Solid oxide fuel cell unit

Abstract

The present invention relates to an improved metal supported solid oxide fuel cell unit, fuel cell stack, fuel cell stack assembly, and method of manufacture.

Description

[0001] Related applications

[0002] This application is a divisional application of patent application filed on August 13, 2018, with application number 2018800518055, entitled "Solid Oxide Fuel Cell Unit". Technical Field

[0003] The present invention relates to an improved metal-supported solid oxide fuel cell unit, fuel cell stack, fuel cell stack assembly, and manufacturing method. Background Technology

[0004] The teachings on fuel cells, fuel cell stacks, fuel cell stack assemblies, and heat exchange systems, configurations, and methods are well known to those skilled in the art, and particularly include WO02 / 35628, WO03 / 07582, WO2004 / 089848, WO2005 / 078843, WO2006 / 079800, WO2006 / 106334, WO2007 / 085863, WO2007 / 110587, WO2008 / 001119, and WO2008 / 003. 976, WO2008 / 015461, WO2008 / 053213, WO2008 / 104760, WO2008 / 132493, WO2009 / 090419, WO2010 / 020797, WO2010 / 061190, WO2015 / 004419, WO2015 / 136295, WO2016 / 124929, WO2016 / 124928, WO2016 / 128721 and WO2016 / 083780. All notices and references cited herein are incorporated herein by reference in their entirety. Definitions of terms may be found in the aforementioned notices as needed.

[0005] Fuel cell stacks, fuel cell stack assemblies, fuel cell units (including fuel cell stack layers), and the configuration of fuel cells within a fuel cell stack unit and fuel cell stack layers are well known.

[0006] This invention aims to improve upon existing technologies. Specifically, it aims to improve fuel flow and fuel distribution within individual fuel cell units (fuel cell stacks). In particular, it aims to achieve one or more of the following: improve fuel velocity within the fuel cell unit, reduce fuel residence time, improve fuel distribution, and reduce fuel pressure drop across the fuel cell unit. Summary of the Invention

[0007] According to a first aspect of the present invention, a metal-supported solid oxide fuel cell unit is provided, comprising:

[0008] a) A metal substrate defining a first and a second opposing surface, wherein at least one solid oxide fuel cell is disposed on the second surface of the metal substrate;

[0009] b) A metal spacer defining the first and second opposing surfaces, the metal spacer comprising:

[0010] (i) An external perimeter,

[0011] (ii) The periphery of at least one fuel inlet defines a fuel inlet port.

[0012] (iii) at least all the periphery of the opening, which defines all the openings, and

[0013] (iv) At least one fuel outlet interior periphery defining a fuel outlet port, wherein the first surface of the metal substrate is attached to the second surface of the metal spacer, and

[0014] c) A metal interconnect plate defining first and second opposing surfaces, the second surface of the metal interconnect plate being hermetically attached to the first surface of the metal spacer.

[0015] in:

[0016] A fuel inlet port volume is defined between the first surface of the metal substrate, the inner periphery of at least one fuel inlet of the metal spacer, and the second surface of the metal interconnect plate.

[0017] The total volume is defined between the first surface of the metal substrate, the inner periphery of the at least one inlet of the metal spacer, and the second surface of the metal interconnect plate.

[0018] A fuel outlet volume is defined between the first surface of the metal substrate, the inner periphery of at least one fuel outlet of the metal spacer, and the second surface of the metal interconnect plate.

[0019] The metal interconnect plate includes a plurality of bridge portions that define a fluid flow path from the at least one fuel inlet port volume to the at least one outlet port volume to the at least one fuel outlet port volume.

[0020] Therefore, in an embodiment that includes a plurality of fuel inlet internal perimeters for defining fuel inlet ports, there are a plurality of fuel inlet port volumes.

[0021] Therefore, in an embodiment that includes a plurality of internal perimeters of the cut to define the cut, there are a plurality of cut volumes.

[0022] Therefore, in an embodiment that includes a plurality of outlet port interior perimeters for defining fuel outlet ports, there are a plurality of fuel outlet port volumes.

[0023] Therefore, the fuel inlet ports, slits, and fuel outlet ports defined within the metal spacers are separated from each other, i.e., distinct from one another. Thus, the internal periphery acts as a separator within the metal spacers that defines the spaces between each other. It can also be described as being partitioned and discontinuous. Preferably, a fluid flow channel is not defined within the metal substrate between any of the fuel inlet ports, slits, and fuel outlet ports.

[0024] Preferably, the metal spacer is generally flat, that is, generally planar. Preferably, the metal substrate is generally flat, that is, generally planar.

[0025] A bridge section is used to define a fluid flow bridge or passage (i.e., a fluid flow path) between adjacent volumes, such as (a) between a fuel inlet port volume and an adjacent cut-out volume, (b) between adjacent cut-out volumes, and (c) between a cut-out volume and a fuel outlet port volume. Therefore, a fluid flow path is defined as a flow path via a bridge section from at least one fuel inlet port to at least one cut-out port to at least one fuel outlet port.

[0026] Preferably, there are multiple bridge sections between adjacent volumes. Preferably, there are at least three bridge sections between adjacent volumes, more preferably at least four, in the direction from the fuel inlet port to the fuel outlet port. Preferably, there are multiple bridge sections between a fuel inlet port volume and all outlet volumes, more preferably between each of them. Preferably, there are multiple bridge sections between all outlet volumes and a fuel outlet port volume, more preferably between each of them. Preferably, there are multiple bridge sections between adjacent cut-out volumes, more preferably between each of them. More preferably, there are multiple bridge sections in a path from a fuel inlet port volume to a fuel outlet port volume between adjacent cut-outs, more preferably in the direction from the fuel inlet port to the fuel outlet port between adjacent cut-outs, or in a direct or shortest path.

[0027] By providing a bridge portion in the metal interconnect plate together with the internal periphery of the fuel inlet in the metal spacer, it is permissible to provide complex fuel inlet and outlet ports, which can provide managed fluid flow distribution from at least one fuel inlet port to at least one outlet port, and from at least one outlet port to at least one fuel outlet port. This can, for example, allow for a more even distribution of fuel within the fuel cell unit, and thus help optimize fuel cell unit operation.

[0028] Preferably, the bridge portion extends outward from a first surface of the metal interconnect board, away from a second surface of the metal interconnect board. More preferably, the bridge portion includes a protrusion from one of the first surfaces of the metal interconnect board. More preferably, the bridge portion includes a recess in one of the second surfaces of the metal interconnect board and a corresponding protrusion from one of the first surfaces of the metal interconnect board. More preferably, the bridge portion includes a recess. More preferably, the bridge portion includes an elongated recess. Thus, the bridge portion may, for example, have a rhombus shape. Other shapes will be readily apparent to those skilled in the art.

[0029] Preferably, the bridge portion defines a volume between the first surface of the metal spacer and the second surface of the metal interconnect plate.

[0030] Preferably, the metal interconnect includes at least one fuel inlet bridge portion defining a fluid flow path between fuel inlet port volumes, and at least one fuel outlet bridge portion defining a fluid flow path between a fuel inlet port volume and a fuel outlet port volume. In embodiments including a plurality of cutouts, preferably, the metal interconnect includes at least one cutout bridge portion defining a fluid flow path between adjacent cutouts.

[0031] Preferably, the metal spacer includes at least two internal peripheries of fuel inlets, defining at least two fuel inlet ports. Preferably, the metal spacer includes at least two internal volumes of cutouts, defining at least two cutouts. Preferably, the metal spacer includes at least two internal peripheries of fuel outlets, defining at least two fuel outlet ports.

[0032] Preferably, each metal spacer fuel port (each fuel inlet port and each fuel outlet port) includes a fuel conduit area, a plurality of fuel throat areas, and a corresponding plurality of fuel distributor passage areas (i.e., each fuel throat area leads to a fuel distributor passage area). Preferably, the fuel conduit area of ​​the metal spacer fuel port is aligned with the fuel port of the metal interconnect plate and the metal substrate.

[0033] By providing multiple fuel throat areas and fuel distributor passage areas, the risk of fuel depletion due to blockage is also reduced.

[0034] Preferably, each fuel distributor passage area and adjacent cuts have at least one bridge section.

[0035] CFD (Computational Fluid Dynamics) analysis shows that: (compared to, for example) Figure 16B (Prior art) and 16C (the present invention), the fuel velocity within the fuel cell unit (particularly across at least one orifice volume) remains more constant in this design compared to prior art products, there are fewer deficiency regions at the corners of the fuel cell, and the fuel is promoted across the cell in a more uniform manner, which improves the chemical reactions occurring within the fuel cell.

[0036] CFD analysis also shows that: compared to existing technology devices (e.g., comparison) Figure 17A (Prior art) and 17B (the present invention) show that the normalized fuel residence time is reduced. This means that the chemical reactions at the fuel cell require a lower concentration of hydrogen. In other words, less fuel is needed for the chemical reactions to occur at the fuel cell, making the present invention more efficient than prior art devices.

[0037] CFD analysis also revealed improved flow distribution across the active region of the fuel cell compared to existing technology devices. CFD analysis also showed that the present invention exhibits a smaller (i.e., improved) pressure drop between the inlet and outlet ports compared to existing technology devices. Minimizing the pressure drop across the cell is beneficial for maintaining compression along the stack.

[0038] Multiple fuel throats are configured to constrain (i.e. control) the fluid flow from the fluid conduit region. Preferably, each fuel distributor passage is wider (i.e., has a larger cross-section) than its corresponding fuel throat. Preferably, the fuel throat defines a fluid flow axis, and the width (cross-section) of the fuel throat perpendicular to the fluid flow axis is smaller than the width (cross-section) of the corresponding fuel distributor passage perpendicular to the fluid flow axis.

[0039] Preferably, each fuel throat region has a constant width "W" between the fuel conduit region and the corresponding fuel distributor passage region. In use, this allows fuel to be transferred from the fuel conduit region to the corresponding fuel distributor passage region at high speed (i.e., high velocity), and this reduces the risk of fuel depletion.

[0040] In a particular embodiment, all fuel throat regions have the same width.

[0041] Preferably, each fuel distributor passage area has a width that increases from the fuel distributor passage closest to the fuel throat area to the endpoint of the fuel distributor passage closest to the inner periphery of the adjacent cut. Preferably, each fuel distributor passage area has a curved shape equal to the width of that fuel distributor passage area. More preferably, this increases from the width "W" of the fuel throat area and ends at a distance equal to a distance (d). a ,d b ,d c The width of ), where (d a <d b <d c ).

[0042] Preferably, the internal periphery of each cut (and the cut defined thereby) has a plurality of corner areas. Fuel flow to the corner areas of the fuel cell is known to be difficult, and optimization of fuel flow to these corner areas is desired. Preferably, since the metal spacer fuel port includes a plurality of fuel throats and corresponding fuel distributor passage areas, the fuel distributor passage area closest to (i.e., adjacent to or near) a corner area (or corner) has a smaller final width (a width at the point closest to or near the internal periphery of the adjacent cut) than the other fuel distributor passage areas. More preferably, the plurality of fuel distributor passage areas are configured in the following order:

[0043] The fuel dispenser passage area closest to a corner (i.e., the corner)

[0044] The fuel dispenser passage area furthest from that corner area (i.e., the corner)

[0045] Each fuel dispenser passage has a larger final width than the previous fuel dispenser passage.

[0046] Preferably, the width (or distance) d at the edge of the fuel distributor passage area adjacent to the inner periphery of the adjacent cut is larger (i.e. longer) in the area closer to the center of the battery, so as to uniformly promote fuel distribution along the middle area of ​​the battery, thereby improving the fuel distribution of the earlier design that had fuel shortage problems in the central area.

[0047] Preferably, each fuel throat region has a length "L". More preferably, in the fuel cell stack and fuel cell stack assembly of the present invention (hereinafter), the fuel throat region 44b is related to the size of the compression shim located between the interconnect of a solid oxide fuel cell unit and the substrate layer of a subsequent solid oxide fuel cell unit. More preferably, the shim includes a hypertoroidal shape surrounding a port of the interconnect. The length "L" of the fuel throat region preferably coincides with (corresponds to, relates to) the outer radius minus the inner radius of the compression shim. These configurations can help reduce or minimize the pressure drop.

[0048] Preferably, the fuel used in the product of the present invention is a hydrocarbon fuel. Suitable hydrocarbon fuels include desulfurized hydrocarbon fuels, reformed oil, or reformed oil mixed with an anode off-gas (i.e., anode-side exhaust gas from a fuel outlet side of a fuel cell unit). Similarly, the fuel used may be start-up or shutdown gas from a fuel cell unit, and more particularly start-up or shutdown anode off-gas (i.e., anode-side exhaust gas from a fuel outlet side of a fuel cell unit).

[0049] The terms "placed on" and "attached to" are used interchangeably in this article.

[0050] Preferably, the metal-supported solid oxide fuel cell unit is a fuel cell stack, and more preferably, a metal-supported solid oxide fuel cell stack. Therefore, a plurality of fuel cell units can be assembled to form a solid oxide fuel cell stack.

[0051] Preferably, the metal substrate (or in one embodiment where the metal spacer includes at least one metal spacer plate), and each metal substrate plate (also referred to as a "fuel cell plate") include at least one porous region. Preferably, the at least one porous region is surrounded by a non-porous region. More preferably, each metal substrate or each metal substrate plate includes a porous region. More preferably, each porous region is surrounded by a non-porous region. More preferably, the porous region is a perforated region. Preferably, it includes (i.e., defined) a plurality of perforations extending from a first surface to a second surface (i.e., between the first and second surfaces). More preferably, the perforations are laser-drilled perforations. Preferably, at least one non-porous region of each metal substrate plate or metal spacer is attached to the metal spacer. Preferably, the internal periphery of each at least one cut is integrally overlapped by the metal substrate.

[0052] Preferably, at least one porous region coincides with (i.e. extends to or overlaps with) the corresponding inner periphery of the cut in the metal substrate, i.e., extends to the boundary of the inner periphery of the cut. This is particularly preferred in embodiments where the metal substrate plate includes a single porous region.

[0053] Preferably, each solid oxide fuel cell system disposed on a metal substrate includes an anode layer deposited over a porous region of the metal substrate; an electrolyte layer deposited over the anode layer; and a cathode layer deposited over the electrolyte layer. Preferably, the electrolyte layer extends over the anode to be hermetically attached to a non-perforated region of the metal substrate surrounding the anode.

[0054] In a particular embodiment, the metal substrate is configured as a single component. In other embodiments, the metal substrate is configured as a plurality of discrete components.

[0055] In a particular embodiment, the metal substrate plate includes at least one metal substrate plate (more preferably, at least two metal substrate plates) and at least two shielding plates, each metal substrate plate defining a first and a second opposing surface and each shielding plate defining a first and a second opposing surface, wherein at least one solid oxide fuel cell is disposed on the second surface of each metal substrate plate, and wherein the first surface of each metal substrate plate and the first surface of each shielding plate are attached to the second surface of the metal spacer, and the inner periphery of each of the at least one cut of the metal spacer is integrally overlapped by a metal substrate plate.

[0056] Therefore, the plurality of metal substrate plates attached to the metal spacers together define a metal substrate (also referred to as a "substrate layer" or "metal substrate layer") attached to the metal spacers. Thus, each fuel cell unit includes a metal substrate, a metal spacer, and a metal interconnect plate.

[0057] The metal substrate plates are preferably disposed on or between the same plane as the shielding plates. The shielding plates are preferably rectangular. Preferably, each shielding plate includes at least one inner perimeter for defining a fuel port, i.e., defining at least one fuel port. More preferably, each shielding plate defines two fuel ports.

[0058] Preferably, the metal substrate and the shielding plate do not contact each other, that is, they do not abut against each other. Therefore, preferably, a shielding plate (such as a first shielding plate) does not abut against or contact an adjacent metal substrate (such as a first metal substrate). Therefore, preferably, adjacent metal substrates do not abut against or contact each other. Therefore, preferably, a second shielding plate does not abut against or contact an adjacent second metal substrate.

[0059] By attaching the shielding plate and the metal substrate plate to the metal spacer without allowing them to abut or contact each other, a "tolerance clearance" is defined within this clearance, allowing for variability in component positioning during the manufacturing process. This provides a significant technical advantage in terms of process technology and can, for example, help accelerate process speed, reduce costs, increase the reliability of fuel cell units, and / or extend the lifespan of fuel cell units.

[0060] Preferably, the shielding plate is a metal shielding plate. More preferably, the shielding plate is made of the same metal as the metal substrate plate. Preferably, the shielding plate has the same thickness as the metal substrate plate.

[0061] Preferably, the metal spacer includes at least two internal peripheries, each defining a fuel port. More preferably, each metal spacer defines two fuel ports at a first end (preferably, a fuel inlet end, i.e., defining at least two fuel inlet ports) and two fuel ports at a second end (preferably, a fuel outlet end, i.e., defining at least two fuel outlet ports). The internal periphery defining the cutout can be considered as a first group of internal peripheries, and the internal periphery defining the fuel ports can be considered as a second group of internal peripheries.

[0062] Each metal substrate plate is attached integrally and overlaps the inner periphery of the opening, that is, on and above the opening. Therefore, each metal substrate plate covers the opening. Each metal substrate plate is attached to the metal spacer between at least one inner periphery defining the opening and the outer periphery of the metal spacer.

[0063] Preferably, the metal substrate (or at least two shielding plates and at least one metal substrate plate) is attached to the metal spacer by welding, more preferably by wire welding.

[0064] Preferably, each metal substrate plate is attached to the metal spacer between the inner periphery of at least one cutout defining the opening and the outer periphery of the metal spacer. More preferably, each metal substrate plate is attached to the metal spacer between the inner periphery of one cutout defining the opening and the outer periphery of the metal spacer.

[0065] Preferably, the metal interconnects are hermetically attached to the metal spacers by soldering.

[0066] Preferably, the metal interconnect plate is hermetically attached to the metal spacer along a line disposed between (a) the outer periphery of the metal spacer and (b) the inner periphery of at least one opening of the metal spacer. Preferably, the line is adjacent to the outer periphery of the metal spacer. More preferably, the line is adjacent to the outer periphery of the metal spacer. More preferably, the line is located within 10 mm, more preferably within 5 mm, more preferably within 4 mm, more preferably within 3 mm, and more preferably within 2 mm of the outer periphery of the metal spacer.

[0067] More preferably, the welding used to attach the metal substrate (or at least two shielding plates and at least one metal substrate plate) to the metal spacer and the welding used to seal the metal interconnect plate to the metal spacer do not overlap.

[0068] Preferably, the first surface of each metal substrate plate and the first surface of each shielding plate are attached to and disposed on the second surface of the metal spacer.

[0069] Preferably, the second surface of the metal interconnect plate is hermetically attached to and disposed on the first surface of the metal spacer.

[0070] Preferably, it has a total of two shielding plates.

[0071] Preferably, the metal interconnect includes a plurality of recesses extending outward from the first surface and away from the second surface. Preferably, the metal interconnect includes a plurality of recesses extending outward from the first surface and away from the second surface, and a plurality of recesses extending away from the first surface and outward from the second surface. Preferably, the recesses are alternating. Therefore, preferably, the recesses alternate between extending away from the first surface of the metal interconnect and away from the second surface of the metal interconnect.

[0072] Preferably, the fuel cell unit includes at least one assembled metal substrate plate, each assembled metal substrate plate including an assembled shielding plate and at least one metal substrate plate. Thus, a substrate and at least one metal substrate plate are attached to each other to form a single assembly (an assembled metal substrate plate), or are integrally formed as a single assembly from the outset before the assembled metal substrate plates are attached to the metal spacers. More preferably, the fuel cell unit includes two assembled metal substrate plates. More preferably, the fuel cell unit includes an assembled metal substrate plate, at least one metal substrate plate, and a shielding plate. Alternatively, the fuel cell unit includes two assembled metal substrate plates and at least one metal substrate plate.

[0073] In embodiments comprising at least one assembled metal substrate, the assembled metal substrate preferably does not abut against or contact an adjacent metal substrate or the assembled metal substrate.

[0074] Similar to the arrangement of metal substrate plates in a 2x1 sequential (linear) configuration between shielding plates, other configurations and numbers of metal substrate plates can also be provided. For example, the metal substrate plates can be arranged in a 1x2 (parallel) configuration between shielding plates. Alternatively, the metal substrate plates can be arranged in a 2x2, 3x2, or 4x2 configuration, and the same shielding plates can be used with different configurations. Similarly, the fuel cell unit can be provided with metal substrate plates in a 2x3, 3x3, or 4x3 configuration using the same shielding plates. Other configurations will be readily apparent.

[0075] The use of multiple metal substrates allows for modular assembly of the substrates to achieve a range of fuel cell unit sizes and power outputs, including, for example, a larger fuel cell unit size and therefore a larger power output. Attaching the metal substrates to metal spacers also reduces the likelihood of fuel cell bending within the fuel cell unit, thus mitigating the risk of decreased conductivity and reduced gas tightness should a fuel cell bend occur. The use of metal substrates also means that a given metal substrate can be manufactured and used in a number of different fuel cell unit products. Thus, for example, it can be used in a fuel cell unit containing two metal substrates. Alternatively, it can be used in a larger fuel cell unit, such as one with 4, 6, 8, 9, 10, or 12 metal substrates. This can reduce costs and increase the speed, quality, and reliability of manufacturing the metal substrates (and at least one fuel cell).

[0076] In various embodiments, two shielding plates are provided, configured (when attached to a metal spacer) such that one is located at either end of the metal substrate, i.e., one is located at a first end of the metal substrate and the other is located at a second end of the metal substrate. In other embodiments, the shielding plate may be divided into first and second portions, i.e., a first shielding plate portion and a second shielding plate portion. Thus, a first shielding plate may include a first shielding plate portion and a second shielding plate portion. Similarly, a second shielding plate may include a first shielding plate portion and a second shielding plate portion, each shielding plate portion being attached to the metal spacer.

[0077] The fuel cell unit has an internal fuel manifold. When a plurality of fuel cell units are assembled in a stack, an open manifold oxidant (air) flow channel is defined between (a) a first surface of a metal interconnect plate of a first fuel cell unit and (b) a second surface of a metal substrate (or at least two shielding plates and at least one metal substrate plate) of an adjacent second fuel cell unit. Preferably, the metal interconnect plate includes a plurality of recesses extending outward from the first surface and away from the second surface. Preferably, the recess of a first fuel cell unit abuts against the cathode layer of at least one solid oxide fuel cell of an adjacent second fuel cell unit and serves as a current collector.

[0078] The aforementioned alternatives and preferred features also apply to other aspects of the invention detailed below.

[0079] The present invention also provides a solid oxide fuel cell stack comprising a plurality of metal-supported solid oxide fuel cell units according to the present invention.

[0080] Preferably, the solid oxide fuel cell units are separated from each other by compression pads.

[0081] According to the present invention, a solid oxide fuel cell stack assembly is also provided, comprising: a substrate, an end plate, a solid oxide fuel cell stack according to the present invention positioned between the substrate and the end plate, and a skirt attached to the substrate and the end plate and defining a volume between the skirt, the substrate and the end plate containing the fuel cell stack.

[0082] The present invention also provides a method for assembling a metal-supported solid oxide fuel cell unit, the metal-supported solid oxide fuel cell unit comprising:

[0083] a) A metal substrate defining a first and a second opposing surface, wherein at least one solid oxide fuel cell is disposed on the second surface of the metal substrate;

[0084] b) A metal spacer defining the first and second opposing surfaces, the metal spacer comprising:

[0085] (i) An external perimeter,

[0086] (ii) The periphery of at least one fuel inlet defines a fuel inlet port.

[0087] (iii) at least all the periphery of the opening, which defines all the openings, and

[0088] (iv) At least one fuel outlet perimeter defines a fuel outlet port; and

[0089] c) A metal interconnect plate defining the first and second opposing surfaces;

[0090] The assembly method includes the following steps:

[0091] (i) attaching the first surface of the metal substrate to the second surface of the metal spacer; and

[0092] (ii) To securely attach the second surface of the metal interconnect to the first surface of the metal spacer.

[0093] in:

[0094] A fuel inlet port volume is defined between the first surface of the metal substrate, the inner periphery of at least one fuel inlet of each of the metal spacers, and the second surface of the metal interconnect plate.

[0095] The volume of each orifice is defined between the first surface of the metal substrate, the periphery of each orifice of the metal spacer, and the second surface of the metal interconnect plate.

[0096] A fuel outlet port volume is defined between the first surface of the metal substrate, the inner periphery of at least one fuel outlet of the metal spacer, and the second surface of the metal interconnect plate.

[0097] The metal interconnect plate includes a plurality of bridge portions that define a fluid flow path from the at least one fuel inlet port volume to the at least one outlet port volume to the at least one fuel outlet port volume.

[0098] In an embodiment in which the metal substrate comprises at least two shielding plates and at least one metal substrate plate (preferably, a plurality of metal substrate plates), step (i) preferably comprises clamping the metal spacer to the at least two shielding plates and at least one metal substrate plate and attaching the metal spacer to the at least two shielding plates and at least one metal substrate plate.

[0099] Preferably, step (ii) includes clamping the metal interconnect board to the metal spacer and attaching the metal interconnect board to the metal spacer.

[0100] Preferably, at least one of steps (i) and (ii) includes attachment by welding. More preferably, both steps (i) and (ii) include attachment by welding.

[0101] Preferably, at least one metal substrate and a plurality of shielding plates are aligned with the metal spacer and with the metal interconnect plate.

[0102] Preferably, locating components (also known as positioning components) are used to position different components during the assembly process. Suitable locating components include reference edges, fixed latches, and spring latches. Other locating components will be readily apparent to those skilled in the art.

[0103] Preferably, the solid oxide fuel cell unit is assembled by attaching a metal substrate (or at least one metal substrate plate and at least one shielding plate) to a metal spacer such that the metal substrate (or at least one metal substrate plate) is attached above at least one opening in the metal spacer. The metal substrate (or at least two shielding plates and at least one metal substrate plate) and the metal spacer are preferably clamped together using a first clamping plate. Preferably, the metal substrate (or at least two shielding plates and at least one metal substrate plate) is positioned on a substrate, and the metal spacer plate is positioned on top. Preferably, a first clamping plate is positioned above the metal spacer. More preferably, clamping components clamp the metal substrate (or at least two shielding plates and at least one metal substrate plate) and the metal spacer between the substrate and the first clamping plate. More preferably, the first clamping plate defines a welding groove through which the metal substrate (or at least two shielding plates and at least one metal substrate plate) is welded to the metal spacer.

[0104] Preferably, the metal interconnect is attached to the metal spacer by soldering. Preferably, the metal interconnect is placed above the metal spacer for which a metal substrate has been attached (or for which at least one metal substrate and at least one shielding plate have been attached). Preferably, a second clamping plate is positioned above the metal interconnect. More preferably, clamping members clamp the metal substrate (or at least two shielding plates and at least one metal substrate), the metal spacer, and the metal interconnect between the substrate and the second clamping plate. Preferably, the second clamping plate defines an opening. More preferably, the metal interconnect is soldered to the metal substrate through the opening. Preferably, the soldering is located between the outer periphery of the metal interconnect and the metal substrate, and the inner periphery of the metal spacer. More preferably, the soldering extends through the metal interconnect, the metal substrate, and to the metal substrate (or at least two shielding plates and at least one metal substrate).

[0105] At least two shielding plates and at least one metal substrate plate attached to a metal spacer together define a metal substrate.

[0106] Preferably, the metal substrate (or at least two shielding plates, at least one metal substrate plate), metal spacers, and metal interconnects are aligned by a reference edge during assembly.

[0107] This document provides an enabling disclosure of the invention for those skilled in the art. Detailed reference will now be made to embodiments of the invention, and one or more examples are presented below. These examples are provided by way of illustration and not limitation. Attached Figure Description

[0108] Figure 1 An exploded perspective view of the fuel cell unit assembly of Example 1 is shown;

[0109] Figure 2 Showing a top view of a metal substrate assembly located on an assembly substrate;

[0110] Figure 3 The display is located at Figure 2 A top view of one of the metal spacers on top of the metal substrate assembly;

[0111] Figure 4 This indicates that it is positioned for welding purposes. Figure 3 A top view of one of the first clamping plates on top of the metal spacer;

[0112] Figure 5 show Figure 3 A top view of the metal spacer after the first clamping component has been welded and removed;

[0113] Figure 6 The display is located at Figure 5 A top view of one of the metal interconnect plates on top of the metal spacer;

[0114] Figure 7 This indicates that it is positioned for welding purposes. Figure 6 A top view of one of the second clamping plates on top of the metal interconnect plate;

[0115] Figure 8 show Figure 6 A top view of the metal interconnect board after the second clamping component has been soldered and removed and removed from the assembly substrate;

[0116] Figure 9 Showing a cross-section through a metal substrate plate;

[0117] Figure 10 An exploded perspective view of the fuel cell unit of Example 2 is shown;

[0118] Figure 11 An exploded perspective view of the fuel cell unit of Example 4 is shown;

[0119] Figure 12Showing a top view of the fuel cell unit components of the fuel cell unit in Embodiment 5;

[0120] Figure 13 Showing a top view of a portion of a metal spacer;

[0121] Figure 14 Showing a top view of a portion of a metal interconnect board;

[0122] Figure 15 An exploded perspective view of a fuel cell unit of Embodiment 1 is shown, which presents a depiction of fluid flow;

[0123] Figure 16A This is a CFD image used to display one of the fuel velocities in a prior art device;

[0124] Figure 16B This is a CFD image showing one of the fuel velocities in a prior art device (the shadow represents the plane velocity of the fuel in ms^-1);

[0125] Figure 16C The image is used to show the fuel velocity in a device according to the present invention (the shadow represents the plane velocity of the fuel in ms^-1);

[0126] Figure 17A This is a CFD image used to display the normalized fuel residence time (age of the fuel) in a prior art device;

[0127] Figure 17B This is a CFD image showing the normalized fuel residence time (fuel age) in an apparatus according to the present invention. Detailed Implementation

[0128] A list of designations used herein is provided at the end of the specific embodiments. Where designations are used repeatedly in this specification and figures, they are intended to represent the same or similar features or elements.

[0129] Those skilled in the art will understand that various modifications and variations can be made to this invention without departing from the scope of the claims. For example, a feature described as one embodiment can be used in another embodiment to derive another further embodiment. Therefore, this invention is intended to cover modifications and variations that fall within the scope of the appended claims and their equivalents.

[0130] Other objects, features, and embodiments of the invention are disclosed in the remainder of the specification. Those skilled in the art will understand that this discussion describes only exemplary embodiments and is not intended to limit the invention to broader embodiments, which are implemented with exemplary construction.

[0131] Example 1

[0132] The figure illustrates the fabrication of a metal-supported solid oxide fuel cell unit 1. The metal-supported solid oxide fuel cell unit 1 is used as a solid oxide fuel cell stack layer.

[0133] In this embodiment, the metal-supported solid oxide fuel cell unit 1 is fabricated to include a metal substrate 65 (also referred to as a "substrate layer" or "metal substrate layer"), a metal spacer 30, and a metal interconnect plate 20.

[0134] Metal substrates 70a and 70b each include a porous region 78, defined by laser-drilled perforations 78a extending between a first surface 71 and a second surface 72. A fuel cell 79 is deposited on the second surface 72 of the metal substrates 70a and 70b above the porous regions 78 and includes an anode layer deposited above the porous regions 78, an electrolyte layer deposited above the anode layer, and a cathode layer deposited above the electrolyte layer. The porous regions 78 are surrounded by non-porous regions 78b.

[0135] like Figure 2 As shown, the assembly substrate 80 includes fixed fasteners 83a, 83b, 83c, 83d, 83e, 83f, and 83g, and spring-loaded fasteners 84a, 84b, 84c, 84d, 84e, 84f, and 84g. The assembly substrate 80 also defines (includes) a reference edge 81.

[0136] The metal substrate plates 70a and 70b, and the shielding plates 50a and 50b are aligned on the assembly substrate 80, and the alignment is achieved by fixed pins 83a, 83b, 83c, 83d, 83e, 83f, 83g, spring-loaded pins 84a, 84b, 84c, 84d, 84e, 84f, 84g and reference edge 81.

[0137] The second surface 52 of the shielding plate 50a is disposed (i.e., contacts / bears) on the assembly base plate 80. The second edge 58 of the shielding plate 50a is aligned with the reference edge 81 by a fixed pin 83g, and the first edge 57 of the shielding plate 50a is aligned with the fixed pin 83a and the spring-loaded pin 84a. The curved edge 55 of the shielding plate 50a is aligned by the spring-loaded pin 84g.

[0138] The second surface 52 of the shielding plate 50b is disposed (i.e., contacts / abuts) on the assembly base plate 80. The second edge 58 of the shielding plate 50b is aligned with the reference edge 81 by means of a fixed pin 83c, and the first edge 57 of the shielding plate 50b is aligned with the fixed pin 83b and the spring-loaded pin 84d. The curved edge 55 of the shielding plate 50b is aligned with the spring-loaded pin 84e.

[0139] The second surface 72 of the metal substrate 70a is disposed (i.e., in contact with / abuts) on the assembly substrate 80.

[0140] Metal substrate plates 70a and 70b are positioned on the assembly base plate 80 between shielding plates 50a and 50b. The second short side 75 of the metal substrate plate 70a is aligned with the reference edge 81 by fixed fasteners 83f and 83e. The first short side 74 of the metal substrate plate 70a is aligned by spring-loaded fasteners 84b.

[0141] The second short side 75 of the metal substrate 70b is aligned with the reference edge 81 by a fixed pin 83d and a spring-loaded pin 84f. The first short side 74 of the metal substrate 70b is aligned by a spring-loaded pin 84c.

[0142] The outer long side 76 of the metal substrate plate 70a is aligned with the inner edge 59 of the shielding plate 50a, thereby defining a tolerance gap 82a between the metal substrate plate 70a and the shielding plate 50a.

[0143] The outer length side 76 of the metal substrate plate 70b is aligned with the inner edge 59 of the shielding plate 50b, thereby defining a tolerance gap 82b between the metal substrate plate 70b and the shielding plate 50b.

[0144] The tolerance clearance 82c is defined between the inner long side 77 of the metal substrate 70a and the inner long side 77 of the metal substrate 70b.

[0145] like Figure 3 As shown, the metal spacer 30 is then placed on top of the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b and the shielding plate 50b.

[0146] The second surface 32 of the metal spacer 30 is disposed (i.e., in contact with / abuts) on the first surface 51 of the shielding plate 50a, the first surface 71 of the metal substrate plate 70a, the first surface 71 of the metal substrate plate 70b, and the first surface 51 of the shielding plate 50b.

[0147] The metal spacer 30 is aligned with the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b and the shielding plate 50b by means of the fixed fastener 83e, the spring-loaded fasteners 84a, 84d, 84e, 84f and 84g and the reference edge 81.

[0148] The second elongated edge 38 of the metal spacer 30 is aligned with the second edge 58 and reference edge 81 of the obscuring plates 50a and 50b and the second short side 75 of the metal substrate plates 70a and 70b using fixed fasteners 83e and spring-loaded fasteners 84f. The first elongated edge 37 of the metal spacer 30 is aligned with the first edge 57 of the obscuring plates 50a and 50b and the first short side 74 of the metal substrate plates 70a and 70b using spring-loaded fasteners 84a and 84d.

[0149] The outer periphery of the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b and the shielding plate 50b does not extend beyond the outer periphery 33 of the metal spacer 30.

[0150] The metal spacer 30 includes inner peripheries 39a and 39b of a cut, each inner periphery defining a separate cut 40a and 40b, and an intersecting member 41 between them. Metal substrate plates 70a and 70b integrally overlap the inner peripheries 39a and 39b of the cut of the metal spacer 30, that is, the metal substrate plates 70a and 70b integrally cover the cuts 40a and 40b.

[0151] The metal spacer 30 also includes a plurality of fuel inlet inner perimeters 33a, 33b, and fuel outlet inner perimeters 33c, 33d for defining fuel ports 34a, 34b, 34c, and 34d. Each fuel port includes a number of zones—fuel conduit zone 44a, fuel throat zone 44b, and fuel distributor passage zone 44c.

[0152] like Figure 4 As shown, the first clamping plate 90 is then placed on top of the metal spacer 30, that is, in contact with / against the first surface 31 of the metal spacer 30.

[0153] The first clamping plate 90 defines the orifices 92a and 92b. The spring-loaded snap fastener 84h protrudes through the orifice 92a, and the fixed snap fastener 83e protrudes through the orifice 92b, allowing the first clamping plate 90 to be aligned with the metal spacer 30 (and therefore also with the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b, and the shielding plate 50b).

[0154] The clamping component (not shown) clamps the first clamping plate 90 and the assembly base plate 80, that is, clamps the metal spacer 30, the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b and the shielding plate 50b.

[0155] The first clamping plate also defines welding grooves 91a, 91b and 91c.

[0156] The welding components (not shown) are used to generate the wire weld joint 100a between the metal spacer 30 and the shielding plate 50a, the wire weld joints 100b and 100c between the metal spacer 30 and the metal substrate plate 70a, the wire weld joints 100d and 100e between the metal spacer 30 and the metal substrate plate 70b, and the wire weld joint 100f between the metal spacer 30 and the shielding plate 50b.

[0157] The non-porous region 78b of the metal substrate plates 70a and 70b is attached to the metal spacer 30.

[0158] The shielding plate 50a, metal substrate plate 70a, metal substrate plate 70b and shielding plate 50b attached to the metal spacer 30 form / define a metal substrate 65, that is, a metal substrate 65 is attached to the metal spacer 30.

[0159] The first clamping plate 90 was then removed, as... Figure 5 As shown (fixed coupling 83e and spring-loaded couplings 84a, 84d and 84f are not shown).

[0160] like Figure 6 As shown, the metal interconnect plate 20 is then placed on top of the metal spacer 30.

[0161] The second surface 22 of the metal interconnect plate 20 is disposed (i.e., in contact with / abuts) on the first surface 31 of the metal spacer 30.

[0162] The metal interconnect plate 20 is aligned with the metal spacer 30 (and therefore also with the shielding plate 50a, metal substrate plate 70a, metal substrate plate 70b, and shielding plate 50b) by means of fixed pins 83e, spring-loaded pins 84a, 84d, and 84f, and a reference edge 81. Spring-loaded pins 84a and 84d abut against the first edge 27 of the metal interconnect plate 20. The second edge 28 of the metal interconnect plate 20 abuts against the reference edge 81, the fixed pins 83e, and the spring-loaded pins 84f.

[0163] The metal interconnect 20 includes a plurality of recesses 110 and elongated bridge recesses 120, 121 extending outward from the first surface 21, i.e. away from the second surface 22 and away from the metal spacer 30 and the metal substrate 65 attached to the metal spacer 30.

[0164] The recess 110 is formed in a number of regions, including regions corresponding to the locations of fuel cells 79 on the metal substrate plates 70a and 70b, so that in a fuel cell stack configuration comprising a plurality of fuel cell units 1 in a stack, the recess 110 of a first fuel cell unit 1 contacts the fuel cell 79 of an adjacent fuel cell unit 1 stacked therewith. Therefore, the recess 110 forms an electrical connection with an outer (cathode) surface of the fuel cell 79, wherein current flows from the first surface 21 of the metal interconnect plate 20 to the cathode layer of one or more adjacent fuel cells 79 of the adjacent fuel cell unit 1.

[0165] As will be described in more detail later, the elongated bridge recesses 120 and 121 serve as fluid flow bridges between the separated zones / regions / volumes of the final fuel cell unit 1.

[0166] like Figure 7 As shown, the second clamping plate 95 is then placed on top of the metal interconnect plate 20, that is, in contact with / against the first surface 21 of the metal interconnect plate 20.

[0167] The second clamping plate 95 defines the orifices 98a and 98b. The spring-loaded snap fastener 84h protrudes through the orifice 98a, and the fixed snap fastener 83e protrudes through the orifice 98b, allowing the second clamping plate 95 to be aligned with the metal interconnect plate 20 (and therefore also with the metal spacer 30, the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b, and the shielding plate 50b).

[0168] The second clamping plate 95 includes an inner periphery 96, which defines an opening 96a.

[0169] The clamping component (not shown) clamps the second clamping plate 95 and the assembly substrate 80, that is, clamps the metal interconnect plate 20, the metal spacer 30, the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b and the shielding plate 50b.

[0170] The welding component (not shown) is used to form a continuous peripheral weld joint 101 between the metal interconnect plate 20, the metal spacer 30, and the shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b, and the shielding plate 50b.

[0171] The second clamping plate 95 was then removed, and the completed metal-supported solid oxide fuel cell unit 1 was removed from the assembly substrate 80.

[0172] In the completed metal-supported solid oxide fuel cell unit 1, the fuel conduit 130 is defined by the fuel conduit regions 44a of the fuel ports 24 and 34a-d, which are aligned with each other. The fuel conduit 130 extends between the first surface 21 of the metal interconnect plate 20 and the second surface 52 of the shielding plates 50a and 50b.

[0173] At the first end 2 of fuel cell unit 1 (for example, see...) Figure 3 The first volume (fuel inlet port volume 35a) is defined between the first surface 51 of the shielding plate 50a, the internal periphery 33a, 33b of the fuel inlet of the metal spacer 30, and the second surface 22 of the metal interconnect plate 20.

[0174] A second volume (cutout volume 35b) is defined between the first surface 71 of the metal substrate 70a, the inner periphery 39a of the cutout of the metal spacer 30, and the second surface 22 of the metal interconnect plate 20.

[0175] A third volume (cut-out volume 35b) is defined between the first surface 71 of the metal substrate 70b, the inner periphery 39b of the cut-out of the metal spacer 30, and the second surface 22 of the metal interconnect plate 20.

[0176] At the second end 3 of the fuel cell unit 1, the fourth volume (fuel outlet port volume 35c) is defined between the first surface 51 of the shielding plate 50b, the inner periphery 33c and 33d of the fuel outlet of the metal spacer 30, and the second surface 22 of the metal interconnect plate 20.

[0177] At the first end 2 of the fuel cell unit 1, an elongated recess 120 is used to define a fluid flow channel between the first and second volumes, that is, to serve as a fluid flow bridge between the first and second volumes. The fluid flow bridge is the volume between the elongated recess 120 and the metal spacer 30.

[0178] The elongated recess 121 is used to define a fluid flow channel between the second and third volumes (i.e., between adjacent cut-out volumes 35b). The fluid flow bridge is the volume between the elongated recess 121 and the metal spacer 30.

[0179] At the second end 3 of the fuel cell unit 1, an elongated recess 120 is used to define a fluid flow channel between the third and fourth volumes, that is, to serve as a fluid flow bridge between the first and second volumes. The fluid flow bridge is the volume between the elongated recess 120 and the metal spacer 30.

[0180] Therefore, the fluid flow path is defined by the following components (using fuel inlet port volume 35a, cut-out volume 35b, fuel outlet port volume 35c, and fluid flow bridge):

[0181] (1) Fuel conduit area 44a of fuel ports 34a and 34b, to

[0182] (2) Fuel throat area 44b of fuel ports 34a and 34b, to

[0183] (3) Fuel distributor passage area 44c of fuel ports 34a and 34b, to

[0184] (4) The elongated recess 120 at the first end 2 of the fuel cell unit 1, to

[0185] (5) The second volume defined between the first surface 71 of the metal substrate 70a, the inner periphery 39a of the cut in the metal spacer 30, and the second surface 22 of the metal interconnect plate 20, to

[0186] (6) Elongated concave 121, to

[0187] (7) The third volume defined between the first surface 71 of the metal substrate 70b, the inner periphery 39b of the cut in the metal spacer 30, and the second surface 22 of the metal interconnect plate 20, to

[0188] (8) Fuel distributor passage area 44c of fuel ports 34c and 34d, to

[0189] (9) Fuel throat area 44b of fuel ports 34c and 34d, to

[0190] (10) Fuel conduit area 44a of fuel ports 34c and 34d.

[0191] Therefore, a fluid flow path 140 (i.e. a fuel flow path) is defined within the fuel cell unit 1, from the fuel conduit 130 at the first end 2 to the fuel conduit 130 at the second end 3.

[0192] Fluid flow path 140 is shown in Figure 15 middle.

[0193] like Figure 13 and 14 As can be seen, the metal interconnect plate 20 includes an elongated bridge recess 120a that transfers fuel from a fuel distributor passage 44c1 to a cutout 40a. Similarly, the metal interconnect plate 20 includes two elongated bridge recesses 120b that transfer fuel from a fuel distributor passage 44c2 to a cutout 40a. Furthermore, the metal interconnect plate 20 includes three elongated bridge recesses 120c that transfer fuel from a fuel distributor passage 44c3 to a cutout 40a.

[0194] The widths of the elongated bridge recesses ra, rb, and rb1 remain constant. However, as the elongated bridge recess 120c gets closer to the center of the fuel cell unit, the widths rc, rc1, and rc2 (the lengths of the shortest side of the rectangular cross-sectional shape of the elongated bridge recess 120c) increase. That is, rc2>rc1>rc, so the flow area inside the elongated bridge recess 120c, which is closer to the center of the fuel cell, gradually increases, allowing fuel to be uniformly promoted to the center of the fuel cell, thus preventing depletion at that center.

[0195] Figure 14 Alternating recesses 110 and 122 are also shown, wherein the recesses alternate between extending away from the first surface of the metal interconnect plate and away from the second surface. For the avoidance of doubt, elongated recesses 120, 120a, 120b, 120c and 121 do not alternate but all extend from the first surface 21 of the metal interconnect plate 20 away from the second surface 22.

[0196] Figure 13 The arrangement of fuel ports 34a, 34b, 34c, and 34d of the metal spacer 30 is illustrated. The fuel throat region 44b includes a constant width "W" between the fuel ports 34a and the corresponding fuel distributor passage regions 44c (fuel distributor passage regions 44c1, 44c2, 44c3), wherein fuel is transferred from these fuel ports 34a to the corresponding fuel distributor passage regions at high speed, thereby reducing the risk of fuel depletion.

[0197] Furthermore, the fuel distributor passage area 44c (44c1, 44c2, 44c3) comprises a curved shape, the width of which gradually increases, starting from the width "W" of the fuel throat area 44b and ending at a width equal to the distance (da, db, dc), where (da... <db<dc)。

[0198] The distance d (da, db, dc) at the edge of the fuel distributor passage area 44c is longer in the area near the center of the fuel cell unit 1, so as to promote fuel evenly along the middle area of ​​the fuel cell unit 1 and improve fuel distribution.

[0199] In a fuel cell stack assembly, the length "L" of the fuel throat region 44b is related to the size of a compression shim located between the metal interconnect plate 20 of a solid oxide fuel cell unit 1 and the substrate layer 65 of the subsequent solid oxide fuel cell unit 1. The shim includes a toroidal shape surrounding a port of the interconnect. The length "L" of the fuel throat region 44b coincides with the outer radius minus the inner radius of the compression shim to minimize the pressure drop.

[0200] The additional recess 122 is located between the recess 110 and the elongated bridge recess 120, adjacent to the elongated bridge recess 120. Furthermore, the additional recess 122 is located between the recess 110 and the elongated bridge recess 121. The recess 122 maintains the gap between the interconnect 20 and the metal substrate 65, thereby preventing fuel blockage in the areas where the additional recess 122 is located.

[0201] The elongated bridge recess 120c includes a wedge along one of its shortest sides of its rectangular cross-sectional shape, which is located on the side connecting the fuel distribution passage 44c3 to the elongated bridge recess 120c. In a fuel cell stack assembly, the wedge maintains the gap between the metal interconnect plate 20 and the next fuel cell unit 1, thereby reducing the risk of short circuits between two adjacent solid oxide fuel cell units 1.

[0202] Figure 16A , 16B And 16C shows the present invention ( Figure 16C This invention achieves a significant improvement in fuel velocity compared to existing technologies. In particular, the fuel velocity around the port area is significantly increased. Figure 16C This allows for a more constant fuel rate, fewer fuel deficit areas at the corners of fuel cell unit 1, and more uniform fuel flow across fuel cell unit 1, which improves the chemical reactions occurring within the fuel cell.

[0203] Figure 17A and 17B As shown in Table 1, compared to the prior art, the normalized fuel residence time in this invention has been reduced, which means that the chemical reaction requires a lower hydrogen concentration. In other words, less fuel is needed for the chemical reaction to occur, thus improving the efficiency of this invention compared to the prior art.

[0204] Table 1

[0205]

[0206] Table 2 shows the active region of fuel cell unit 1. Flow uniformity A higher coefficient indicates better flow distribution across one of the active regions, resulting in better fuel distribution across the cell in this application.

[0207] Table 2

[0208] Existing technology 0.56 0.51 This invention 0.81 0.81

[0209] Table 3 shows the operation points. pressure drop Due to better fuel distribution, the pressure drop between the inlet and outlet ports is reduced in this invention compared to existing technologies. Minimizing the pressure drop across the battery is beneficial for maintaining compression along the stack.

[0210] Table 3

[0211] Existing technology 58.17mbar This invention 49.8mbar

[0212] Suitable materials for different components include (Table 4):

[0213] Table 4:

[0214] Metal spacer 30 Fermented iron stainless steel, grade 441 Covering panels 50a and 50b Crofer 22APU (VDM Metal GmbH) Metal substrate 70a, 70b Crofer 22APU (VDM Metal GmbH)

[0215] Example 2

[0216] like Figure 10 As shown, Example 2 is the same as Example 1, except that in the metal-supported solid oxide fuel cell unit 1:

[0217] (i) The shielding plate 50a and the metal substrate plate 70a are formed into an assembled metal substrate plate 170a, and

[0218] (ii) The shielding plate 50b and the metal substrate plate 70b are formed into an assembled metal substrate plate 170b.

[0219] The manufacturing and operation are otherwise the same as those in Example 1.

[0220] Example 3

[0221] As per WO2015 / 136295, a fuel cell stack assembly is formed using a plurality of fuel cell units 1. More specifically, a stack of fuel cell units 1 is assembled on top of a metal substrate (ferro-iron stainless steel 3CR12), wherein a Thermiculite 866 spacer electrically insulates the substrate from adjacent fuel cell units 1, and a power take-off is located between the Thermiculite 866 spacer and adjacent fuel cell units 1. The Thermiculite 866 spacer is located between the first ends 2 of adjacent fuel cell units 1 and between the second ends 3 of adjacent fuel cell units 1. A power take-off is then positioned (i.e. exposed) on top of the fuel cell unit 1, a Thermiculite 866 spacer is then placed on top of the power take-off, and a metal end plate (ferro-iron stainless steel 3CR12) is placed on the Thermiculite spacer. Subsequently, a compression component applies compressive force between the substrate and the end plate, and a skirt is attached to the substrate and the end plate to define a volume therebetween containing a fuel cell stack and its fuel cell units.

[0222] Example 4

[0223] like Figure 11As shown, Example 4 is the same as Example 1, except that in the solid oxide fuel cell unit 1:

[0224] (i) The shielding plate 50a, the metal substrate plate 70a, the metal substrate plate 70b and the shielding plate 50b are formed into a single assembled metal substrate plate 180 (a metal substrate).

[0225] (ii) The metal spacer 30 has a single-cut internal periphery 39a that defines the single-cut.

[0226] The manufacturing and operation are otherwise the same as those in Example 1.

[0227] Example 5

[0228] like Figure 12 As shown, a fuel cell unit 1 is manufactured as in Embodiment 1. In this embodiment, it has a total of six metal substrate plates 70 and a total of six corresponding cutouts 40.

[0229] Example 6

[0230] This embodiment is similar to Embodiment 4, except that the metal substrate 180 includes a single porous region 78, and a single fuel cell 79 is disposed on the second surface 72 of the metal substrate 180. The porous region and the fuel cell extend to the periphery of the single cut-out inner periphery 39a.

[0231] When manufacturing fuel cell unit 1, a first welding step (where the metal substrate 65 / 70 assembly is welded to the metal spacer 30) is not required. Instead, a single weld is performed around the perimeter of the three layers.

[0232] Different modifications, adaptations, and alternative embodiments will be readily apparent to those skilled in the art without departing from the scope of the appended claims. The designations are included in the claims for ease of understanding only and do not limit the scope of the claims.

[0233] Symbol Explanation

[0234] 1…Solid oxide fuel cell unit

[0235] 2…First end

[0236] 3…Second end

[0237] 20…Metal interconnect board

[0238] 21…(the first surface of the metal interconnect board 20)

[0239] 22…(Second surface of metal interconnect 20)

[0240] 23…(the outer periphery of the metal interconnect board 20)

[0241] 24… (Fuel port of metal interconnect 20)

[0242] 27…(the first edge of the metal interconnect board 20)

[0243] 28… (Second edge of metal interconnect board 20)

[0244] 30…Metal spacers

[0245] 31…(the first surface of the metal spacer 30)

[0246] 32…(the second surface of the metal spacer 30)

[0247] 33…(the outer periphery of the metal spacer 30)

[0248] 33a… Fuel inlet internal perimeter

[0249] 33b… Fuel inlet internal perimeter

[0250] 33c… Fuel outlet internal perimeter

[0251] 33d… Fuel outlet interior perimeter

[0252] 34a… Fuel Port

[0253] 34b… Fuel Port

[0254] 34c… Fuel Port

[0255] 34d… Fuel Port

[0256] 35a… Fuel inlet port volume

[0257] 35b…cut volume

[0258] 35c… Fuel outlet port volume

[0259] 37…(the first elongated edge of the metal spacer 30)

[0260] 38…(the second elongated edge of the metal spacer 30)

[0261] 39a…Incision periphery

[0262] 39b…Incision inside and around

[0263] 40… incision

[0264] 40a… incision

[0265] 40b… cut

[0266] 41…intersecting members

[0267] 44a… Fuel duct area

[0268] 44a1… Fuel duct area

[0269] 44a2… Fuel duct area

[0270] 44a3… Fuel duct area

[0271] 44b… Fuel throat area

[0272] 44c… Fuel distributor passage area

[0273] 44c1… Fuel distributor passage area

[0274] 44c2… Fuel distributor passage area

[0275] 44c3… Fuel distributor passage area

[0276] 50a…masking plate

[0277] 50b…covering plate

[0278] 51…(the first surface of the shield)

[0279] 52… (the second surface of the shield)

[0280] 54… (The one with the shield) Fuel Port

[0281] 55… (the curved edge of the panel)

[0282] 57…(the first edge of the masking panel)

[0283] 58… (Second edge of the masking panel)

[0284] 59…(the inner edge of the shield)

[0285] 65…metal substrate

[0286] 65a…First surface of metal substrate

[0287] 65b…Second surface of metal substrate

[0288] 70… Metal substrate board

[0289] 70a…metal substrate board

[0290] 70b… Metal substrate board

[0291] 71…(the first surface of the metal substrate)

[0292] 72… (Second surface of metal substrate)

[0293] 74…(the first short side of the metal substrate)

[0294] 75… (Second short side of metal substrate)

[0295] 76… (outer length side of metal substrate)

[0296] 77… (Inner length side of metal substrate)

[0297] 78… (Porous region of metal substrate)

[0298] 78a…perforation

[0299] 78b… (Non-porous region of metal substrate)

[0300] 79…Solid Oxide Fuel Cells

[0301] 80… Assembly board

[0302] 81…Reference Edge

[0303] 82a…tolerance clearance

[0304] 82b…tolerance clearance

[0305] 82c…tolerance clearance

[0306] 83a…Fixed snap fastener

[0307] 83b… Fixed fastener

[0308] 83c…Fixed snap fastener

[0309] 83d… Fixed fastener

[0310] 83e… Fixed fastener

[0311] 83f… Fixed fastener

[0312] 83g… Fixed fastener

[0313] 84a…Spring-loaded coupling

[0314] 84b…Spring-loaded snap fastener

[0315] 84c…Spring-loaded snap fastener

[0316] 84d…Spring-loaded snap fastener

[0317] 84e…Spring-loaded snap fastener

[0318] 84f…Spring-loaded snap fastener

[0319] 84g…Spring-loaded snap fastener

[0320] 84h…Spring-loaded snap fastener

[0321] 90…First clamping plate

[0322] 91a… Welding groove

[0323] 91b… Welding groove

[0324] 91c… Welding groove

[0325] 92a…orifice

[0326] 92b…orifice

[0327] 95…Second clamp plate

[0328] 96…surrounding area

[0329] 96a…opening

[0330] 98a…orifice

[0331] 98b…orifice

[0332] 100a… wire welded joint

[0333] 100b… wire welded joint

[0334] 100c… wire welded joint

[0335] 100d… wire welded joint

[0336] 100e… wire welded joint

[0337] 100f… wire welded joint

[0338] 101…peripheral welded joint

[0339] 110… dent

[0340] 120… Long bridge depression

[0341] 120a… Long bridge depression

[0342] 120b… Long bridge depression

[0343] 120c… Long bridge depression

[0344] 121… Long bridge depression

[0345] 122…depression

[0346] 130… Fuel conduit

[0347] 140… Fuel Flow Path

[0348] 170a…Assembled metal substrate plate

[0349] 170b…Assembled metal substrate plate

[0350] 180…Assembled metal substrate plate

[0351] da… distance

[0352] db… distance

[0353] DC... distance

[0354] rc1…width

[0355] rc2…width

[0356] rc3…width

[0357] L…(length of fuel throat 44b)

[0358] W… (width of fuel throat region 44b).

Claims

1. A fuel port terminal for a metal-supported solid oxide fuel cell unit, comprising: a) A metal substrate defining a first surface and an opposite second surface, wherein at least one solid oxide fuel cell is disposed on the second surface of the metal substrate; b) A metal spacer defining a first surface and an opposing second surface, the metal spacer including at least one fuel port interior periphery defining a cutout, wherein the first surface of the metal substrate is attached to the second surface of the metal spacer. and c) A metal interconnect plate defining a first surface and an opposing second surface, the second surface of the metal interconnect plate being hermetically attached to the first surface of the metal spacer. in: One or more fuel port volumes are defined between the first surface of the metal substrate, the internal periphery of at least one fuel port of the metal spacer, and the second surface of the metal interconnect plate; and The metal interconnect plate includes a bridge portion that defines a fluid flow path to define a fluid flow bridge or channel from the one or more fuel port volumes to an adjacent volume in the solid oxide fuel cell unit when the fuel port is a fuel inlet port, or to define a fluid flow bridge or channel from an adjacent volume in the solid oxide fuel cell unit to the one or more fuel port volumes when the fuel port is a fuel outlet port. The adjacent volumes in the solid oxide fuel cell unit are the active regions of the solid oxide fuel cell unit.

2. The fuel port terminal according to claim 1, wherein, There are multiple bridge sections between adjacent volumes.

3. The fuel port terminal according to claim 1, wherein, The fuel port volume, or each fuel port volume, includes a fuel conduit area, multiple fuel throat areas, and corresponding multiple fuel distributor passage areas.

4. The fuel port terminal according to claim 3, wherein, Each fuel throat region has a constant width between the fuel conduit region and the fuel distributor passage region.

5. The fuel port terminal according to claim 1, wherein, The bridge portion extends outward from the first surface of the metal interconnect plate and away from the second surface of the metal interconnect plate.

6. The fuel port terminal according to claim 1, wherein, The bridge section includes an elongated recess.

7. The fuel port terminal according to claim 1, wherein, The bridge portion defines the volume between the first surface of the metal spacer and the second surface of the metal interconnect plate.

8. The fuel port terminal according to claim 1, wherein, The metal spacer includes at least two internal fuel peripheries that define at least two fuel ports.

Images