US4467050A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fuel cell catalyst member and method of making same
Assignee: Fuelcell Energy Inc
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Filing: 1982-07-08
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Granted: 1984-08-21
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Expires: 2002-07-08
Abstract
Abstract A fuel cell catalyst member formed from a metallic plate to whose surface is electrophoretically applied a porous support layer of ceramic material into which is impregnated an active catalyst material.
Inventors
- 👤 Pinakin Patel
- 👤 Dilip Dharia
- 👤 Hansraj Maru
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 23:51
CPC Classifications
H; H01; H01M; H01M8/00; H01M8/06; H01M8/0606; H01M8/0612; H01M8/0625; H01M8/10; H01M8/12; H01M2008/1293; H01M8/14; H01M2008/147; H01M2300/00; H01M2300/0017; H01M2300/0048; H01M2300/0051; H01M2300/0065; H01M2300/0068; H01M2300/0071; H01M2300/0074; Y; Y02; Y02E; Y02E60/00; Y02E60/30; Y02E60/50; Y02P; Y02P70/00; Y02P70/50
Claims Analysis
Total Claims: 52
Claim 1
Independent Claim
74 words
A fuel cell catalyst member for use in a fuel cell which receives process gas containing hydrocarbon content, said member reforming said hydrocarbon content through communication between said process gas and said member, said member comprising: a metallic plate having a continuous surface of extended dimension; a porous support layer of ceramic material electrophoretically deposited on said surface, said ceramic material comprising lithium aluminate; and an active catalyst material dispersed in said support layer.
Claim 2
Dependent Claim
74 words
A fuel cell catalyst member for use in a fuel cell which receives process gas containing hydrocarbon content, said member reforming said hydrocarbon content through communication between said process gas and said member, said member comprising: a metallic plate having a continuous surface of extended dimension; a porous support layer of ceramic material electrophoretically deposited on said surface, said ceramic material comprising lithium aluminate; and an active catalyst material dispersed in said support layer.
Claim 3
Dependent Claim
23 words
A fuel cell catalyst member in accordance with claim 1 wherein: said active material contains nickel; and said metallic plate contains stainless steel.
Claim 4
Dependent Claim
22 words
A fuel cell catalyst member in accordance with claim 1 wherein: said active catalyst material is uniformly dispersed in said support layer.
Claim 5
Dependent Claim
21 words
A fuel cell catalyst member in accordance with claim 1 wherein: said active catalyst is non-uniformly dispersed in said support layer.
Claim 6
Dependent Claim
21 words
A fuel cell catalyst member in accordance with claim 1 wherein: said support layer is on preselected portions of said surface.
Claim 7
Dependent Claim
23 words
A fuel cell catalyst member in accordance with claim 1 wherein: said plate has opposing upper and lower surfaces which comprise said surface.
Claim 8
Dependent Claim
22 words
A fuel cell catalyst member in accordance with claim 6 wherein: said support layer is on both said upper and lower surfaces.
Claim 9
Dependent Claim
24 words
A fuel cell catalyst member in accordance with claim 6 wherein: said support layer is exclusively on one of said upper and lower surfaces.
Claim 10
Dependent Claim
36 words
A fuel cell catalyst member in accordance with claim 6 wherein: said metallic plate is corrugated and includes crest regions and valley regions; and said support material is on said lower surface in said crest regions.
Claim 11
Dependent Claim
24 words
A fuel cell catalyst member in accordance with claim 9 wherein: said support material is excluded from said lower surface in said valley regions.
Claim 12
Independent Claim
66 words
A method of producing a catalyst member for in situ reforming of the hydrocarbon content of process gas of a fuel cell comprising the steps of: electrophoretically depositing a porous support layer of ceramic material to a continuous surface of extended dimension of a metallic plate; and impregnating said support layer with an active catalyst material capable of reforming said hydrocarbon content of said fuel gas.
Claim 13
Independent Claim
66 words
A method of producing a catalyst member for in situ reforming of the hydrocarbon content of process gas of a fuel cell comprising the steps of: electrophoretically depositing a porous support layer of ceramic material to a continuous surface of extended dimension of a metallic plate; and impregnating said support layer with an active catalyst material capable of reforming said hydrocarbon content of said fuel gas.
Claim 14
Dependent Claim
16 words
A method in accordance with claim 11 wherein said method further includes: drying said impregnated plate.
Claim 15
Dependent Claim
13 words
A method in accordance with claim 12 further comprising: activating said applied catalyst.
Claim 16
Dependent Claim
42 words
A method in accordance with claim 11 wherein: the support material is an emulsion; and electrophoresis is at a voltage in the range of 500-700 volts and at a current density of 1-2 mA/cm 2 for a period of about 20-50 seconds.
Claim 17
Dependent Claim
16 words
A method in accordance with claim 14 wherein: said emulsion comprises lithium aluminate and a solvent.
Claim 18
Dependent Claim
28 words
A method in accordance with claim 15 wherein: said solvent is isopropanol and the emulsion contains about 50 to 90 mg. of lithium aluminate per cc of isopropanol.
Claim 19
Dependent Claim
22 words
A method in accordance with claim 12 or 13 wherein: said impregnation is by soaking in a solution containing the active material.
Claim 20
Dependent Claim
28 words
A method in accordance with claim 17 wherein: soaking is carried out with the plate held horizontally to obtain uniform concentration of catalyst material in said support layer.
Claim 21
Dependent Claim
32 words
A method in accordance with claim 17 wherein: said soaking is carried out with said plate inclined to the horizontal to obtain a non-uniform concentration of catalyst material in said support layer.
Claim 22
Dependent Claim
29 words
A method in accordance with claim 17 wherein: said soaking is carried out by first applying a vacuum on the plate, and then contacting the solution containing active material.
Claim 23
Dependent Claim
13 words
A method in accordance with claim 17 wherein: said active material comprises nickel.
Claim 24
Dependent Claim
15 words
A method in accordance with claim 21 wherein: said solution is a nickel salt solution.
Claim 25
Dependent Claim
17 words
A method in accordance with claim 21 wherein: said salt solution contains Ni(NO 3 ) 2 .
Claim 26
Dependent Claim
15 words
A method in accordance with claim 21 wherein: said salt solution contains NiSO 4 .
Claim 27
Dependent Claim
17 words
A method in accordance with claim 21 wherein: said salt solution contains nickel formate or nickel acetate.
Claim 28
Dependent Claim
29 words
A method in accordance with claim 11 further including: prior to depositing said support layer, treating the surface of said plate to provide a desired flatness and surface area.
Claim 29
Dependent Claim
33 words
A method in accordance with claim 26 wherein: said treating of said plate provides a plate surface area of from about 2 cm 2 /cm 2 to 10 cm 2 /cm 2 .
Claim 30
Dependent Claim
21 words
A method in accordance with claim 27 wherein: treating of said plate provides a plate flatness of ±0.5 to ±3 mils.
Claim 31
Dependent Claim
15 words
A method in accordance with claim 28 wherein: treating said plate includes annealing said plate.
Claim 32
Dependent Claim
32 words
A method in accordance with claim 29 wherein: annealing is carried out at a temperature of about 1800°-2100° F. in a hydrogen atmosphere for a period of about 2 to 4 hours.
Claim 33
Dependent Claim
22 words
A method in accordance with claim 29 wherein: treating said plate further includes sand blasting said plate subsequent to said annealing operation.
Claim 34
Dependent Claim
23 words
A method in accordance with claim 31 wherein: treating said plate further includes further annealing said plate subsequent to said sand blasting operation.
Claim 35
Dependent Claim
33 words
A method in accordance with claim 31 wherein: treating said plate further includes flattening said plate at pressures in a range of 0.5 to 1-0 tons/sq. in. area subsequent to said sand blasting.
Claim 36
Dependent Claim
25 words
A method in accordance with claim 11 further comprising: drying said impregnated plate, said drying being for a period of about 2 to 4 hours.
Claim 37
Dependent Claim
12 words
A method in accordance with claim 34 wherein: drying is with air.
Claim 38
Dependent Claim
13 words
A method in accordance with claim 11 further comprising: activating said catalyst material.
Claim 39
Dependent Claim
22 words
A method in accordance with claim 13 or 36 wherein: activating comprises subjecting the plate to a hydrogen atmosphere under controlled heating.
Claim 40
Dependent Claim
26 words
A method in accordance with claim 37 wherein: the quantity of hydrogen is about 0.5-1.0 cc/min-cm 2 , heated at a rate of about 0.5°-2° C./min.
Claim 41
Dependent Claim
23 words
A method in accordance with claim 11 further comprising: removing said support layer and said active catalyst from selected areas of said surface.
Claim 42
Dependent Claim
28 words
A method in accordance with claim 11 wherein: said depositing of said support layer and application of said active catalyst material is to selected areas of said surface.
Claim 43
Dependent Claim
20 words
A method in accordance with claim 11 wherein: said plate has first and second opposing surfaces which form said surface.
Claim 44
Dependent Claim
17 words
A method in accordance with claim 41 wherein: said depositing is to said first and second surfaces.
Claim 45
Dependent Claim
20 words
A method in accordance with claim 42 wherein: said depositing is exclusively to one of said first and second surfaces.
Claim 46
Dependent Claim
18 words
A method in accordance with claim 43 wherein: said depositing is to preselected areas of said one surface.
Claim 47
Dependent Claim
25 words
A method in accordance with claim 11 wherein: said porous support layer has a surface area in the range 1 to 30 m 2 /g.
Claim 48
Dependent Claim
28 words
A method in accordance with claim 11 or 45 wherein: said active catalyst material has a surface area in the range of 0.1 to 10 m 2 /g.
Claim 49
Dependent Claim
29 words
A fuel cell catalyst member in accordance with claim 1 wherein: said porous support layer has a surface area in the range of 1 to 30 m 2 /g.
Claim 50
Dependent Claim
31 words
A fuel cell catalyst member in accordance with claim 1 or 47 wherein: said active catalyst material has a surface area in the range of 0.1 to 10 m 2 /g.
Claim 51
Dependent Claim
21 words
A fuel cell catalyst member in accordance with claim 1 wherein: said hydrocarbon content includes one of methane, propane and alcohol.
Claim 52
Dependent Claim
19 words
A fuel cell catalyst member in accordance with claim 49 wherein: said alcohol includes one of methanol and ethanol.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-08-21 | 1988-02-20 | 1988-08-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-08-21 | 1992-02-20 | 1992-08-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-08-21 | 1996-02-20 | 1996-08-21 | $7700.00 | Window Closed / Lapsed |