configured to separate reactant gas and unreacted gas.

[0098] 16. The fuel cell unit of any preceding clause, wherein the at least one enhancement feature is configured to be additively manufactured within each flow channel of the plurality of flow channels.

[0099] 17. A fuel cell unit according to any preceding clause, wherein the support structure is conductive.

[0100] 18. A fuel cell unit according to any preceding clause, wherein the active layer membrane comprises a solid oxide.

[0101] 19. A fuel cell unit according to any preceding clause, wherein the support structure and the active layer membrane are formed to be positioned on an aircraft, wherein the support structure is conductively connected to one or more electronic loads of the aircraft so that at least some of the current generated by the active layer membrane powers the one or more electronic loads.

[0102] 20. The fuel cell unit of any preceding clause, wherein each flow channel of the plurality of flow channels extends to a combustion outlet, wherein the combustion outlets of the plurality of flow channels are oriented on the aircraft to propel the aircraft.

[0103] 21. A fuel cell comprising a plurality of fuel cell units, each of the plurality of fuel cell units comprising: a support structure having a plurality of flow channels; and an active layer membrane coupled to the support structure, the active layer membrane comprising at least one electrode layer, wherein each of the plurality of flow channels is configured to guide one of air and fuel across at least one electrode layer of the active layer membrane to generate current, and wherein each of the plurality of flow channels comprises at least one enhancement feature, the at least one enhancement feature being configured to disrupt formation of a boundary layer near a surface of the active layer membrane where a reaction occurs.

[0104] 22. A fuel cell according to any preceding clause, wherein the active layer membrane of a first fuel cell unit is arranged adjacent to a plurality of flow channels of a second fuel cell unit.

[0105] 23. A fuel cell according to any preceding clause, wherein the active layer membrane of each fuel cell unit comprises a solid oxide.

[0106] 24. A fuel cell according to any preceding clause, wherein the support structure and the active layer membrane of each fuel cell unit are formed to be positioned on an aircraft, wherein the support structure is conductively connected to one or more electronic loads of the aircraft so that at least some of the current generated by the active layer membrane of each fuel cell unit powers the one or more electronic loads.

[0107] 25. A fuel cell according to any preceding clause, wherein each of the plurality of flow channels of each fuel cell unit extends to a combustion outlet, wherein the combustion outlets of the plurality of flow channels are directed at the aircraft to propel the aircraft.

[0108] 26. A fuel cell unit comprising: a support structure having a plurality of flow channels, wherein (i) a first group of flow channels among the plurality of flow channels is configured to guide air flow located on one side of the support structure, and (ii) a second group of flow channels among the plurality of flow channels is configured to guide fuel flow located on an opposite side of the support structure; and an active layer membrane coupled to the support structure, the active layer membrane comprising at least one electrode layer, wherein each of the plurality of flow channels is configured to guide one of air and fuel across at least one electrode layer of the active layer membrane to generate current, and wherein the first group of flow channels and the second group of flow channels are arranged in a zigzag configuration.

[0109] 27. The fuel cell unit of any preceding clause, wherein the zigzag configuration creates a cyclonic flow channel configured to separate reactant gas from unreacted gas.

[0110] 28. A fuel cell unit according to any preceding clause, wherein each flow channel of the plurality of flow channels includes at least one enhancement feature, the at least one enhancement feature being configured to disrupt the formation of a boundary layer near a surface of the active layer membrane where the reaction occurs.

[0111] 29. A fuel cell unit according to any preceding clause, wherein the at least one enhancement feature comprises a webbing material attached to a surface of each of the plurality of flow channels, wherein the webbing material is configured to disrupt the formation of a boundary layer near a surface of the active layer membrane where the reaction occurs.

[0112] 30. A fuel cell unit according to any preceding clause, wherein the at least one enhancement feature includes (i) multiple internal three-dimensional features, (ii) multiple internal fins, (iii) multiple chevron flow disruption fins, (iv) multiple boundary layer travel features, and (v) combinations thereof.

[0113] 31. The fuel cell unit of any preceding clause, wherein the plurality of internal three-dimensional features comprises one or more of (i) a plurality of internal bumps, (ii) a plurality of internal ridges, and (iii) a spiral shape.

[0114] 32. The fuel cell unit of any preceding clause, further comprising a plurality of internal posts positioned within each of the plurality of flow channels, wherein the plurality of internal posts are configured to allow pressurization of the fuel cell unit.

[0115] 33. A method comprising: directing fuel into a fuel inlet of a fuel cell in a fuel cell stack extending from an inlet end to a combustion outlet end, the fuel inlet being positioned proximate to the inlet end of the fuel cell stack; directing air into an air inlet of the fuel cell, the air inlet being positioned proximate to the inlet end of the fuel cell stack; generating electrical energy by directing the air and the fuel across opposite sides of an active layer membrane comprising an anode layer, an electrolyte layer, and a cathode layer; directing at least some of the fuel and at least some of the air through a flow channel of the fuel cell toward a combustion outlet of the fuel cell proximate to the combustion outlet end of the fuel cell stack; and burning the at least some of the fuel and the at least some of the air as output combustion from the fuel cell proximate to the combustion outlet end, wherein one or more of the flow channels of the fuel cell include at least one enhancement feature, the at least one enhancement feature being configured to disrupt formation of a boundary layer near a surface of the active layer membrane where a reaction occurs.

[0116] 34. The method of any preceding clause, further comprising one or more of: using the output combustion to propel a vehicle; or supplying the electrical energy to one or more systems of the vehicle to power the one or more systems.

[0117] Although the foregoing description is directed to preferred embodiments, it should be noted that other variations and modifications will be apparent to those skilled in the art and may be made without departing from the spirit or scope of the present disclosure. In addition, features described in conjunction with one embodiment may be used in conjunction with other embodiments, even if not explicitly stated above.

Claims

1. A fuel cell unit, characterized in that: include: a) a support structure having a plurality of flow channels; as well as b) an active layer membrane, the active layer membrane being coupled to the support structure, the active layer membrane comprising at least one electrode layer, wherein each of the plurality of flow channels is configured to direct one of air and fuel across at least one electrode layer of the active layer membrane to generate an electric current; and wherein each flow channel of the plurality of flow channels comprises at least one enhancement feature configured to disrupt formation of a boundary layer near a surface of the active layer membrane where a reaction occurs; wherein (i) a first group of the plurality of flow channels directing air flow is located on one side of the support structure, and (ii) a second group of the plurality of flow channels directing fuel flow is located on an opposite side of the support structure, wherein the first group of flow channels and the second group of flow channels are arranged in a zigzag configuration.

2. The fuel cell unit according to claim 1, characterized in that in, The at least one electrode layer includes a first electrode layer and a second electrode layer.

3. The fuel cell unit according to claim 1, characterized in that in, The active layer membrane further includes a porous support layer disposed between the support structure and the at least one electrode layer.

4. The fuel cell unit according to claim 1, characterized in that in, The at least one reinforcing feature includes a webbing material attached to a surface of each of the plurality of flow channels, wherein the webbing material is configured to disrupt formation of a boundary layer near a surface of the active layer membrane where a reaction occurs.

5. The fuel cell unit according to claim 1, characterized in that in, The at least one enhancement feature includes a plurality of internal three-dimensional features.

6. The fuel cell unit according to claim 5, characterized in that in, The plurality of internal three-dimensional features include one or more of (i) a plurality of internal bumps, (ii) a plurality of internal ridges, and (iii) a spiral shape, wherein the plurality of internal bumps are disposed along an inner surface of one or more sidewalls of the plurality of flow channels, wherein the plurality of internal ridges include protruding portions extending into the plurality of flow channels and recessed portions extending away from the plurality of flow channels, and wherein the spiral shape is formed by generating a mesh-like member within the plurality of flow channels that forms a turbulator.

7. The fuel cell unit according to claim 1, characterized in that Further included are a plurality of internal posts positioned within each of the plurality of flow channels, wherein the plurality of internal posts are configured to allow pressurization of the fuel cell unit.

8. The fuel cell unit according to claim 1, characterized in that in, The support structure includes plates disposed between different groups of flow channels.

9. The fuel cell unit according to claim 8, characterized in that in, A first set of the flow channels directing air flow is located on one side of the plate, and a second set of the flow channels directing fuel flow is located on an opposite side of the plate.

10. The fuel cell unit according to claim 1, characterized in that in, The zigzag configuration creates a cyclonic flow channel configured to separate reacted gas from unreacted gas.

11. The fuel cell unit according to claim 1, characterized in that in, The at least one reinforcement feature is configured to be additively manufactured within each flow channel of the plurality of flow channels.

12. The fuel cell unit according to claim 1, characterized in that in, The active layer membrane includes a solid oxide.

13. The fuel cell unit according to claim 1, characterized in that in, The support structure and the active layer membrane are configured to be positioned on an aircraft, wherein the support structure is conductively coupled to one or more electronic loads of the aircraft such that at least some of the current generated by the active layer membrane powers the one or more electronic loads.

14. The fuel cell unit according to claim 13, characterized in that in, Each flow channel of the plurality of flow channels extends to a combustion outlet, wherein the combustion outlets of the plurality of flow channels are oriented on the aircraft to propel the aircraft.

15. A fuel cell comprising a plurality of fuel cell units, characterized in that: Each fuel cell unit of the plurality of fuel cell units comprises: a) a support structure having a plurality of flow channels; and b) an active layer membrane, the active layer membrane being coupled to the support structure, the active layer membrane comprising at least one electrode layer, wherein each of the plurality of flow channels is configured to direct one of air and fuel across at least one electrode layer of the active layer membrane to generate an electric current; and wherein each flow channel of the plurality of flow channels comprises at least one enhancement feature configured to disrupt formation of a boundary layer near a surface of the active layer membrane where a reaction occurs; wherein (i) a first group of the plurality of flow channels directing air flow is located on one side of the support structure, and (ii) a second group of the plurality of flow channels directing fuel flow is located on an opposite side of the support structure, wherein the first group of flow channels and the second group of flow channels are arranged in a zigzag configuration.

16. The fuel cell according to claim 15, characterized in that in, The active layer membrane of the first fuel cell unit is disposed adjacent to the plurality of flow channels of the second fuel cell unit.

17. A fuel cell unit, characterized in that: include: a) a support structure having a plurality of flow channels, wherein (i) a first set of flow channels of the plurality of flow channels are configured to direct air flow on one side of the support structure, and (ii) a second set of flow channels of the plurality of flow channels are configured to direct fuel flow on an opposite side of the support structure; as well as b) an active layer membrane, the active layer membrane being coupled to the support structure, the active layer membrane comprising at least one electrode layer, wherein each of the plurality of flow channels is configured to direct one of air and fuel across at least one electrode layer of the active layer membrane to generate an electric current, and Wherein, the first group of flow channels and the second group of flow channels are arranged in a zigzag configuration.

18. The fuel cell unit according to claim 17, characterized in that in, The zigzag configuration creates a cyclonic flow channel configured to separate reacted gas from unreacted gas.

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