Fully internal manifolded fuel cell stack

Claim 2

In a fuel cell stack comprising a plurality of fuel cell units, each said fuel cell unit comprising an anode and a cathode, an electrolyte in contact on one side with the electrolyte facing face of said anode and in contact on the opposite side with the electrolyte facing face of said cathode, and a separator plate separating said cell units between an anode and cathode forming an anode chamber between the anode facing face of said separator plate and said anode and forming a cathode chamber between the opposite cathode facing face of said separator plate and the separator facing face of the cathode of an adjacent said fuel cell unit, said anode chamber in gas communication with fuel gas supply and outlet and said cathode chamber in gas communication with oxidant gas supply and outlet the improvement comprising; said electrolytes and said separator plates extending to the peripheral edge of said fuel cell stack, said separator plates having a flattened peripheral wet seal structure extending to contact less than about 1 inch width of said electrolytes on each face of said separator plates completely around their periphery forming a peripheral wet seal less than about 1 inch width under cell operating conditions, said electrolytes and said separator plates each having a plurality of aligned perforations said perforations in said separator plates being surrounded by a flattened manifold wet seal structure extending to contact less than about 1 inch width of said electrolyte on each face of said separator plate forming a manifold wet seal less than about 1 inch width under cell operating conditions to form a plurality of gas manifolds extending through said cell stack, conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chambers on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chambers on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack.

Claim 3

In a fuel cell stack according to claim 1 wherein cell stack end plates are configured the same as said separator plates on their inner faces and form half cells on each end of said fuel cell stack.

Claim 4

In a fuel cell stack according to claim 2 wherein said fuel cell stack has interspersed along its axis a plurality of reforming chambers each formed by two separator/reformer plates, one having the configuration of said anode facing face of said separator plate facing one of said anode chambers and the second having the configuration of said cathode facing face of said separator plate facing one of said cathode chambers, said two separator/reformer plates sealingly joined in their edge area to enclose a reformer chamber, conduits through said extended manifold wet seal structure providing reaction gas and steam communication from a third set of said manifolds to said reformer chamber, and conduits through said extended manifold wet seal structure providing enriched hydrogen product gas communication to a fuel gas supply manifold, thereby providing fully internal manifolding of reactant gas and steam to and product gas from each said reformer unit in said fuel cell stack.

Claim 5

In a fuel cell stack according to claim 3 wherein said separator and separator/reformer plates are pressed metal plates about 0.010 to about 0.050 inch thick.

Claim 6

In a fuel cell stack according to claim 4 wherein said flattened peripheral wet seal structure on one face of said plates comprises a pressed shaping of said plates to form said extended peripheral wet seal on said one face of said plates and on the other face of said plates comprises a pressed sheet metal shape forming said extended peripheral wet seal fastened to said other face of said plates.

Claim 7

In a fuel cell stack according to claim 5 wherein said extended manifold wet seal structure on one face of said plates comprises a pressed shaping of said plates to form said extended manifold wet seal on said one face of said plates and on the other face of said plates comprises a pressed sheet metal shape forming said extended manifold wet seal fastened to said other face of said plates.

Claim 8

In a fuel cell stack according to claim 3 wherein said reformer chambers are interspersed between groups of about five to about ten adjacent fuel cell units.

Claim 9

In a fuel cell stack according to claim 1 wherein said separator plates are pressed metal plates about 0.010 to about 0.050 inch thick.

Claim 10

In a fuel cell stack according to claim 1 wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed sheet metal shape forming said extended peripheral wet seal fastened to said other face of said separator plates.

Claim 11

In a fuel cell stack according to claim 1 wherein said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed sheet metal shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 12

In a fuel cell stack according to claim 1 wherein the width of said wet seals are about 1/4 to about 3/4 inch.

Claim 13

In a fuel cell stack according to claim 1 wherein said separator plates on the side facing said anode are coated or clad with a metal selected from the group consisting of nickel and copper.

Claim 14

In a fuel cell stack according to claim 1 wherein said electrolyte comprises a solid ion conductor/solid oxide compound.

Claim 15

In a fuel cell stack according to claim 1 wherein said electrolyte comprises alkali metal carbonates.

Claim 16

In a fuel cell stack according to claim 14 wherein said electrolyte is assembled into the fuel cell stack in the form of carbonate tapes and matrix tapes.

Claim 17

In a fuel cell stack according to claim 14 wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed sheet metal shape forming said extended peripheral wet seal fastened to said other face of said separator plates and said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed sheet metal shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 18

In a fuel cell stack according to claim 1 wherein a current collector is between at least one of said anode and said cathode and said separator plate.

Claim 19

In a fuel cell stack comprising a plurality of fuel cell units, each said fuel cell unit comprising an anode and a cathode, an electrolyte in contact on one side with the electrolyte facing face of said anode and in contact on the opposite side with the electrolyte facing face of said cathode, and a separator plate separating said cell units between an anode and cathode forming an anode chamber between the anode facing face of said separator plate and said anode and forming a cathode chamber between the opposite cathode facing face of said separator plate and the separator facing face of the cathode of an adjacent said fuel cell unit, said anode chamber in gas communication with fuel gas supply and outlet and said cathode chamber in gas communication with oxidant gas supply and outlet the improvement comprising: said electrolytes, said anodes, said cathodes, and said separator plates extending to the peripheral edge region of said fuel cell stack, said separator plates having a flattened peripheral wet seal structure extending to contact less than about 1 inch width of at least one of an electrode and a current collector on each face of said separator plates completely around their periphery forming a peripheral wet seal less than about 1 inch width under cell operating conditions, said electrolytes, said anodes, said cathodes, and said separator plates each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure extending to contact less than about 1 inch width of at least one of said electrode and said current collector on each face of said separator plate forming a manifold wet seal less than about 1 inch width under cell operating conditions to form a plurality of gas manifolds extending through said cell stack, conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chambers on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chambers on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack.

Claim 20

In a fuel cell stack comprising a plurality of fuel cell units, each said fuel cell unit comprising an anode and a cathode, an electrolyte in contact on one side with the electrolyte facing face of said anode and in contact on the opposite side with the electrolyte facing face of said cathode, and a separator plate separating said cell units between an anode and cathode forming an anode chamber between the anode facing face of said separator plate and said anode and forming a cathode chamber between the opposite cathode facing face of said separator plate and the separator facing face of the cathode of an adjacent said fuel cell unit, said anode chamber in gas communication with fuel gas supply and outlet and said cathode chamber in gas communication with oxidant gas supply and outlet the improvement comprising: said electrolytes, said anodes, said cathodes, and said separator plates extending to the peripheral edge region of said fuel cell stack, said separator plates having a flattened peripheral wet seal structure extending to contact less than about 1 inch width of at least one of an electrode and a current collector on each face of said separator plates completely around their periphery forming a peripheral wet seal less than about 1 inch width under cell operating conditions, said electrolytes, said anodes, said cathodes, and said separator plates each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure extending to contact less than about 1 inch width of at least one of said electrode and said current collector on each face of said separator plate forming a manifold wet seal less than about 1 inch width under cell operating conditions to form a plurality of gas manifolds extending through said cell stack, conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chambers on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chambers on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack.

Claim 21

In a fuel cell stack according to claim 18 wherein cell stack end plates are configured the same as said separator plates on their inner faces and form half cells on each end of said fuel cell stack.

Claim 22

In a fuel cell stack according to claim 19 wherein said fuel cell stack has interspersed along its axis a plurality of reforming chambers each formed by two separator/reformer plates, one having the configuration of said anode facing face of said separator plate facing one of said anode chambers and the second having the configuration of said cathode facing face of said separator plate facing one of said cathode chambers, said two separator/reformer plates sealingly joined in their edge area to enclose a reformer chamber, conduits through said extended manifold wet seal structure providing reaction gas and steam communication from a third set of said manifolds to said reformer chamber, and conduits through said extended manifold wet seal structure providing enriched hydrogen product gas communication to a fuel gas supply manifold, thereby providing fully internal manifolding of reactant gas and steam to and product gas from each said reformer unit in said fuel cell stack.

Claim 23

In a fuel cell stack according to claim 20 wherein said flattened peripheral wet seal structure on one face of said plates comprises a pressed shaping of said plates to form said extended peripheral wet seal on said one face of said plates and on the other face of said plates comprises a pressed sheet metal shape forming said extended peripheral wet seal fastened to said other face of said plates.

Claim 24

In a fuel cell stack according to claim 21 wherein said extended manifold wet seal structure on one face of said plates comprises a pressed shaping of said plates to form said extended manifold wet seal on said one face of said plates and on the other face of said plates comprises a pressed sheet metal shape forming said extended manifold wet seal fastened to said other face of said plates.

Claim 25

In a fuel cell stack according to claim 19 wherein said reformer chambers are interspersed between groups of about five to about ten adjacent fuel cell units.

Claim 26

In a fuel cell stack according to claim 18 wherein said separator plates are pressed metal plates about 0.010 to about 0.050 inch thick.

Claim 27

In a fuel cell stack according to claim 18 wherein said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed sheet metal shape about 0.010 to about 0.050 inch thick forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 28

In a fuel cell stack according to claim 18 wherein the width of said wet seals are about 1/4 to about 3/4 inch.

Claim 29

In a fuel cell stack according to claim 18 wherein said separator plates on the side facing said anode are coated or clad with a metal selected from the group consisting of nickel and copper.

Claim 30

In a fuel cell stack according to claim 18 wherein said electrolyte comprises a solid ion conductor/solid oxide compound.

Claim 31

In a fuel cell stack according to claim 18 wherein said electrolyte comprises alkali metal carbonates.

Claim 32

In a fuel cell stack according to claim 29 wherein said electrolyte is assembled into the fuel cell stack in the form of carbonate tapes and matrix tapes.

Claim 33

In a fuel cell stack according to claim 29 wherein said flattened peripheral wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended peripheral wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed sheet metal shape forming said extended peripheral wet seal fastened to said other face of said separator plates and said extended manifold wet seal structure on one face of said separator plates comprises a pressed shaping of said separator plates to form said extended manifold wet seal on said one face of said separator plates and on the other face of said separator plates comprises a pressed sheet metal shape forming said extended manifold wet seal fastened to said other face of said separator plates.

Claim 34

A subassembly for a fuel cell unit comprising an anode, a separator plate, and a cathode, said fuel cell unit having said anode, said cathode, and said separator plate extending to the edge region of a fuel cell stack, said separator plate having a flattened peripheral wet seal structure less than about 1 inch width extending form each face completely around their periphery, said anode, said cathode, and said separator plate each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure less than about 1 inch width extending from each face of said separator plate completely around said perforations, conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chamber on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chamber on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack, said anode, said separator plate, and said cathode sealingly joined in each said seal areas.

Claim 35

A subassembly for a fuel cell unit comprising an anode, a separator plate, and a cathode, said fuel cell unit having said anode, said cathode, and said separator plate extending to the edge region of a fuel cell stack, said separator plate having a flattened peripheral wet seal structure less than about 1 inch width extending form each face completely around their periphery, said anode, said cathode, and said separator plate each having a plurality of aligned perforations, said perforations in said separator plates being surrounded by a flattened manifold wet seal structure less than about 1 inch width extending from each face of said separator plate completely around said perforations, conduits through said extended manifold wet seal structure providing fuel gas communication between one set of said manifolds and said anode chamber on one face of said separator plates and conduits through said extended manifold wet seal structure providing oxidant gas communication between a second set of said manifolds and said cathode chamber on the other face of said separator plates, thereby providing fully internal manifolding of fuel and oxidant gases to and from each said unit fuel cell in said fuel cell stack, said anode, said separator plate, and said cathode sealingly joined in each said seal areas.

Claim 36

A subassembly according to claim 32 wherein said sealingly joined comprises welding.

Claim 37

A subassembly according to claim 32 wherein aid separator plate and said wet seal structure are about 0.010 to about 0.050 inch thick and said about 1/4 to about 3/4 inch wide in the flattened portions of the wet seal structures.

Claim 38

A subassembly according to claim 32 wherein a current collector is between at least one of said anode and said cathode and said separator plate.

Claim 39

In a fuel cells tack according to claim 19 wherein said separator and separator/reformer plates are pressed metal plates about 0.010 to about 0.050 inch thick.

Claim 40

In a fuel cell stack according to claim 18, wherein said current collector extends to the peripheral edge region of said fuel cell stack.

Claim 41

A subassembly according to claim 35 wherein said current collector extends to the edge region of said fuel cell stack.