Electrical power connection of an electrochemical cell stack

Abstract

The invention relates to an electrochemical cell assembly (300, 500) comprising a bottom plate (308) and a top plate (303), between which a stack of planar cell units (306) and at least one positive electrical end plate (302, 507) and at least one negative electrical end plate (302, 507) are arranged in a compressed state by means of compression means (307) acting between the bottom plate (308) and the top plate (303). The at least one electrical end plate (302, 507) is connected to or integrally formed with and in electrical contact with an electrical stud (301, 505) extending from a base of the at least one electrical end plate (302, 507) and through an opening in one of the bottom plate (308) and the top plate (303) to form an electrical terminal. The compression means (307) maintain a fluid seal between the base and the respective one of the bottom plate (308) and the top plate (303) so as to prevent fluid loss through the opening.

Description

Technical Field

[0001] This invention relates to electrochemical battery stacks, and more particularly, to the design of fuel cell stacks and electrolytic cell stacks and their terminal plates. The battery stacks of this invention include solid oxide, polymer electrolyte membrane, and molten carbonate type cells. More specifically, this invention relates to solid oxide fuel cell (SOFC) and solid oxide electrolytic cell (SOEC) stacks, and may include metal-supported solid oxide fuel cell (MS-SOFC) or electrolytic cell stacks (MS-SOEC). Background Technology

[0002] Some fuel cell units can generate electricity by oxidizing fuel using an electrochemical conversion process. Some fuel cell units can also, or conversely, operate as regenerative fuel cell (or reverse fuel cell) units; these are often referred to as electrolytic fuel cell units, for example, separating hydrogen and oxygen from water, or carbon monoxide and oxygen from carbon dioxide. They can have tubular or planar configurations. Planar fuel cell units can be stacked on top of each other in a stacked arrangement, for example, with 100-200 fuel cell units in a stack, where the individual fuel cell units are arranged electrically in series.

[0003] Solid oxide fuel cells (SOFCs) that generate electricity are based on solid oxide electrolytes, which conduct 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), and an 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, in which the active fuel cell component layers are supported on a metal substrate. In these cells, the ceramic layers are very thin because they only perform an electrochemical function: that is, the ceramic layers are not self-supporting but rather thin coatings / films laid on and supported by the metal substrate. Such metal-supported SOFC stacks are more robust, less expensive, have better thermal performance than ceramic-supported SOFCs, and can be manufactured using conventional metal welding techniques.

[0004] Solid oxide electrolytic cells (SOECs) can have the same structure as SOFCs, but are essentially SOFCs operating in reverse or regenerative mode. They achieve the electrolysis of water and / or carbon dioxide by inputting electrical energy and using solid oxide electrolytes to generate hydrogen and / or carbon monoxide and oxygen.

[0005] This invention relates to stacks of repetitive electrochemical battery cells and to the design of their electrical terminals (power take-off or delivery). Therefore, it is applicable to various types of fuel cells and electrolytic cells, such as those based on solid oxide electrolytes, polymer electrolyte membranes, or molten electrolytes. For convenience, "battery cell" is used to refer to "electrochemical battery cell," including fuel cell or electrolytic cell cells.

[0006] Electrical energy generated by a fuel cell (or input to an electrolytic cell) can be transferred through the cell stack and from (or to) the stack via two electrical studs (with opposite polarities) and associated terminal plates that make electrical contact between the studs and the ends of the stack. The electrical studs and terminal plates can also be referred to as positive and negative "power take-offs," and for convenience, this terminology is used regardless of whether the power is output (e.g., in a fuel cell) or transmitted (e.g., in an electrolytic cell).

[0007] The stack is typically enclosed in a container to form a fluid volume, thereby retaining one of the fluids (fuel or air and / or exhaust) for use by the stack or for venting gases from the stack. Electrical studs typically pass through the container to allow electrical energy to be transferred between the stack and a load or source outside the stack (electric studs or bolts pass through openings in the container for external connections; the (distal) portion of the stud outside the container may form a terminal). Maintaining a fluid seal between the power output and the container is usually necessary to preserve the integrity of the fluid volume enclosed by the container. Operating fuel cell (e.g., SOFC) systems where the stack operates in the 450–650°C range (e.g., intermediate-temperature solid oxide fuel cell IT-SOFC) presents a number of challenging technical challenges in transferring electrical energy to / from the stack while maintaining a fluid seal.

[0008] JPH05326000 A relates to a fuel cell stack with a self-supporting electrochemically active fuel cell layer. Current collectors are disposed at both ends of the fuel cell stack and function as electrical end plates. The current collectors have an undercoat and a ceramic body superimposed on a metal plate (SUS 310). The undercoat and ceramic body are deposited on the metal plate by spraying.

[0009] JPH05326000 A does not disclose any electrical studs, nor does it disclose whether a container encloses the stack and current collector. Therefore, JPH05326000 A fails to address the problem of transferring electrical energy from the stack while maintaining a fluid seal between the power output device and the container.

[0010] US 2016 / 102410 A1 relates to a fuel cell system having a stacked cover plate located between end plates and a stack comprising self-supporting MEA cell units. The stacked cover plate has a two-layer structure: a contact plate and a separator half-plate, both made of stainless steel. Conductors passing through plastic end plates are provided on the contact plate to provide a connection between the stack and the outside of the system. Channels for conveying gas or coolant are also provided on the end plates and the stacked cover plate. An annular groove on the end plate surrounds this channel, and a sealing ring is disposed therein. In the uncompressed state, the sealing ring extends beyond the end plate. Compression in the stacking direction is used to compress the sealing ring, bringing the end plates into contact with the contact plates.

[0011] Figure 1 Referenced from US 2001 / 0046619 A1. Figure 1 A fuel cell stack 20 enclosed within a housing 23 is shown. An internal inlet manifold 6 is used to deliver fuel flow 4, while an internal outlet manifold 7 is used to remove fuel flow 4. An external manifold 9 is used to deliver oxidant flow 3 to an inlet chamber 41, while an external manifold 8 is used to remove oxidant flow 3 from an outlet chamber 33. The negative electrode 30, or anode electrode, of the fuel cell stack 20 is separated from the housing 23 by a dielectric spacer 31. A power output terminal 32 extends from below the fuel cell stack 30 and into the outlet chamber 33 of the housing 23. A conductive busbar 34 is disposed adjacent to the power output terminal 32 outside the housing 23. A dielectric spacer 35 is disposed between the busbar 34 and the housing 23. A conductive fastener 36 connects the power output terminal 32 to the busbar 34 through an opening 37 formed in the housing 23. A dielectric spacer 38 isolates the fastener 36 from the surface of the opening 37 extending through the housing 23. The positive electrode 21, or cathode electrode, of the fuel cell stack 20 is in close electrical contact with the housing 23. The conductive busbar 39 is located outside the housing 23 and is attached to the housing 23 by conductive fasteners 40. Electricity generated within the fuel cell stack 20 can flow from the negative terminal 30 of the fuel cell stack 20 through the power output terminal 32 and the busbar 34 to an external circuit to power electrical appliances or machinery. Current can return to the positive terminal 21 of the fuel cell stack 20 through the busbar 39 and the housing 23.

[0012] In US 2001 / 0046619 A1, conductive fasteners 36, 40 are under tension to seal housing 23 (and thus retain fluid volume in chamber 33), and the seal can be maintained by dielectric spacer 38 (e.g., ceramic plate).

[0013] Figure 2 Quoted from WO 2007 / 001189 Al. Figure 2This is an illustration showing a housing including wall 45 and a first end plate 42 and a second end plate 48. A fuel cell stack 3 is compressed between end plates 42 and 48. End plate 42 also functions as an electrical end plate and is connected to an electrical end bolt 50. A fuel cell stack 43 is arranged between the electrical end plate 42 and the second electrical end plate 46. The electrical end plate 46 is connected to an electrical bolt 51 and inserted into the housing, electrically insulated from the housing. Insulation is achieved by an insulating ring 49 between the bolt 51 and the end plate 48 and an electrically insulating elastic pad 47. The elastic pad 47 is placed between the electrical end plate 46 and the end plate 48. Bolts 50 and 51 are described as "electric bolts" in WO2007 / 001189 A1 and therefore have the function of outputting power from the stack 43. The elastic pad 47 provides a seal around the electrical bolt 51 and insulates the electrical end plate 46 from the housing (including end plates 48 and wall 45). Electrical bolt 50 is a power output device that makes electrical contact with end plate 42, wall 45, and end plate 48. The potential difference between electrical bolt 51 (which has the opposite polarity to bolt 421, and therefore also the opposite polarity to 42, 45, and 48) is equal to the potential difference across the battery stack 43. Therefore, electrical sparks and short circuits are very likely to occur between end plate 48 and electrical bolt 51.

[0014] Space 44 is described as a “void space” in WO 2007 / 001189 A1. WO 2007 / 001189 A1 does not explain how stack 43 is compressed, nor how the fuel and oxidizer (and their respective exhaust gases) volumes are separated, nor how these volumes are connected to the external connector.

[0015] In the arrangement described in US 2001 / 0046619 A1, the sub-assemblies for power output are under tension to maintain a seal, thereby limiting the fluid volume. Electrochemical cells, including intermediate-temperature solid oxide fuel cells, operate at relatively high temperatures, and to maintain a seal at such temperatures, ceramic seals are typically required, which themselves require high compressive loads to be effective. Maintaining high compressive loads in such environments is challenging and necessitates the fabrication of components under tension using expensive materials, such as chromium-nickel-iron alloys, to resist creep. Creep in such components reduces the compressive load, causing the electrochemical cell system to fail due to loss of seal (compressive force decreases to the minimum required for a seal between components, or the creep-affected component undergoes severe failure). Similar disadvantages are evident in the electrochemical cells described in WO 2007 / 001189 A1.

[0016] The present invention aims to solve, overcome or mitigate at least one of the disadvantages of the prior art. Summary of the Invention

[0017] In a first aspect, an electrochemical battery assembly is provided, the electrochemical battery assembly comprising: A bottom plate and a top plate, between which a planar battery cell stack, at least one positive terminal plate, and at least one negative terminal plate are configured to be compressed by a compression device acting between the bottom plate and the top plate. In this embodiment, at least one of the electrical terminal plates is connected to or integrally formed with an electrical stud and is in electrical contact with it. The electrical stud extends from the base of the at least one electrical terminal plate and passes through an opening in one of the bottom plate and the top plate to form an electrical terminal. The base is kept fluid-sealed with one of the bottom plate and the top plate by the compression device to prevent fluid from leaking out through the opening.

[0018] For ease of use, the electrical terminals on the electrochemical cell assembly are located externally, necessitating an opening in the assembly. However, fluid within the assembly should not leak through this opening. Existing solutions for sealing the opening are often susceptible to creep, which weakens the seal and leads to system failure. The electrochemical cell assembly in the claims advantageously utilizes a compression device for maintaining compression within a planar cell stack to seal the opening (through the action of the compression device on the base).

[0019] Preferably, the terminal plate and the corresponding stud are separate components connected by a welded joint. Alternatively, the terminal plate and the corresponding stud can be a single unit or separate components connected by screwing the stud into a threaded groove on the terminal plate that does not fully penetrate the terminal plate (in the latter case, the stud can be welded into place). When the stud and terminal plate are separate components joined together, the base can be part of either component.

[0020] "Top plate" and "bottom plate" are used to refer to plates located outside the stack, with pressure applied between them. The names "top plate" and "bottom plate" are for convenience only; they are interchangeable and should not be construed as restricting the orientation of the components. Compression devices may be connected between these plates (i.e., positioned inwards) (e.g., under tension), for example, as compression plates or skirts, or the compression devices may include conventional compression bolts and fasteners for gripping and compressing the plates against each other.

[0021] Positive and negative terminal plates can make electrical contact with opposite ends of the planar cell stack. Electrical studs can make electrical contact with their respective terminal plates. One or more electrical studs can make electrical contact with each of the positive and negative terminal plates. The distal end of a stud (away from the terminal plate) can be referred to as an electrical terminal, which is where the stud (and therefore the stack) is used for external connections. When the electrochemical cell assembly operates as a fuel cell, the electrical stud can be referred to as a power output stud for transferring power from the planar cell stack. When the electrochemical cell assembly operates as an electrolytic cell, the electrical stud can be referred to as a power supply stud for transferring power to the planar cell stack. In some cases, the positive and negative terminal plates can also be referred to as end electrodes and single electrodes, respectively.

[0022] The openings on the base plate and / or top plate can be holes or orifices that completely penetrate the base plate or top plate, and can have any cross-section. The openings are large enough to allow an electrical stud to pass through the opening from one side of the base plate or top plate to the other. The electrical stud passing through the openings on the base plate and / or top plate provides an external electrical connection (to the stack and its housing, which is at least partially formed by the base plate and top plate) to the planar battery cell stack.

[0023] The compression device maintains compression (i.e., compressive force) between the base plate and the top plate, which is applied during the manufacturing process of the electrochemical cell assembly. This compression provides good electrical contact between each planar cell (also called a repeating cell) in the stack, between the terminal plate and adjacent planar cells, and maintains compression within a fluid seal between the base plate and the top plate. The seal may be formed by gaskets, for example, alternating with the cell cells along the length of the stack (i.e., in the stacking direction), wherein the gaskets seal internal manifolds for delivering fluid to a fluid volume within each cell, thereby separating a first fluid volume and a second fluid volume (e.g., a fuel volume and an oxidant volume).

[0024] The fluid seal between one or both of the terminal plates and the corresponding one of the bottom and top plates is maintained by the compression device. This also means that the openings on the bottom and / or top plates are sealed by the compression device (while allowing the electrical stud to pass through the openings). Conversely, this means that the electrical stud itself does not need to maintain the seal of the openings it passes through. In other words, the electrical stud itself is not a fastener or bolt, nor does it need to maintain the seal of the openings under tension. Reducing the number of components under tension is advantageous because components under tension in fuel or electrolytic battery environments typically must be made of expensive creep-resistant materials to resist creep under a wide range of operating conditions (e.g., over a temperature range from atmospheric temperatures around 20 degrees Celsius to higher operating temperatures of at least 400 degrees Celsius). Any component under tension should provide sufficient sealing force over a wide temperature range, but also should do so over many thermal cycles throughout the life of the battery cell, as loss of seal can lead to failure of the electrochemical battery system. Chromium-nickel-iron alloy is such a creep-resistant material. However, using the compression device to seal the opening through which the electric stud passes means that the components related to the electric stud do not need to be under tension, thus avoiding creep problems, and also means that the electric stud does not need to be made of creep-resistant material, but can be made of material based on its electrical properties.

[0025] Furthermore, the stud can freely expand and contract with temperature changes (relative to the base or top plate it passes through). Therefore, the thermal expansion of the stud (and related components, such as the terminal plates) does not affect the sealing of openings on the base and / or top plates. The sealing of the openings on the base and / or top plates (between the base and / or top plates and the corresponding terminal plates) prevents gas from escaping from the assembly through these openings (this gas is typically a second fluid volume, such as an oxidant, and a first fluid volume, such as fuel, including the internal manifolds of the battery cell and the volume between the support plate and the separator). Gaskets can be provided between the terminal plates and the corresponding base or top plates to maintain a seal between them.

[0026] Preferably, by providing corresponding insulating layers between the respective ends of the planar battery cell stack and the respective bottom and top plates, each of the bottom and top plates is electrically insulated from the planar battery cell stack (and therefore not at the same potential as either end of the planar battery cell stack). Therefore, the compression device will also act on the insulating plates. In this preferred embodiment, the bottom plate, top plate, and compression device are not at the same potential as either end of the planar battery cell stack, and therefore not at the same potential as the stud. In other words, their potentials are floating relative to the stud because the stud has no electrical contact with the bottom plate, top plate, and compression device. Therefore, when the stud passes through the bottom or top plate, there may be a relatively low potential difference between the stud and the bottom or top plate (meaning that even if the gap between them is small, the potential gradient between them is low), thus minimizing the risk of a short circuit between the stud and the bottom and / or top plate.

[0027] In one example, the stud passes through an opening in the base plate or top plate, with an air gap between them. Therefore, the stud cannot be electrically connected to the base plate or top plate. In other words, the base plate and / or top plate is not at the same potential as the stack and the stud, but rather at a floating potential relative to the stud.

[0028] In an alternative example, the electric stud passes through an opening in the base plate or top plate, through which an electrically insulating sleeve is disposed. The sleeve (also referred to as a collar) may be made of mica or ceramic material.

[0029] The electrical insulating sheet can be made of mica or ceramic material, which can improve the electrical insulation between the terminal plate and the corresponding base plate or top plate. Gaskets of the same type used elsewhere in the assembly can be placed between the terminal plate and the electrical insulating sheet, and between the electrical insulating sheet and the base plate and / or top plate. The gaskets form a good fluid seal between the corresponding plates / sheets. Using the same type of gaskets (e.g., thickness, planar dimensions, and material) throughout the assembly (i.e., using the same type of gaskets between the planar cell stack and the terminal plate, and between the terminal plate and the corresponding base plate or top plate) can reduce the parts count, thereby reducing costs, and can ensure consistent pressure transmission throughout the assembly. The gaskets can be prefabricated or formed in situ. The gaskets can be formed from a suitable non-conductive material that provides sufficient fluid seal and can withstand the temperature and chemical environment of the electrochemical cell assembly (and will not contaminate the cell stack due to its degradation). Preferably, the gasket is compliant (e.g., flexible and compressible) to provide a good seal, and in some cases, reduce the requirement for compressive force, because compliant materials can easily conform to and seal surfaces with different parallelism, surface finish, and separation (e.g., the surfaces of corresponding plates). The gasket may be a mica gasket. More preferably, the gasket is a vermiculite gasket, which is compliant and relatively inexpensive. The assembly may also include an electrically insulating liner surrounding the outer end of the electric stud and contacting the outer surface of the base plate or top plate. The liner may be made of mica or ceramic material. An external connection device (e.g., a threaded segment) may form part of the outer end of the electric stud to connect to a load on the assembly (when operating as a fuel cell) or to power the assembly (when operating as an electrolytic cell). The collar and / or liner may provide mechanical stability to the electric stud (e.g., during handling of the assembly or during external connection with the electric stud) and may prevent any foreign matter from entering the assembly through the opening.

[0030] Preferably, the component includes: at least one positive terminal plate, the at least one positive terminal plate being connected to or integrally formed with and electrically contacting a positive stud, the positive stud extending from its base and passing through a first opening on one of the base plate and top plate to form a positive terminal; and at least one negative terminal plate, the at least one negative terminal plate being connected to or integrally formed with and electrically contacting a negative stud, the negative stud extending from its base and passing through a second opening on one of the base plate and top plate to form a negative terminal; and wherein each base is fluidly sealed to a corresponding one of the base plate and top plate by the compression device to prevent fluid from leaking through each corresponding opening.

[0031] In this preferred configuration, both the positive and negative studs pass through an opening in one or the other of the base plate and top plate.

[0032] Preferably, the positively charged stud passes through a first opening on one of the top and bottom plates, while the negatively charged stud passes through a second opening, i.e., an opening on the other of the top and bottom plates. In this case, the positively and negatively charged studs are positioned at opposite ends of the assembly. In this configuration, the repeating unit can occupy a larger proportion of the volume (in terms of planar area, e.g., due to the absence of any busbars) within the assembly (e.g., within the range of the bottom plate, top plate, and skirt, or within the enclosure of the device), thus providing higher power density.

[0033] Alternatively, both the positive and negative studs pass through corresponding first and second openings on either the base or top plate. For convenience, both the positive and negative studs are located at the same end of the stack, facilitating electrical connection and installation of the assembly. In this case, one of the positive and negative studs can be electrically connected via a busbar and an additional terminal plate with the same polarity as the stud. This facilitates electrical connection of the assembly. Alternatively, it can be connected to the busbar via at least one tab that is more flexible than the busbar and the connected terminal plate. The flexibility of the tab takes into account the different thermal expansion between the busbar and the planar battery cell stack. The tab can be made of the same material as the busbar and / or the terminal plate and the additional terminal plate, in which case its flexibility is increased because it is thinner than these components. Alternatively, the busbar may be more flexible (e.g., because it is thinner) than the tabs, terminal plates, and additional terminal plates, allowing the busbar to bend to account for the different thermal expansion between the busbar and the planar battery cell stack.

[0034] Preferably, the battery cells in the planar battery cell stack are provided with at least one port and are stacked on top of each other such that the corresponding ports are aligned to form a corresponding internal manifold extending through the stack, and wherein an electric stud extending through its corresponding opening is also aligned with the corresponding internal manifold, such that the compressive force applied by the compression device to seal the corresponding internal manifold also seals the corresponding opening. The internal manifold is located within a planar region defined by the battery cells. In some cases, the internal manifold may be referred to as a flue. The internal manifold allows fluid communication between the battery cells. The internal volume of each battery cell and the internal manifold can form a first fluid volume. In fuel cell applications, the first fluid volume may be the fuel volume. Two internal manifolds may be provided, namely a first internal manifold for supplying the first fluid volume and a second internal manifold for discharging the first fluid volume. The bottom plate and / or top plate may be provided with ports corresponding to (e.g., aligned with) the ports in the battery cells, these ports forming part of the internal manifold and allowing the supply and / or discharge of the first fluid volume (i.e., internal disproportionation of the first fluid volume). There may be more than one internal inlet manifold, or in fact, more than one internal outlet manifold.

[0035] Preferably, the base of the respective terminal plate extends across the respective internal manifold to block it (i.e., block the respective internal manifold). The base of the terminal plate can block and fluid-tighten the respective internal manifold, such that the high compressive force associated with the seal within the internal manifold is also advantageously used for sealing the opening. The positive and negative terminal plates can extend across the planar region of the stack, covering a planar region substantially the same as the planar battery cell. This allows the terminal plates to transfer compressive force to the planar battery cell stack within the scope of the planar battery cell; in other words, the base across the opening and / or across the aligned internal manifold forms a fluid seal, which is maintained by the compressive force applied by the compression device.

[0036] Preferably, the component includes: a first corresponding internal manifold and a second corresponding internal manifold extending through the stack; and a negatively charged stud connected to or integrally formed with a negatively charged end plate and electrically contacting it, and aligned with the first corresponding internal manifold; and a positively charged stud connected to or integrally formed with a positively charged end plate and electrically contacting it, and aligned with the second corresponding internal manifold. The stud and opening may be partially or completely aligned (i.e., coaxial) with the corresponding internal manifold, such that the stud passes through the opening from the region of the end plate blocking the corresponding internal manifold. (The actual width of the opening may be greater than or less than the width of the internal manifold, but must at least overlap it, such that a portion of the stud passes through the opening.) When aligned in this way, maximum compression transfer occurs, and rotational force problems can be avoided; in particular, the stud is preferably coaxial with the corresponding opening on one of the internal manifold and the bottom and top plates (e.g., the opening on the bottom and / or top plates may be a continuation of the internal manifold). If present, the electrical insulating sheet is also provided with corresponding ports that form continuations of the corresponding internal manifolds (by being either fully aligned with or coaxial with the corresponding internal manifold portion).

[0037] Preferably, both the negative and positive studs pass through corresponding openings in either the base or top plate, and one of the negative and positive studs is electrically connected to an additional terminal block via a busbar. For convenience, both the positive and negative studs are located at the same end of the stack, facilitating electrical connection and installation of the assembly. In this case, one of the positive and negative studs can be electrically connected via a busbar and an additional terminal block with the same polarity as the stud. This facilitates electrical connection of the assembly. Alternatively, it can also be connected to the busbar via at least one tab, and the tab or busbar can be as described above.

[0038] In this configuration, the first fluid volume, including the first and second internal manifolds, can be supplied and discharged through corresponding fluid inlet and outlet openings on the other of the base and top plates. This facilitates both electrical and fluid connections of the components, as both studs pass through openings on one of the base and top plates, while the inlet and outlet of the first fluid volume are located on the other. In one example, one of the positive and negative studs is aligned with one of the internal manifolds for the first fluid volume inlet and outlet, and the other of the positive and negative studs is aligned with the other of the internal manifolds for the first fluid volume inlet and outlet.

[0039] In this configuration, both the negative and positive studs can pass through corresponding openings in either the base or top plate, and one of the studs can also pass through an opening in a terminal plate that is connected to or integrally formed with and electrically contacts the other stud. This allows the terminal plate with the opening through which one stud passes to have the same planar area or extent as the other terminal plate and the battery cell. This means that both manifolds (and their extensions) are formed from the same components, maximizing the transmission of compressive forces and avoiding rotational force issues. The opening is located on the terminal plate, through which the stud passes, and the opening is separated from the stud by an air gap and can be separated by a collar made of insulating material.

[0040] In one example, both the positive and negative studs can pass through corresponding openings on the top plate, wherein the negative stud is directly and mechanically connected to a negative terminal plate located between the positive terminal plate and the top plate. An additional terminal plate is located between the planar battery cell stack and the bottom plate, and is electrically and mechanically connected to the negative terminal plate via the busbar. In this case, the positive terminal plate may block all internal manifolds at the stack end (i.e., the end of the stack closest to the positive terminal plate). Therefore, the negative terminal plate is not exposed to the first fluid volume and may be thinner than the positive terminal plate (if made of the same material) and / or may be made of a different material. Electrically insulating and fluid-sealing gaskets may be disposed between the negative and positive terminal plates to provide electrical insulation between them and seal the continuation of the internal manifolds. An electrically insulating plate may be disposed between the negative and positive terminal plates to improve electrical insulation therebetween. The electrical insulation plate can be made of mica or electrically insulating ceramic material. Electrical insulation and fluid sealing gaskets can be disposed between each plate. For convenience, "negative" and "positive" are used, and the positive terminal plate can be additionally or alternatively connected to additional terminal plates via busbars in a similar manner.

[0041] Preferably, at least one of the positive and negative terminal plates separates the first and second fluid volumes within the stack. The terminal plate can seal the first and second fluid volumes, the first fluid volume comprising the volume defined by the internal manifold and the volume between the support plate and separator of each cell. The corresponding internal manifold can be used to supply and discharge the first fluid volume, and can be in fluid communication with the anode of each cell. The second fluid volume can include any remaining volume defining the housing of the assembly (e.g., within and contained therein by seals around openings on the top plate, bottom plate, compression device, and bottom and / or top plates). When operating as a fuel cell, the first fluid volume is typically used for fuel, while the second fluid volume is typically used for oxidant.

[0042] Preferably, the compression device includes a skirt attached under tension between the bottom plate and the top plate, the skirt at least surrounding the planar battery cell stack.

[0043] Preferably, the skirt also surrounds the positive and negative terminal plates, as well as the busbar and any additional terminal plates (if present). The skirt may also be referred to as a cover. Optionally, the skirt forms an airtight fluid volume, referred to as a second fluid volume, for example, an oxidant disproportionation volume. In this case, the skirt is hermetically attached to the bottom and top plates (e.g., by gas-sealed welding) around the periphery of the bottom and top plates. The skirt (compressor), bottom plate, and top plate are electrically isolated from the stack, meaning that the skirt can be made of metal, allowing for easy and convenient attachment of the skirt to the bottom and top plates (e.g., by gas-sealed welding). This electrical isolation means that the skirt is not energized, which protects anyone performing repairs or maintenance on or around the operating fuel cell stack and provides simple component grounding within the product.

[0044] Preferably, the first fluid flow path from the fuel inlet to the exhaust fuel outlet, for example, a fuel flow path, is internally disproportionated, meaning that within the first fluid flow path, there is at least one internal manifold or flue (e.g., an inlet flue or an outlet flue) within the planar cell stack, and preferably aligned with the PTO opening such that the seal provided for the flue itself is also used to seal the PTO opening. The second fluid flow path from the oxidant inlet to the exhaust outlet, for example, an oxidant flow path, may be externally disproportionated, and may include at least one segment disproportionated to the outside of the planar cell stack. More preferably, it disproportionates externally to the planar cell stack and internally to the electrochemical cell assembly. More preferably, a volume is defined between the base plate, top plate, skirt, and planar cell stack. Such a volume can be considered a second fluid disproportionation volume.

[0045] In some battery assemblies, the second fluid flow path from the oxidant inlet to the emission outlet, for example, the oxidant flow path, may be internally disproportionated, i.e., within the second fluid flow path, there is at least one internal manifold or flue (e.g., an inlet flue or an outlet flue) in the planar battery cell stack, and preferably aligned with the PTO opening, such that the seal provided for the flue itself is also used to seal the PTO opening.

[0046] Alternative compression devices can be used, such as, for example, tie rods within or outside the volume defined by the planar battery cell stack, and these devices can also be used in addition to the skirt that forms the airtight fluid volume.

[0047] Preferably, the interconnect plate, or the 3D contour structure formed in the negative terminal plate, or the 3D contour structure formed in the additional electrical terminal plate (if present), or the 3D contour structure formed in the outermost cell of the planar cell stack, provides electrical contact between the respective electrical terminal plate and the planar cell stack to facilitate current transfer therebetween. The interconnect plate or 3D contour structure provides good electrical contact between the plates within the electrochemical cell assembly. The compression device provides compression of the planar cell stack (and within the stack, between and inside each cell) through the plates, through the interconnect plate, or through the recesses, thereby ensuring good electrical connection throughout the electrochemical cell assembly.

[0048] The 3D contour structure, for example, includes a pattern of spaced channels and ribs or spaced recesses to control fluid flow.

[0049] The components of the first aspect detailed above may be combined with any feature of the alternative first aspect, which will be detailed below, and / or with features of the second aspect, which will be detailed below.

[0050] According to the first aspect of the alternative, an electrochemical battery assembly is provided, the electrochemical battery assembly comprising: A bottom plate and a top plate, between which a planar battery cell stack, at least one positive terminal plate, and at least one negative terminal plate are compressed by a compression device acting between the bottom plate and the top plate, wherein: At least one electrical terminal plate is mechanically and electrically connected to, or integrally formed with, an electrical stud extending from the stud base. The electric stud passes through an opening in one of the base plate and the top plate to form an electrical terminal. Each of the battery cells is provided with at least one port, and the battery cells are stacked on top of each other such that the corresponding ports are aligned to form corresponding internal manifolds extending through the stack. The electric stud extending through the corresponding opening is also aligned with the corresponding internal manifold, such that the compressive force applied by the compression device to seal the corresponding internal manifold also seals the opening.

[0051] In this way, the compressive force applied by the compression device near the manifold is necessarily high for sealing the corresponding internal manifold (typically formed by alternating battery cells and staggered manifold (e.g., annular) gaskets), and therefore can also be used to seal the opening. The internal manifold can be substantially or completely aligned (i.e., coaxial) with the opening, allowing it to extend therefrom as a continuous passage.

[0052] The components according to this alternative first aspect can be combined with any features of the first aspect outlined above and / or with features of the second aspect, which will be detailed below. Thus, the electrical stud can extend from a stud base that typically forms part of the at least one electrical terminal plate or forms part of another plate connected thereto and also under compression between the base and top plates. The seal can be provided by the stud base and can be located between the at least one electrical terminal plate (or other plate) and the corresponding base and top plates. For convenience, the stud base extends completely across the internal manifold to block the internal manifold and may need to be thick enough to withstand dual atmospheric conditions.

[0053] According to a second aspect, an electrochemical battery assembly is provided, the electrochemical battery assembly comprising: - A base plate and a top plate, between which a planar battery cell stack and at least one terminal plate are configured in a compressed state, wherein: The electrical terminal board comprises a two-layer structure, wherein a first layer and a second layer, formed of different corresponding materials, are permanently connected together to form a single conductor. The first layer of the electrical terminal board is electrically connected to the external electrical terminals of the battery assembly, and The second layer of the electrical terminal board has an outward-facing side, on which a first conductive ceramic layer is joined, facing and electrically connected to the adjacent battery cell.

[0054] It has been found that using a second layer (or plate) of a different material and thickness than the first layer (or plate) and bonded with a ceramic layer provides good electrical connectivity while reducing the likelihood of ceramic layer delamination. The at least one terminal plate is located between one end of the planar battery cell stack and either a bottom plate or a top plate located at the other end of the stack, to supply or remove power from the stack via adjacent battery cells in electrical communication with it. Typically, the first and second layers are permanently connected by welding (forming as separate or independent plates), but any suitable connection method can also be used to provide a permanent electrical connection between the layers (or plates). Typically, the first and second layers are permanently connected around their perimeters and around any ports provided through the terminal plate to prevent fluid communication with the volume between the first and second layers.

[0055] Preferably, the adjacent battery cell has a second conductive ceramic layer, which is bonded to a side facing the first conductive ceramic layer of the terminal board, and the first and second conductive ceramic layers are made of the same material.

[0056] Forming the first and second conductive ceramic layers from the same material ensures good electrical contact between them (e.g., reduced contact resistance compared to the contact resistance between two different materials), thus also ensuring good electrical contact between the terminal plate and adjacent battery cells. Therefore, the efficiency of the assembly as a fuel cell or electrolytic cell is improved.

[0057] Preferably, the first conductive ceramic layer of the terminal plate has a selected thickness such that the spacing between the at least one terminal plate and the adjacent battery cell is the same as the spacing between the remaining battery cells in the stack.

[0058] In this way, when the battery cells in the stack are separated by (e.g., compressible) gaskets, for convenience, the same type of gaskets can be used to separate the at least one terminal board and adjacent battery cells (e.g., gaskets of the same material and thickness). This reduces costs and the number of different materials because the same components are used in multiple locations within the assembly, and it ensures that compressive forces are consistently transmitted throughout the assembly.

[0059] Preferably, the stack includes electrochemically active battery cells, wherein each of the electrochemically active battery cells includes a separator and a battery-supporting metal substrate.

[0060] In an electrochemically active cell, the metal substrate supports an active electrochemical cell layer (i.e., a cell layer that undergoes an electrochemical reaction during operation) bonded thereon, which may be coated, deposited, or otherwise attached thereto. However, at either end of the stack, one or more "dummy" cells that are not electrochemically active may be provided, as described in WO 2015 / 136295 A1. Thus, adjacent cell units may be electrochemically active, meaning they will perform the function of an electrochemical cell under operating conditions. Alternatively, adjacent cell units may be electrochemically inactive, but may still form an electrical connection between the terminal plate and other parts of the fuel cell stack. For example, this may include a separator and a metal substrate, the latter selectively supporting a cathode material layer made of the same material used for the cathode of the electrochemically active cell.

[0061] Typically, the adjacent battery cells include at least one of a metal substrate and a separator. Typically, the battery cells are metal-supported battery cells. The separator separates the oxidant fluid volume from the fuel fluid volume in each battery cell of the stack and typically has a 3D profile structure, for example, including spaced channels and ribs or spaced recesses to control fluid flow.

[0062] Typically, the adjacent battery cells can be arranged such that either the separator or the metal substrate is face-to-face abutting the outermost surface of the second layer of the electrical terminal board. Typically, one or both of the metal substrate and the separator can be made of the same material as the second layer of the electrical terminal board. This material typically contains iron, more commonly steel, and even more commonly stainless steel, particularly ferritic stainless steel. Examples of suitable substrate and / or separator materials, without limitation on the type of metal, include SS441, SS444, and Crofer 22.

[0063] Typically, the separator plate has a series of raised areas (e.g., spaced channels and ribs or spaced recesses) on the side facing the electrical terminal plate to control fluid flow. When a second conductive ceramic layer is bonded to the separator plate of the adjacent battery cell, the ceramic layer typically covers these raised areas of the separator plate.

[0064] When the metal substrate and the electrical terminal plate are face-to-face adjacent, the metal substrate may also have a second conductive ceramic layer, which is bonded to the side facing the first conductive ceramic layer. Typically, the first and second ceramic layers will be in electrical contact.

[0065] Typically, the first ceramic layer will comprise a material suitable for use as a solid oxide fuel cell cathode. The inventors have found that materials suitable for solid oxide fuel cell cathodes provide good electrical connection between the terminal plate and adjacent fuel cell units. Typical examples of suitable materials, without being limited by ceramic type, include LSCF, LCN, and BSCF. Typically, the second ceramic layer will comprise a material suitable for use as a solid oxide fuel cell cathode. More commonly, the first and second ceramic layers will have substantially the same composition.

[0066] Preferably, the second layer of the terminal board is made of the same material as the separator. This reduces the number of different materials used in the assembly. This ensures that the second layer of the terminal board is chemically compatible with the battery cell and the first conductive ceramic layer, and also ensures that the second layer of the terminal board is chemically compatible with the chemical environment of the assembly (i.e., chemically resistant to the first fluid volume and / or the second fluid volume, which may be fuel and oxidant fluid volumes).

[0067] Preferably, the second layer of the terminal board has a configuration substantially the same as that of the separator. For convenience, the second layer of the terminal board is made of the same material as the separators of the battery cells in the battery cell stack, and preferably also has a configuration substantially the same as the separator (e.g., shape and orientation) (except where different (e.g., perimeter) features are required to perform its function as a terminal board), i.e., the second layer itself is a plate (e.g., a self-supporting rigid plate). Essentially, the second layer can be formed from the same separator (or very similar components) as the remaining separators in the stack, which has the advantage of being very similar to the electrical connections and mechanical forces between the adjacent battery cells, so that the first conductive ceramic layer is face-to-face adjacent to the metal substrate of the adjacent battery cell, just like the other separators in the stack.

[0068] Preferably, the second layer of the terminal board has a 3D profile structure in which a series of protrusions extend outward to abut adjacent battery cells, and above these protrusions, the first conductive ceramic layer extends as a discontinuous layer to which it is bonded. The 3D profile structure may include, for example, a pattern of spaced channels and ribs or spaced recesses to provide volume between the terminal board and adjacent battery cells, thereby allowing fluid to be supplied to and controlled in the adjacent battery cells. The protrusions abut (e.g., contact) adjacent battery cells, providing an electrical connection between the terminal board and adjacent battery cells, thereby enabling the terminal board to transfer electrical energy to or from the ends of the battery cell stack.

[0069] Preferably, the first conductive ceramic layer and the second conductive ceramic layer bonded to the metal substrate of the adjacent battery cell are made of the same material, and the metal substrate is adjacent to the first conductive ceramic layer face to face.

[0070] Forming the first and second conductive ceramic layers from the same material ensures good electrical contact between them (e.g., reduced contact resistance compared to the contact resistance between two different materials), thus also ensuring good electrical contact between the terminal plate and adjacent battery cells. Therefore, the efficiency of the component operating as a fuel cell or electrolytic cell is improved.

[0071] In one example, the adjacent battery cell is electrochemically active, and the second conductive ceramic layer includes the outermost electrode layer of the electrochemically active battery layer bonded to the metal substrate of the adjacent battery cell.

[0072] In an electrochemically active battery cell, the metal substrate supports and bonds an active electrochemical battery layer (i.e., a battery layer that undergoes electrochemical reactions during operation), which may be coated, deposited, or otherwise attached thereto. In one example, the outermost electrode layer of the electrochemically active battery layer is a cathode layer. In this case, the first conductive ceramic layer comprises the same material used in the cathode layer.

[0073] In an alternative example, the adjacent battery cells are electrochemically inert, and the second conductive ceramic layer is an electrode material layer bonded to the metal substrate of the adjacent battery cell. The second conductive ceramic layer is an electrode material layer that can be directly bonded to the metal substrate of the adjacent battery cell.

[0074] As described in WO 2015 / 136295 A1, one or more electrochemically inert cells (also referred to as "virtual" cells) can be provided, which are not electrochemically active. In this case, the adjacent cell units may be electrochemically inert, but can still form electrical connections between the terminal plate and other parts of the fuel cell stack. For example, it may have a metal substrate supporting a cathode material layer, the same material used in the cathodes of the electrochemically active cell units. The one or more electrochemically inert cells provide electrical connections between the terminal plate and the electrochemically active cell units in the cell stack.

[0075] In an alternative where the second layer of the electrical terminal board is made of the same material as the separator, the second layer of the electrical terminal board is made of the same material as the battery-supported metal substrate.

[0076] This reduces the number of different materials used in the component. This ensures that the second layer of the terminal board is chemically compatible with the battery cell and the first conductive ceramic layer, and also ensures that the second layer of the terminal board is chemically compatible with the chemical environment of the component (i.e., chemically resistant to the first fluid volume and / or the second fluid volume, which may be fuel and oxidant fluid volumes).

[0077] In this case, it is preferable that the second layer of the electrical terminal board has a configuration substantially the same as that of the battery-supported metal substrate.

[0078] For convenience, the second layer of the terminal board is made of the same material as the battery-supporting metal substrate of the battery cells in the battery cell stack, and preferably also has a configuration substantially the same as the battery-supporting metal substrate (except where different features are required to perform its function as a terminal board), that is, the second layer itself is a plate (e.g., a self-supporting rigid plate). Essentially, the second layer can therefore be formed from the same battery-supporting metal substrate (or a very similar component) as the remaining battery-supporting metal substrates in the stack, with the advantage that the electrical connection and mechanical forces with the adjacent cell cells are very similar to those of the adjacent cell cells, and the first conductive ceramic layer is therefore adjacent face-to-face to the separator of the adjacent cell cells, the same as the other battery-supporting metal substrates in the stack.

[0079] In this configuration, preferably, the second layer of the terminal block has a flat, outward-facing side to which the first conductive ceramic layer, comprising a continuous layer, is bonded. The first conductive ceramic layer may be made of the same material as the second conductive ceramic layer of a separator plate bonded to the adjacent battery cell, the separator plate being face-to-face with the first conductive ceramic layer.

[0080] Forming the first and second conductive ceramic layers from the same material ensures good electrical contact between them (e.g., reduced contact resistance compared to the contact resistance between two different materials), thus also ensuring good electrical contact between the terminal plate and adjacent battery cells. Therefore, the efficiency of the components used in fuel cells or electrolytic cells is improved.

[0081] The thickness of the first conductive ceramic layer can be equal to the thickness of the electrochemical cell layer of the adjacent battery cell. In this way, when the stacked battery cells are separated by (e.g., compressible) gaskets, for convenience, the same type of gasket can be used to separate the at least one terminal plate and the adjacent battery cells (e.g., gaskets of the same material and thickness). This reduces costs and the number of different materials used, as the same components are used in multiple locations within the assembly, and ensures that compressive forces are consistently transmitted within the assembly.

[0082] The component may include a first terminal board located at one end of the stack (where the second layer of the terminal board is made of the same material as the separator) and a second terminal board located at the other end of the stack (where the second layer of the terminal board is made of the same material as the battery-supporting metal substrate). The first and second terminal boards provide electrical connections between the stack and corresponding terminals.

[0083] Preferably, a portion of the external electrical terminal extends through an opening in one of the base plate and the top plate to be electrically connected to a first layer of the electrical terminal board. Optionally, the electrical terminal board is the electrical terminal board as described in the first aspect above.

[0084] For example, the opening can be aligned with an internal manifold (formed by a port through each battery cell in the stack), and the electrical terminals (also referred to as electrical studs) can also be aligned with the internal manifold. Washers can separate each plate and are placed around the ports and openings to form the internal manifold.

[0085] Typically, the first and second layers of the electrical terminal board are iron-containing layers. More commonly, the layers are steel, even more commonly stainless steel, and even more commonly ferritic stainless steel. Without being limited by the type of metal, examples of suitable materials for the first layer include SS441 and Crofer 22, and examples of suitable materials for the second layer include SS441, SS444, and Crofer 22.

[0086] Typically, the first layer of the electrical terminal board will have a thickness of at least 0.5 mm, more commonly between 0.5 mm and 5 mm, even more commonly between 0.5 mm and 2 mm, and even more commonly between 1 mm and 2 mm. In other words, the first layer of the electrical terminal board is itself a plate, which can also be called a self-supporting rigid plate.

[0087] Typically, the thickness of the first ceramic layer and the second ceramic layer is 50-200 micrometers, preferably 80-150 micrometers, and more preferably 90-100 micrometers.

[0088] Typically, the thickness of the substrate (also known as a support plate, metal substrate, or battery-supported metal substrate) is 50-250 micrometers, preferably 50-150 micrometers, and more preferably 100 micrometers.

[0089] Preferably, any of the electrochemical cells detailed above comprises planar, solid oxide, fuel cell, or electrolytic cell units. The electrochemical cell assembly can be used as a fuel and / or electrolytic cell or any other variant capable of performing electrochemical reactions. The planar cell stack can be based on a solid oxide electrolyte, a polymer electrolyte membrane, or a molten electrolyte or any other variant capable of performing electrochemical reactions. In one example, the electrochemical cell is based on multiple planar cell units (e.g., tens to hundreds of cell units) having a solid oxide electrolyte; therefore, the electrochemical cell can be referred to as a solid oxide fuel cell (SOFC) and a solid oxide electrolytic cell. The solid oxide electrolyte can be supported by foil; in this case, they can be referred to as metal-supported cells, particularly metal-supported solid oxide fuel cells (MS-SOFC) or electrolytic cells.

[0090] The stack may include electrochemically active cell units, each of which includes a separator and a cell-supporting metal substrate. In the electrochemically active cell unit, the metal substrate supports an active electrochemical cell layer (i.e., a cell layer that undergoes an electrochemical reaction during operation) bonded thereon, which may be coated, deposited, or otherwise attached thereto. However, as described in WO 2015 / 136295 A1, one or more “virtual” cells without electrochemical activity may be disposed at either end or both ends of the stack. Therefore, a cell adjacent to a terminal plate may be electrochemically active, meaning it will perform the function of an electrochemical cell under operating conditions, and the terminal plate may contact a corresponding electrochemically active cell at the end of the cell stack. Alternatively, the adjacent cell may be electrochemically inert but may still form an electrical connection between the terminal plate and other parts of the fuel cell stack. For example, it may have a metal substrate supporting a cathode material layer, the same material used for the cathode of the electrochemically active cell unit. In both cases, the electrical terminal board can be described as having electrical contact with the adjacent battery cell located at the end of the stack.

[0091] Typically, the adjacent battery cells include at least one of a metal substrate and a separator. Typically, the battery cells are metal-supported battery cells. The separator separates the oxidant fluid volume from the fuel fluid volume in each battery cell of the stack and is typically provided with a 3D profile structure, for example, including spaced channels and ribs or spaced recesses, to control fluid flow.

[0092] As mentioned above, "battery cell" or "battery stack" is used to refer to "electrochemical battery cell" or "electrochemical battery stack". Attached Figure Description

[0093] Figure 1 and Figure 2 This is a schematic diagram of the existing battery stack layout.

[0094] Figure 3 This is a cross-sectional view of the battery stack arrangement according to the first aspect of the present invention.

[0095] Figure 4 It is a cross-sectional view of the battery stack arrangement according to the first aspect.

[0096] Figure 5A It is a cross-sectional view of the battery stack arrangement according to the first aspect, and Figure 5B yes Figure 5A An enlarged view of a portion of the battery stack arrangement.

[0097] Figure 6A It is a cross-sectional view of the battery stack arrangement according to the first aspect, and Figure 6B and Figure 6C yes Figure 6A An enlarged view of a portion of the battery stack arrangement.

[0098] Figure 7 It is a plan view of the first and second electrical terminal boards according to the first aspect.

[0099] Figure 8 According to the first aspect Figure 5A An exploded 3D view of the battery stack arrangement shown.

[0100] Figure 9 Based on the first aspect Figure 6A An exploded 3D view of the battery stack arrangement shown.

[0101] Figure 10 This is a cross-sectional view of the battery stack arrangement according to the second aspect of the present invention.

[0102] Figure 11 yes Figure 10 An exploded perspective view of the battery stack arrangement shown.

[0103] Figure 12 This is an exploded view of the first electrical terminal board according to the second aspect.

[0104] Figure 13 This is an exploded view of the second electrical terminal board according to the second aspect.

[0105] Figure 14 It is a cross-sectional view of a portion of the battery stack arrangement according to the second aspect.

[0106] Figure 15 It is a cross-sectional view of a portion of the battery stack arrangement according to the second aspect.

[0107] In the illustrations and descriptions below, similar reference numerals will be used for similar elements in different figures.

[0108] Specific Implementation Methods of the First Aspect Reference Figure 3 The figure shows a cross-sectional view of an electrochemical cell stack arrangement 300, truncated on the right side to show details of the internal manifolds (flues), studs, and terminal plates. The figure shows an electrochemical cell stack composed of five repeating cell cells 306 stacked together; for illustrative purposes, the number of cell cells is reduced, but typically much larger (e.g., 30-200). Cell cell 306 includes a substrate (or metal support plate) 306a and separators (or interconnects) 306b, and may resemble those described in the applicant's earlier patent application WO 2015 / 136295. The substrate 306a carries an electrochemical active layer (or active fuel cell component layer, not shown), which includes respective anode, electrolyte, and cathode layers deposited (e.g., as a thin coating / film) on and supported by the metal support plate (e.g., a steel plate or foil), the electrochemical active layer facing the separators 306b of adjacent cell cells 306. The metal support plate 306a has a porous region (not shown) surrounded by a non-porous region. An active layer is deposited on the porous region, allowing gas to pass from one side of the metal support plate 306a through the pores to the other side and into the active layer coated thereon. For example... Figure 3As shown, each battery cell 306 includes two plates or two layers – a metal support plate 306a and a separator plate 306b (but a spacer plate may be sandwiched between the metal support plate 306a and the separator plate 306b). It also has fluid ports (for oxidant and / or fuel) disposed in the plates, and these plates are stacked and welded (fused together) to form a single metal-supported repeatable battery cell 306, with the fluid volume defined by the space provided between the metal support plate 306a and the separator plate 306b. The metal components of the fuel cell stack repeatable layer 306 are in electrical contact with each other, and the electron flow between them is primarily through a fusion / welding path, thereby avoiding surface-to-surface contact resistance loss.

[0109] As discussed in WO2015 / 136295, the porous region includes small orifices (through holes drilled in the metal foil substrate) extending through the metal support plate 306a (not shown), which cover the anode (or cathode, depending on the polarity orientation of the electrochemically active layer) located below the metal support plate 306a. These orifices are located in a large space or opening between the metal support plate 306a and the spacer plate 306b (and may be defined by the spacer plate) to allow fluid volume to be fluidly communicated with the electrochemically active layer on the bottom surface of the support plate 306a through the orifices.

[0110] In the separator 306b, upper and lower corrugations are provided to extend upward to the cathode (or anode, depending on the polarity orientation of the electrochemical active layer) of the subsequent (or adjacent) fuel cell units stacked on this fuel cell unit, and downward to the metal support plate 306a of its own fuel cell unit 306. Thus, an electrical connection is formed between adjacent fuel cell units 306 in the stack, causing the electrochemical active layers of the stack (typically one on each fuel cell unit) to be connected in series.

[0111] exist Figure 3 In this configuration, battery cells 306 are stacked together using gaskets 304 located between adjacent battery cells 306. Each gasket 304 surrounds a fluid port of a battery cell and is electrically insulating. The stack of battery cells 306 and the corresponding gaskets 304 are stacked on top of each other, thereby aligning the corresponding fluid ports in the battery cells 306 to form an internal manifold or flue through the battery cell stack, through which fluid can be delivered to and from the battery cells (specifically, through an opening between the metal support plate 306a and the separator plate 306b of each battery cell 306). The gasket 304 provides a fluid seal between its surface and the adjacent surface. The gasket 304 is a prefabricated gasket and is non-conductive. The gasket can be, for example, made of vermiculite (e.g., thermoulite), which can provide superior sealing performance compared to mica or ceramic, while requiring a much lower load to achieve the seal.

[0112] The metal support plate 306a and the separator plate 306b of the battery cell 306 may be provided with a recess ( Figure 3 (Not shown in the diagram) or other 3D protrusions protruding into and contacting the other of the metal support plate 306a and separator plate 306b in the area surrounding the fluid port (i.e., surrounding the flue) and disposed along the gasket 304. The recess transmits pressure through the battery cell stack, supports the battery cell by the pressure applied to it by the gaskets (port gaskets, i.e., gaskets surrounding the port, these gaskets are typically annular gaskets surrounding a port with a circular cross-section) 304 located above and below the battery cell, and maintains separation (gap) between the metal support plate 306a and separator plate 306b of the individual battery cell 306. The recess may be arranged in annular form around the port and allow the first fluid to enter or exit the gap between the metal support plate 306a and separator plate 306b of the battery cell 306 (which will be referred to in the diagram). Figure 5A , Figure 5B , Figure 6A , Figure 6B and Figure 6C (To be further described).

[0113] In this embodiment, a power output assembly and a top or bottom plate are disposed at each end of the battery cell stack. The power output assembly, including a first terminal plate 302 and an electrical stud 301, is positioned at the top of the battery cell stack, with the first terminal plate 302 positioned on top of the battery cell stack. The first terminal plate 302 is separated from the ends of the stack by a (port) gasket 304, which is the same as the (port) gasket used between battery cells 306 in the stack. The first terminal plate 302 blocks the flue from its vertically extending base via the electrical stud, preventing fluid from passing through the first terminal plate 302, as will be discussed further below. The first terminal plate 302 makes electrical contact with the battery cells 306 located at the top end of the battery cell stack 306. The first terminal plate 302 transfers potential from the battery cells 306 at the top end of the battery cell stack 306 to the electrical stud 301, which transfers potential to the outside of the battery stack arrangement 300, acting as an electrical terminal. The first electrical terminal board 302 and the electrical stud 301 can be a single unit; or they can be two separate components that are welded, brazed, screwed, or otherwise attached to each other.

[0114] The first electrical insulating plate 305a is located above (i.e., outward) the first electrical terminal plate 302, thus the first electrical terminal plate 302 is located between the first electrical insulating plate 305a and the battery cell stack. The first electrical insulating plate 305a preferably extends across the stack to at least the same extent as the battery cells in the bottom stack and is separated from the first electrical terminal plate 302 by a (port) gasket 304, the same gasket used between battery cells 306 in the stack. The gasket 304 surrounds an opening in the first electrical insulating plate 305a, which is coaxial with (and forms a continuation of) a flue (or internal manifold) through the stack, through which the electrical stud 301 needs to pass.

[0115] The top plate 303 is located above the first electrical insulation plate 305a, and therefore, the first electrical insulation plate 305a is located between the top plate 303 and the first electrical terminal plate 302. The first electrical insulation plate 305a is separated from the top plate 303 by a (port) gasket 304, which is the same gasket used between the battery cells 306 in the stack. The gasket 304 surrounds an opening on the top plate 303, which is coaxial with (and forms a continuation of) the flue gas duct passing through the stack, through which the electrical stud 301 passes. The first electrical insulation plate 305a provides electrical insulation between the electrical terminal plate 302 and the top plate 303. The first electrical insulation plate 305a may be made of mica or a non-conductive ceramic material.

[0116] The second electrical terminal plate 310, the second electrical insulation plate 305b, and the bottom plate 308 are located below the battery cell stack (i.e., at the end of the stack opposite to the first electrical terminal plate 302, the first electrical insulation plate 305a, and the top plate 303). The second electrical terminal plate 310 is separated from the end of the stack by a gasket 304, which is the same as the (port) gasket used between the battery cells 306 in the stack. The second electrical terminal plate 310 is provided with a port that aligns with the port through the battery cell 306, through which fluid can pass, thus defining a portion of the flue. The second electrical terminal plate 310 is in electrical contact with the battery cell 306 at the lower end of the battery cell stack 306 and has the opposite polarity to the first electrical terminal plate. The second electrical terminal plate 310 can be in electrical contact with a second electrical stud (not shown) to transfer electrical energy from the battery stack arrangement 300.

[0117] The second electrical insulation plate 305b is located below the second electrical terminal plate 310; therefore, the second electrical terminal plate 310 is located between the second electrical insulation plate 305b and the battery cell stack. The second electrical insulation plate 305b and the second electrical terminal plate 310 are separated by a gasket 304, which is the same gasket used between the battery cells 306 in the stack. The gasket 304 surrounds an opening on the second electrical insulation plate 305b, which is coaxial with (and forms part of) a flue through the stack, through which fluid can pass.

[0118] The base plate 308 is located below the second electrical insulation plate 305b, thus the second electrical insulation plate 305b is located between the base plate 308 and the second electrical terminal plate 310. The base plate 308 and the second electrical insulation plate 305b are separated by a gasket 304, the same gasket used between the battery cells 306 in the stack. The gasket 304 surrounds an opening on the base plate 308, which is coaxial with (and forms part of) the flue gas duct that runs through the stack. Fluid can pass through this opening, providing a port for fluid to be delivered to or discharged from the flue gas duct, thereby also providing a port for the stack. Similar to the first electrical insulation plate 305a, the second electrical insulation plate 305b provides electrical insulation between the electrical terminal plate 310 and the base plate 308. The second electrical insulation plate 305b may be made of mica or a non-conductive ceramic material.

[0119] The compression device 307 is provided to maintain the compressive force applied during the manufacturing process. The compression device 307 is disposed between the bottom plate 308 and the top plate 303 and keeps the components therebetween (i.e., gasket 304, electrical insulation plates 305a, 305b, first electrical terminal plate 302 and second electrical terminal plate 310, and battery cell 306) compressed. Figure 3The compression device 307 is shown as a skirt, which can be welded or otherwise permanently attached to the base plate 308 and top plate 303 while applying external pressure between them during manufacturing. Once the external compressive force is removed, the tensile force through the skirt sustains the compressive load in the stack through the base plate 308 and top plate 303. Weld paths can surround the base plate 308 and top plate 303 and form a fluid seal, fluidly sealing the (fluid) volume defined by the base plate 308, top plate 303, and the skirt 307 that houses the stack. The base plate 308 and top plate 303 are relatively rigid plates (more rigid than any other plate in the arrangement, such as metal support plates, separators, battery cell units, and terminal plates, for example, because they are thicker, not necessarily because they are made of inherently harder materials), and they distribute the compressive load to planar areas of the stack (at least in the areas where they contact the gasket 304 and along the electrochemically active layer). The compression device maintains compression to ensure good electrical contact between repeating units (including battery cells) in the stack. The compression device also maintains compression on seals (e.g., (port) gaskets 304) to seal the flue and maintain the structural integrity of the stack, as described in the applicant's earlier patent application WO 2019 / 002829A. Therefore, a first fluid volume is defined in the space between the flue and the metal support plates 306a and separators 306b of each battery cell 306. A second fluid volume, fluidly sealed to the first fluid volume, is defined by the remaining volume within the volume defined by the bottom plate 308, the top plate 303, and the skirt (compression device) 307. Thus, in this configuration, the compression device achieves the further objective of defining and sealing the fluid volume (i.e., the second fluid volume). The first fluid volume may be in fluid communication with the anode of the electrochemically active layer, and the second fluid volume may be in fluid communication with the cathode of the electrochemically active layer, or vice versa, depending on the arrangement of the electrochemical battery layers.

[0120] Alternatively, the compression device 307 may include a pull rod arranged to pass through (secured with a fastening device, such as a lock nut) or screw into an opening and connect the base plate 308 and the top plate 303, maintaining a compressive force applied to the battery stack arrangement between the base plate 308 and the top plate 303. In this case, the compression device does not define and seal the fluid volume; rather, the second fluid volume may be contained by a container where the arrangement 300 is located.

[0121] In one example, the first terminal plate 302 is in electrical contact with the outermost layer (e.g., the anode layer) of the uppermost battery cell 306 in the battery cell stack, while the second terminal plate 310 is in electrical contact with the cathode layer of the lowermost battery cell 306 in the battery cell stack (the stacked battery cells are connected in series). The anode may be in fluid communication with a first fluid volume, while the cathode may be in contact with a second fluid volume. During fuel cell operation, fuel is supplied to the first fluid volume, and oxidant is supplied to the second fluid volume, creating a potential difference between the first terminal plate 302 and the second terminal plate 310, through which a load may be connected. In this configuration, the first terminal plate 302 may be referred to as a single electrode, and the second terminal plate 310 as a terminal electrode.

[0122] When operating as an electrolytic cell, a potential difference is applied between the first terminal plate 302 and the second terminal plate 310 to drive the generation of hydrogen and / or carbon monoxide and oxygen.

[0123] Reference Figure 4 This shows a cross-sectional view of the battery stack arrangement 400. The battery stack arrangement 400 is... Figure 3 A 300-cell battery stack configuration variation. Figure 4 In the variant shown, the battery cell (repeating cell) 406 includes a metal support plate 406a and a separator plate 406b. In this variant, pre-fabricated (port) gaskets are not required between the battery cells 406 in the battery cell stack. Instead, the annulus surrounding the fluid port of the metal support plate 406a protrudes (downwards in the figure) by causing the annulus to protrude away from the separator plate 406b of this battery cell and toward the separator plate of the adjacent battery cell.

[0124] An in-situ seal, namely sealant material ring 409, is formed on the annulus, and this material can be used during the stack assembly process. It can be any conventional sealant material, designed to withstand the operating environment of the fuel cell after curing. (Pre-fabricated) gaskets can also be used instead if needed, but using in-situ seals offers significant advantages such as reduced parts count, lower costs, and simplified assembly, as the careful positioning of gaskets is no longer required.

[0125] Using this arrangement, the thickness of the sealant material can be significantly lower than that typically required for prefabricated gaskets. Electrically insulating seals or in-situ seals can be used on one or both of the abutment surfaces of adjacent fuel cell units (forming hard stop surfaces, for example, formed by raised annular structures and partitions of adjacent fuel cell units) to prevent electrical contact between adjacent fuel cell units through the abutment surfaces.

[0126] An annular groove (not shown for clarity) may also be provided in the annulus, protruding towards the separator 406b of the battery cell, for accommodating in-situ sealing material. The annular groove can be formed into a uniform circle with a constant depth, but it can also be made less uniform in both radius and depth; however, for simplicity, a uniform radius and depth are provided. The annular groove can accommodate the volume (or beads) of sealant material and contacts the separator 306b of the adjacent battery cell 306, thus functioning similarly to... Figure 3 The washer in the middle is made of 304 stainless steel.

[0127] Figure 3 The thickness of the gasket 304 helps to provide space for air or fuel flow between adjacent fuel cell units. To preserve this space, shaped port features can be provided in the annular portion of the metal support plate 406a. This also ensures that the final height of the top of the gasket sealing material remains correct to allow the outer surface of the electrochemical active layer to properly contact the separator plate 406b of the adjacent cell 406.

[0128] The raised ring-shaped object in Figure 4 It is shown as part of the metal support plate 406a, but may alternatively be provided in the separator plate 406b of each battery cell 406.

[0129] As illustrated in the embodiments below, such as Figure 3 and Figure 4 As described in the arrangement, any or all of the shaped features and shaped peripheral flanges provided in the metal support plate 406a (through which the battery cells are welded into a two-piece battery) may alternatively be provided in the separator plate 406b.

[0130] Reference Figure 5A This shows a cross-sectional view of the battery stack arrangement 500, and refers to... Figure 5B It shows Figure 5A An enlarged view of the area surrounded by the image. Figure 8 yes Figure 5A The arrangement of 500 is an exploded 3D diagram.

[0131] The battery stack arrangement 500 includes a battery cell 306 stack similar to the battery cell 306 described above. Figure 5A An electrochemically active layer 506 is shown, comprising respective anode, electrolyte, and cathode layers deposited (e.g., as thin coatings / films) on and supported by a metal support plate 306a. Figure 5A The upper and lower protrusions of the separator 306b are also shown, which are in contact with the metal support plate 306a of the battery cell 306 and the outermost layer of the electrochemical active layer 506 of the adjacent (nearby) battery cell 306.

[0132] The stud 301 and the first electrical terminal plate 302 are similar to those described above. In this case, an electrically insulating sleeve 503 (also referred to as a collar) surrounds the stud 301. The cross-section of the stud 301 and the openings through the first electrically insulating plate 305a and the top plate 303 can be circular, and in this case, the sleeve 503 is a hollow cylinder. The sleeve 503 is formed of an (electrically) insulating material (such as mica or ceramic). It provides mechanical stability to the stud 301 during the handling of the stack arrangement 500 and the connection of loads to the stud 301. The sleeve 503 also prevents foreign objects (e.g., dust) from entering the stack arrangement 500 through the openings on the top plate 303. A gasket 504 surrounds the sleeve 503 (and the stud 301) and is located on the outer surface of the top plate 303, providing further mechanical stability. The outer surface of the gasket 504 protrudes from the outer end of the sleeve 503 (i.e., protrudes further than the outer surface of the top plate 303), thereby allowing any mechanical force applied to the stud to be transmitted through the gasket 504 to the top plate 303, rather than through the sleeve 503 or through the stud 301 to the first electrical terminal plate 302. The gasket can be formed of any suitable (electrically) insulating material, such as ceramic or mica. Figure 5B As shown, the busbar 509 can be attached to the stud 301 by the nut 508 and is outside the stack arrangement 500 and in contact with the gasket 504.

[0133] Further details of the first electrical terminal board 302 are in Figure 5A The meaning is obvious. A first terminal plate 302 (preferably) is provided with a material layer 510, which is deposited (e.g., as a thin coating / film) on or attached to the first terminal plate 302 and supported by it. The material layer 510 is a conductive ceramic material and may have a composition similar to that of the cathode of the electrochemical active layer 506; for example, it may be LSCF, LCN, BSCF, such as LCN60. Advantageously, the thickness of the material layer 510 is comparable to the thickness of the electrochemical active layer 506 of the battery cell 306, meaning that the outermost ( Figure 5A The protrusion in the separator 306b of the uppermost battery cell 306 contacts the surface of the material layer 510. This also facilitates allowing all gaskets 304 to have a similar thickness. This reduces the number of different components required in the stack arrangement 500, as no special components are needed to connect the battery cell stack 306 and the first terminal plate 302. The material layer 510 contacts the outermost ( Figure 5A The uppermost battery cell's separator 306b contacts the (upward) protrusion and electrically connects the separator to the first electrical terminal plate 302 to allow the transfer of electrical energy therebetween. The electrical terminal plate 302 is shown as a single plate with a material layer 510 attached, coated, or deposited on it, but it can also be a two-(or more) part structure, as described in the second aspect, for example, Figure 10Electrical terminal board 1402.

[0134] Figure 5A The image shows a second electrical stud 505, which is similar to the aforementioned electrical stud 301 but has the opposite polarity. The second electrical stud 505 is connected to the second electrical terminal plate 507 and passes through openings in the second electrical insulation plate 305b and the base plate 308. The second electrical stud 505 is provided with a sleeve 503, a washer 504, a busbar, and a nut, and is similar to the first electrical stud 301, but is associated with the base plate 308 instead of the top plate 303.

[0135] Further details of the second terminal board 507 are in Figure 5A The middle is obvious. The second terminal plate 507 is provided with a protrusion extending into the battery cell stack to contact the outermost ( Figure 5A The outermost electrode (e.g., cathode) of the electrochemically active layer 506 of the bottommost battery cell 306. These protrusions have the same height as the protrusions in the separator 306b that project (upwards) onto the electrochemically active layer 506 of the adjacent battery cell 306. This advantageously allows the gasket 304 located between the second terminal plate 507 and the battery cell stack to have the same thickness (effectively the same gasket) as the gaskets used between adjacent battery cells 306 in the battery cell stack.

[0136] The protrusion in the second terminal plate 507 is adjacent to the outermost electrochemical active layer (e.g., cathode) of the outermost battery cell in the battery cell stack. Figure 5A The bottommost surface of the electrochemically active layer is in contact with the surface of the second terminal plate 507, allowing electrical energy to be transferred therebetween. The terminal plate 507 is shown as a single plate with protrusions as part of it, but it can also be a two-(or more) part structure, as described in the second aspect, for example, Figure 10 The electrical terminal board 1407 in the middle.

[0137] It should be noted that stud 301 and stud 505 are located at opposite ends of the battery cell stack. Two flues are present in arrangement 500, and the studs are aligned with each flue (e.g., preferably coaxial with each flue). The flue is defined / formed by gasket 304, a port through battery cell 306, and a port through first terminal plate 302, first electrical insulation plate 305a, and top plate 303 or through second terminal plate 507, second electrical insulation plate 305b, and bottom plate 308. First terminal plate 302 ( Figure 5A On the left side, the first flue is blocked by the base of the vertically extending electric stud, and the second electric terminal plate 507 ( Figure 5A The second flue is blocked on the right side (by the base of the vertically extending electric stud).

[0138] like Figure 5A As indicated by the arrows, the first flue is used to supply the first fluid to the first fluid volume, while the second flue is used to discharge the first fluid volume. The first fluid volume is enclosed between the metal support plate 306a and the separator plate 306b of the battery cell 306 and is supplied / discharged by the flue. The second fluid volume can be disposed around the battery cell and the flue, enclosed by the skirt, bottom plate, and end plate, and in fluid communication with the outermost electrode of the electrochemical active layer 506. Ports for supplying and discharging the second fluid volume can be provided in the bottom plate and / or end plate. Figure 5A (Not shown in the image).

[0139] Figure 5A The diagram further shows a support layer 511, which is disposed between the power output device of plate 302 and the first electrical insulating plate 305a, between the first electrical insulating plate 305a and the top plate 303, between the second electrical terminal plate 507 and the second electrical insulating plate 305b, and between the second electrical insulating plate 305b and the bottom plate 308. The extent of the support layer 511 corresponds to the extent of the electrochemical active layer 506 (and the protrusions in the separator plate 306b) (along which it is disposed and covers the corresponding planar area in the plan view). The support layer 511 transfers a portion of the compressive force applied between the bottom plate 308 and the top plate 303 through the battery cell stack. This ensures good electrical contact (e.g., even across a planar region) between adjacent battery cells within the battery cell 306 and in the battery cell stack (i.e., good electrical contact between the downward protrusion of the separator 306b and the metal support plate 306a of the same battery cell 306, and good electrical contact between the upward protrusion of the separator 306b and the outermost electrode of the electrochemically active layer 506 of adjacent or neighboring battery cells 306 in the battery cell stack). Of course, the same compressive force provides good electrical contact between the first terminal plate 302 and the second terminal plate 507 and the outermost battery cells of the battery cell stack through the support layer 511. The support layer 511 can be formed of any conductive or non-conductive elastic material (e.g., a mesh or expanded metal foil) capable of transmitting compressive force to the stack.

[0140] Reference Figure 8 For clarity, a portion of the skirt 307 is shown. It should be understood that the skirt 307 may include two additional sidewalls to connect the edges of the shown skirt component 307, thereby allowing the skirt to surround the stack. It should also be noted that the metal support plate 306a and the separator 306b are not shown in an exploded view; therefore, only the separator 306b is readily apparent in this view. The metal support plate 306a and the separator 306b of the battery cell 306 are welded or otherwise attached to each other around their perimeters.

[0141] When used as a fuel cell, the electrical load can be connected between the stud 301 and the second stud 505 arranged in a 500-degree configuration. In the example where the anode is the electrochemically active layer closest to the metal support plate 306a, the first fluid is fuel. Fuel is supplied to the anode through the first flue, the gap between the metal support plate 306a and the separator 306b, and the porous region of the metal support plate 306b, and fuel emissions are routed from the anode through the gap between the metal support plate 306a and the separator 306b to the second flue. The second fluid is an oxidant and is supplied to the cathode through a second fluid volume.

[0142] When used as an electrolytic cell, a potential difference can be established between the first stud 301 and the second stud 505 to provide electrical energy to the arrangement 500. The relevant fluid is supplied to the first fluid volume and the second fluid volume, and then discharged from there.

[0143] Reference Figure 6A This shows a cross-sectional view of the battery stack arrangement 600. The battery stack arrangement 600 is... Figure 5A A 500-cell battery stack configuration variation. Figure 6B and Figure 6C Showing Figure 6A The battery stack is arranged in a magnified area of ​​600. Figure 7 This is a plan view of the first terminal plate 602 and the second terminal plate 606 of the battery stack arrangement 600, each with studs. Figure 9 yes Figure 6A , Figure 6B , Figure 6C and Figure 7 An exploded 3D view of the arrangement at 600 degrees. It should be noted that, relative to... Figure 5A and Figure 5B Arrangements 500 and 600 (including battery cells 306 in the battery cell stack) are shown rotated 180 degrees.

[0144] exist Figure 6A , Figure 6B and Figure 6C In the illustrated arrangement 600, a first electrical terminal plate 602 with studs 601 is connected to an additional electrical terminal plate 607 via an additional busbar 612, thereby allowing both electrical studs 601 and 605 to be located at the same end of the stack arrangement 600. It also allows the fluid inlet and outlet of a first fluid volume to be located at the same end of the stack arrangement 600 (the fluid inlet and outlet are located at one end of the stack arrangement 600 opposite to the electrical studs 601 and 605). Gaskets 304 are provided between each additional component of the arrangement 600 to define a flue or its continuation.

[0145] The second electrical stud 605 and associated second electrical terminal plate 606 are similar to the second electrical stud 505 and second electrical terminal plate 507 arranged in 500, except that the second electrical stud 605 passes through an opening in an additional electrical insulating plate 613 (for reasons described below) and through the first electrical terminal plate 602. Therefore, the second electrical terminal plate 606 has a protrusion 614 facing and contacting the outermost layer of the outermost battery cell 306 of the battery cell stack, which may be the outermost electrochemically active layer of the electrochemically active layer 506. The second electrical terminal plate 606 is shown as a single plate with protrusions as part of it, but it may also be a two-(or more) part structure, as described in the second aspect, for example, Figure 10 The electrical terminal board 1407 in the middle.

[0146] Between the second electrical terminal plate 606 and the additional electrical insulation plate 613, a support layer 511 is disposed on one side of the second electrical terminal plate 606 opposite to the protrusion to maintain compression within the electrochemically active region of the stack.

[0147] The first electrical stud 601 is connected to or integrally formed with the first electrical terminal plate 602, similar to the electrical stud 301 and first electrical terminal plate 302 of arrangement 500. Unlike arrangement 500, the first electrical terminal plate 602 does not have a coated or deposited conductive ceramic layer 510. The first electrical terminal plate 602 is electrically connected to a busbar 612, which in turn is electrically connected to an additional electrical terminal plate 607, such that both terminal plates are of the same polarity and are both subjected to compressive forces applied by the compression device, particularly near the flue. The additional electrical terminal plate 607 is located at the other end of the battery cell stack opposite the first electrical terminal plate 602. The additional electrical terminal plate 607 is provided with a material layer 510, which is deposited (e.g., as a thin coating / film) on—or attached to—the first electrical terminal plate 607 and supported by it. The material layer 510 is otherwise similar to that described above. Figure 5A Similar to what is described.

[0148] The first electrical plate 602 is located between the additional electrical insulating plate 613 and the top plate 303 of the stack arrangement 600. The first electrical plate 602 and the additional electrical insulating plate 613 are separated by a support layer 511 and a gasket 304. In other words, the first electrical plate 602 is positioned on the other side of the additional electrical insulating plate 613 opposite to the second electrical terminal plate 606. Therefore, the additional electrical insulating plate 613 provides electrical insulation between the first electrical plate 602 and the second electrical terminal plate 606. Similarly, the additional electrical terminal plate 607 is separated from the first electrical insulating plate 305a by the support layer 511 and the gasket 304.

[0149] Busbar 612 is welded or otherwise attached (and electrically connected to) the first terminal plate 602 and the additional terminal plate 607 via tabs at both ends of busbar 612 and / or the first terminal plate 602 and the additional terminal plate 607. The busbar is located on one side of the battery cell stack, between the battery cell stack and the skirt, and is generally parallel to the stacking direction. The tabs are more flexible than busbar 612, the first terminal plate 602, and the additional terminal plate 607 (e.g., because they are thinner), meaning that the flexibility of the tabs takes into account the different thermal expansion between the stack and the busbar, thus minimizing stress transfer to busbar 612, the first terminal plate 602, and the additional terminal plate 607.

[0150] The additional electrical terminal board 607 is shown as a single board on which a material layer 510 is attached, coated, or deposited, but it can also be a two-(or more) part structure, similar to the board described in the second aspect, for example, Figure 10 The electrical terminal board 1407 in the middle.

[0151] It should be noted that, in Figure 6A In the example shown, the second terminal plate 606 extends across both flues, thus blocking the left flue and being compressed by the compressive forces within it. In this case, the first terminal plate 602 could be made of the same material as the second terminal plate 606, but might be thinner because it is not exposed to the fluid (typically fuel in fuel cell applications) in the flue. Therefore, in cases where there are two terminal plates, but one is exposed to a dual atmosphere (two different fluids) in the stack while the other is exposed to a single atmosphere (one fluid), the latter plate might be made of a less corrosion-resistant material and / or have less or no corrosion-protective coating and / or be manufactured thinner than the former plate. Alternatively, if the second terminal plate 606 does not additionally block... Figure 6A The first electrical plate 602 and the second electrical terminal plate 606 on the left side of the flue can be made of the same material and have the same thickness, since both are exposed to similar (dual) chemical environments.

[0152] Reference Figure 9The partially exploded view of arrangement 600 shown shows a portion of the skirt 307 for clarity. It should be understood that the skirt 307 may include two additional sidewalls to connect the edges of the skirt component 307, thereby allowing the skirt to surround the stack. It should also be noted that the metal support plate 306a and separator 306b are not shown in an exploded view; therefore, only the metal support plate 306a is readily apparent in this view. The metal support plate 306a and separator 306b of the battery cell 306 are welded or otherwise attached to each other at their periphery. Further attention should be paid to the additional terminal plate 607, busbar 612, and first terminal plate 602, shown in their assembled (e.g., welded, brazed, or otherwise attached) form, with dashed lines indicating the positions occupied by plates 607 and 602 in the exploded arrangement. The busbar 612 can only be attached to plates 607 and 602 after these plates are properly positioned in the stack (and preferably after pressure is applied to the stack). Furthermore, the conductive ceramic layer 510 is shown to be separated from the additional electrical terminal plate 607, but it is understood that the conductive ceramic layer 510 is often coated or deposited on the additional electrical terminal plate 607.

[0153] When used as a fuel cell, the electrical load can be connected between the electric stud 601 and the second electric stud 605 in arrangement 600. In the example where the anode is the electrochemically active layer closest to the metal support plate 306a, the first fluid is the fuel, and the flow within the first fluid volume is... Figure 6A The arrows indicate this. Fuel is supplied to the anode through the first flue, the gap between the metal support plate 306a and the separator 306b, and the porous area of ​​the metal support plate 306b. Emission products are routed from the anode through the gap between the metal support plate 306a and the separator 306b to the second flue. The second fluid is an oxidant and is supplied to the cathode through its volume.

[0154] When used as an electrolytic cell, a potential difference can be established between the electric stud 601 and the second electric stud 605 to provide electrical energy to the stack in arrangement 600. The associated fluid is supplied to the first fluid volume and the second fluid volume, and then discharged therefrom.

[0155] Arrangement 600 allows for convenient electrical and fluid connections to the system in which the battery stack arrangement 600 is located, because all electrical connections are located at one end of the arrangement, while all fluid connections are located at the other end.

[0156] Figure 7 Showing Figure 6A , Figure 6B and Figure 6CPlan view of the first terminal plate 602 and the second terminal plate 606. The first terminal plate 602 is provided with an electrical stud 601 for alignment with a first flue in the battery stack arrangement 600. The first terminal plate 602 is provided with an opening 704 through which the second electrical stud 605 and the associated sleeve 503 pass. The end of the first terminal plate 602 closest to the electrical stud 601 may be upright for attachment to the busbar 612.

[0157] The second terminal plate 606 is provided with a second electrical stud 605 for alignment with a second flue in the battery stack arrangement 600. A plurality of protrusions 614 are provided, which protrude toward the outermost electrode of the electrochemically active layer of the outermost battery cell in the battery cell stack to transfer power from the stack to the second terminal plate 606. A port 706 may be optionally provided through the second terminal plate 606. If port 706 is provided, it forms part of the first flue; if port 706 is not provided, the second terminal plate 606 blocks the first flue. In the latter case, the second terminal plate 606 blocks both flues.

[0158] The specific implementation method of the second aspect Reference Figure 10 This shows a cross-sectional view of the battery stack arrangement 1400. The battery stack arrangement 1400 is... Figure 5A and Figure 5B A 500-cell battery stack configuration variation. Figure 11 yes Figure 10 An exploded perspective view of arrangement 1400. It should be noted that, for clarity, compression devices (e.g., skirt 307) are not shown in arrangement 1400.

[0159] Figure 12 This is an exploded view of the first terminal board of the 1400 battery stack arrangement. Figure 13 This is an exploded view of the second terminal board of the 1400 battery stack arrangement.

[0160] In arrangement 1400, a first electrical terminal board 1402 is shown, which functions substantially similarly to the first electrical terminal board described above. The first electrical terminal board 1402 comprises a two-layer structure, wherein a first layer 1416 is soldered (or otherwise connected) to a second layer 1417 (the soldering path is in...). Figure 11 and Figure 12 (As shown by dashed line 1621). The first layer 1416 is a planar plate. The first layer 1416 blocks one flue in the battery stack arrangement (the stud 301 leaves the battery stack arrangement through the continuation of the blocked flue) and is provided with a port that forms part of another flue for conveying fluid or discharging a first fluid volume.

[0161] As can be seen, the second layer 1417 is a planar plate. The second layer 1417 is similar to the metal support plate 306a of the battery cell 306 in the battery cell stack. The second layer 1417 has ports arranged (in similar positions) in the same manner as the metal support plate 306a in the battery cell stack. A conductive ceramic layer 1418 is bonded to (e.g., attached to or deposited on) the surface of the second layer 1417 opposite to the first layer 1416. The conductive ceramic layer 1418 may be similar to the conductive ceramic layer 510 described above and may be a material type suitable for use as a fuel cell cathode, such as LSCF, LCN, BSCF, for example, LCN60. The thickness of the conductive ceramic layer 1418 is similar to the thickness of the electrochemically active layer 506 of the battery cell 306 in the battery cell stack. This means that the gasket 304 separating the second layer 1417 from the separator plate 306b of the adjacent (outermost or uppermost) battery cell 306 in the battery cell stack can be the same as the gasket 304 used elsewhere in arrangement 1400.

[0162] The surface of the conductive ceramic layer 1418, opposite to the second layer 1417, contacts a protrusion on the separator 306b of the adjacent (outermost or uppermost) battery cell 306 of the battery cell stack. The protrusions on the separator 306b alternate in the vertical direction; upward protrusions point towards and contact the conductive ceramic layer 1418, while moving away from the metal support plate 306a of the same battery cell 306, while downward protrusions move away from the conductive ceramic layer 1418 and point towards and contact the metal support plate 306a of the same battery cell 306. The downward protrusions of the separator 306b contact the metal support plate 306a, thus electrically connecting to the layer 506, which may be electrochemically active. In this case, the downward protrusions of the separator are electrically connected to the electrodes (typically anodes) of the electrochemically active layers closest to the metal support plate 306a (these electrochemically active layers are on the other side of the substrate). This electrical connection is reinforced by welding the metal support plate 306a and the separator 306b around their peripheries. Therefore, the electric stud 301 is electrically connected to the battery cell stack through the first layer 1416, the second layer 1417 and the conductive ceramic layer 1418.

[0163] Arrangement 1400 also includes a second electrical terminal board 1407, such as Figure 10 As shown, its function is likely similar to that of the first electrical terminal board 1402 described above. The second electrical terminal board 1407 includes a two-layer structure, wherein the first layer 1419 is soldered (or otherwise connected) to the second layer 1420 (soldering path 1722 is in...). Figure 11 and Figure 13(Represented by dashed lines). The first layer 1419 is a planar plate. The first layer 1419 blocks one flue in the battery stack arrangement (the stud 505 leaves the battery stack arrangement through the continuation of the blocked flue) and is provided with a port that forms part of another flue for conveying fluid or discharging a first fluid volume.

[0164] The second layer 1420 is similar to the separator 306b of the battery cell 306 in the battery cell stack. The second layer 1420 has ports (in similar positions) arranged in the same manner as the separator 306b in the battery cell stack. The second layer 1420 is welded to or otherwise connected to the first layer 1419 around its periphery (it can also be welded around the ports). As can be seen, the second layer 1420 is a contour plate (i.e., it has 3D features). The second layer 1420 has ridges that alternate in the vertical direction. The upward ridges point to and contact the layer body 506 (which may be the electrochemical active layer) of the adjacent (bottommost) battery cell 306 in the battery cell stack and are away from the first layer 1419 of the terminal plate 1407, while the downward ridges are away from the adjacent (bottommost) battery cell 306 in the battery cell stack and point to and contact the first layer 1419 of the terminal plate 1407. The upward protrusion of the second layer 1420 contacts the layer 506 of the adjacent (bottommost) battery cell 306 in the battery cell stack, and is therefore electrically connected to the electrode (typically the cathode) of the adjacent (bottommost) battery cell 306. Thus, the stud 505 is electrically connected to the battery cell stack via the first layer 1419 and the second layer 1420. The studs 301 and 505 are attached to or otherwise connected to the base of the respective electrical terminal plates in a manner similar to that described in the first aspect above, the base being subjected to compressive forces in the respective flues.

[0165] The first layer (1416, 1419) and the second layer (1417, 1420) of the electrical terminal blocks (1402, 1407) are iron-containing layers, for example, the layer body is steel (typically stainless steel, or ferritic stainless steel). Examples of suitable materials for the first layer include SS441 and Crofer 22, while examples of suitable materials for the second layer include SS441, SS444, and Crofer 22. The first and second layers are formed of different metals and are permanently connected. The first layer of the electrical terminal block will have a thickness of at least 0.5 mm, for example, between 0.5 mm and 5 mm, or between 0.5 mm and 2 mm, or between 1 mm and 2 mm.

[0166] By using busbars and additional circuit boards, the following can be changed. Figure 10 The arrangement 1400 is such that a first electric stud 301 and a second electric stud 505 are provided at the same end of the stack, as in the first aspect. Figure 6A , Figure 6B and Figure 6C The arrangement described in 600.

[0167] Figure 12 This is an exploded view of the first electrical terminal board 1402 (manual). Figure 12 In the first electrical terminal plate 1402, the first layer 1416 and the second layer 1417 are self-supporting rigid plates. Welding path 1621 is indicated by a dashed line and extends along the periphery of the second layer 1417. Other welding paths (not shown) may also exist around the fluid port periphery to prevent fluid from flowing from the flue formed by the corresponding port into the space between the first layer 1416 and the second layer 1417 of the first electrical terminal plate 1420.

[0168] Figure 13 This is an exploded view of the second electrical terminal board 1407. Figure 13 In the second electrical terminal plate, the first layer 1419 and the second layer 1420 are self-supporting rigid plates. The welding path 1722 is indicated by a dashed line and extends along the periphery of the first layer 1419 and the second layer 1420. Figure 13 The upper and lower protrusions 1723 of the second layer 1420 of the second electrical terminal plate 1407 are also shown. Other welding paths (not shown) may also exist around the fluid port to prevent fluid from flowing from the flue formed by the corresponding port into the space between the first layer 1419 and the second layer 1420 of the second electrical terminal plate 1407.

[0169] Reference Figure 14 This shows a cross-sectional view of a portion of the battery stack arrangement. This portion of the battery stack arrangement is... Figure 10 The battery stack arrangement 1400 includes the battery cell stack, the electrical stud 505, the second electrical terminal plate 1407, and the adjacent ( Figure 10 The bottommost battery cell 306 is a variant.

[0170] exist Figure 14 In the variant shown, a conductive ceramic layer 1824 is provided on the protrusions 1723 of the second layer 1420 of the second terminal plate 1407 facing the adjacent battery cell 306 of the battery cell stack. A conductive ceramic layer 1824 is also provided on the protrusions of the electrochemically active layer of the separator plate 306b of each battery cell 306 facing the adjacent battery cell 306 of the battery cell stack. The conductive ceramic layer 1824 is bonded or deposited onto the protrusions.

[0171] The conductive ceramic layer 1824 is in face-to-face contact with the layer body 506 of the adjacent battery cell 306 in the battery cell stack, and provides improved electrical contact between the protrusion (and therefore, the separator 306b or the second plate 1420) and the layer body 506. When the layer body 506 is the electrochemically active layer of the battery cell, the outermost electrode of the adjacent battery cell is typically a cathode, and the conductive ceramic layer 1824 uses a cathode-type material, such as LSCF, LCN, or BSCF.

[0172] Figure 15 The second terminal plate 1407 and conductive ceramic layer 1824 are shown as part of the battery stack arrangement 1900. The battery stack arrangement 1900 is... Figure 10 A variation of the 1400 arrangement. Figure 15 Additionally, a conductive ceramic layer 1824 is shown, which is bonded to or deposited on an upward protrusion of the separator plate 306b of the uppermost battery cell 306 in the battery cell stack that is in contact with the conductive ceramic layer 1418 of the first electrical terminal plate 1402. These conductive ceramic layers 1824 are adjacent to (the first electrical terminal plate 1402 and the battery cell stack) Figure 15 The topmost battery cell provides a good electrical connection.

[0173] The present invention is not limited to the examples described above, and other examples will be apparent to those skilled in the art without departing from the scope of the appended claims.

[0174] The above description of these and other features of the invention is merely illustrative. Modifications to the invention may be made within the scope of the claims.

Claims

1. An electrochemical battery assembly, the electrochemical battery assembly comprising: A bottom plate and a top plate, between which a planar battery cell stack, at least one positive terminal plate, and at least one negative terminal plate are configured to be compressed by a compression device acting between the bottom plate and the top plate. In this embodiment, at least one of the electrical terminal plates is connected to or integrally formed with an electrical stud and is in electrical contact with it. The electrical stud extends from the base of the at least one electrical terminal plate and passes through an opening in one of the bottom plate and the top plate to form an electrical terminal. The base is kept fluid-sealed with one of the bottom plate and the top plate by the compression device to prevent fluid from leaking through the opening; In this embodiment, the battery cells in the planar battery cell stack are provided with at least one port and are stacked on top of each other such that the corresponding ports are aligned to form a corresponding internal manifold extending through the stack, and wherein the electric studs extending through their respective openings are also aligned with the corresponding internal manifolds, such that the compressive force applied by the compression device for sealing the corresponding internal manifolds also serves to seal the corresponding openings.

2. The electrochemical battery assembly according to claim 1, wherein, An insulating layer is provided between the respective ends of the planar battery cell stack and the respective bottom and top plates, each of the bottom and top plates being electrically insulated from the planar battery cell stack.

3. The electrochemical battery assembly according to claim 1 or claim 2, wherein the electrochemical battery assembly comprises: At least one positive terminal plate, the at least one positive terminal plate being connected to or integrally formed with and in electrical contact with a positive stud, the positive stud extending from its base and passing through a first opening on one of the bottom plate and the top plate to form a positive terminal; and, At least one negative terminal plate, the at least one negative terminal plate being connected to or integrally formed with and in electrical contact with a negative stud, the negative stud extending from its base and passing through a second opening on one of the bottom plate and the top plate to form a negative terminal; and, Each base is fluid-sealed with a corresponding one of the bottom and top plates by the compression device to prevent fluid from leaking through each corresponding opening.

4. The electrochemical battery assembly according to claim 3, wherein, The positively charged stud passes through a first opening in one of the top and bottom plates, while the negatively charged stud passes through a second opening, which is an opening in the other of the top and bottom plates.

5. The electrochemical battery assembly according to claim 3, wherein, Both the positive and negative studs pass through the corresponding first and second openings on either the base plate or the top plate.

6. The electrochemical battery assembly according to claim 5, wherein, One of the positive and negative studs is electrically connected via a busbar and an additional terminal plate of the same polarity as the stud, and optionally, the busbar is connected via at least one tab that is more flexible than the busbar and the connected terminal plate.

7. The electrochemical battery assembly according to claim 1, wherein, The base of the at least one electrical terminal board extends across the corresponding internal manifold to block the internal manifold.

8. The electrochemical battery assembly according to claim 1, wherein, The components include: A first corresponding internal manifold and a second corresponding internal manifold, the first corresponding internal manifold and the second corresponding internal manifold extending through the stack; and... The negatively charged stud is connected to or integrally formed with the negatively charged end plate and is in electrical contact with it, and is aligned with the first corresponding internal manifold; and, The positively charged stud is connected to or integrally formed with the positively charged end plate and is in electrical contact with it, and is aligned with the second corresponding internal manifold.

9. The electrochemical battery assembly according to claim 8, wherein, Both the negative and positive studs pass through corresponding openings in either the base plate or the top plate, and one of the negative and positive studs is electrically connected to an additional electrical terminal plate via a busbar.

10. The electrochemical battery assembly according to claim 9, wherein, The first fluid volume, including the first corresponding internal manifold and the second corresponding internal manifold, is supplied and discharged through corresponding fluid inlet and outlet openings on the other of the bottom plate and the top plate.

11. The electrochemical battery assembly according to claim 8, wherein, Both the negative and positive studs pass through corresponding openings in either the base plate or the top plate, and one of the studs also passes through an opening in an electrical terminal plate that is connected to or integrally formed with and in electrical contact with the other stud.

12. The electrochemical battery assembly according to claim 1, wherein, At least one of the positive and negative terminal plates separates the first and second fluid volumes within the stack.

13. The electrochemical battery assembly according to claim 1, wherein, The compression device includes a skirt attached under tension between the base plate and the top plate, the skirt at least surrounding the planar battery cell stack.

14. The electrochemical battery assembly according to claim 1, wherein, The electrochemical cell includes planar, solid oxide, fuel cell, or electrolytic cell unit.

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