Fuel cell battery and solid electrolyte fuel cells therefore

Claim 2

A fuel cell for a fuel cell battery, comprising: an active cell element comprised of a support electrode, a counterelectrode, and an electrolyte layer positioned between the support electrode and the counterelectrode, wherein the support electrode supports the active cell element and includes an edge region, a spring-loaded region, and a porous region provided between the edge region and the spring-loaded region, the support electrode being composed of a metallic substance and the edge region, porous region and spring-loaded region of the support electrode being composed of the same metallic substance, and wherein the support electrode has a thickness effective to provide a transverse electrical conductivity which is effective to produce a uniform electrochemical reaction homogeneously distributed over the electrolyte layer, wherein the spring-loaded region mechanically decouples the active cell element of the fuel cell for a fuel cell battery from frame structure thereby protecting the electrolyte layer from thermally induced mechanical stresses produced by differing coefficients of expansion of materials, wherein the counterelectrode is porous and composed of a metallic substance, and wherein the electrolyte layer is gastight and is composed of an oxide.

Claim 3

The fuel cell for a fuel cell battery according to claim 1, wherein the support electrode is comprised of at least one flat metal plate having a shape which is one of round or rectangular, having a thickness which is at least effective to withstand mechanical stresses to which the support electrode is to be exposed, and wherein the edge region has a thickness which is at least twice as thick as the thickness of the at least one metal plate.

Claim 4

The fuel cell for a fuel cell battery according to claim 1, wherein the support electrode has a shape which is cylindrical and has an internal diameter which ranges from 1 to 5 cm.

Claim 5

The fuel cell for a fuel cell battery according to claim 1, wherein the spring-loaded region of the support electrode extends and surrounds the active cell element on all sides.

Claim 6

The fuel cell for a fuel cell battery according to claim 1, wherein the porous region of the support is produced by thermal spraying of a powder of the metallic substance of the support electrode, the powder having a particle size wherein the porous region has at thickness corresponding at least to that of the support electrode, and wherein the porous region has a porosity which is selected by selecting the particle size of the powder which is thermally sprayed.

Claim 7

The fuel cell for a fuel cell battery according to claim 5, wherein the powder has a particle size ranging from 15 to 125 μm, and wherein about 20% of the particles have a particle size below 32 μm and about 40% of the particles have a particle size above 62 μm thereby producing a porosity of 40% and a mean pore size of about 25 μm.

Claim 8

The fuel cell for a fuel cell battery according to claim 5, wherein thermal spraying is vacuum plasma spraying.

Claim 9

The fuel cell for a fuel cell battery according to claim 1, wherein the support electrode is composed of a metallic substance which is a high-temperature alloy, wherein the support electrode may be a cathode or an anode, and wherein the metallic substance for the support electrode is selected in dependence upon the atmosphere to be encountered in use, which atmosphere is selected from the group consisting of an oxygen-containing gas and a fuel gas.

Claim 10

The fuel cell for a fuel cell battery according to claim 1, wherein the porous region of the support electrode is incorporated into the support electrode by sintering a powder of the metallic substance, and wherein the porous region has a porosity which is a function of at least one of the sintering powder and sintering conditions.

Claim 11

The fuel cell for a fuel cell battery according to claim 8, further comprising a boundary layer provided between the support electrode and the electrolyte layer to at least one of improve the electrical contact therebetween or catalytically accelerate the electrochemical reaction, and having a thickness ranging from about 1 to about 10 μm.

Claim 12

The fuel cell for a fuel cell battery according to claim 10, wherein the support electrode is a cathode, and wherein the boundary layer is composed of perovskite.

Claim 13

The fuel cell for a fuel cell battery according to claim 1, wherein the electrolyte layer is composed of at least one metal oxide, and wherein the electrolyte layer is provided directly onto at least the porous region of the support electrode and has at thickness which does not exceed 100 μm, whereby an effective oxygen ion conductivity, gas-tightness, and adequate insulation against electron conduction are simultaneously provided.

Claim 14

The fuel cell for a fuel cell battery according to claim 12, wherein the electrolyte layer is produced by vapor plasma spraying of a powder composed of cubic ZrO 2 containing 12% by weight of Y 2 O 3 which thereby stabilizes the cubic ZrO 2 and has a particle size ranging from 6 to 16 μm whereby a dense finely lamellar electrolyte layer structure is produced having a homogeneous residual leakage rate of below 10 -6 mbar.1/cm.s over the electrolyte layer.

Claim 15

The fuel cell for a fuel cell battery according to claim 13, wherein the residual leakage rate is such that no more than 15% of fuel gas burns in a uniformly distributed manner over the surface of the electrolyte layer so that a temperature favorable for oxygen ion conductivity is established in the electrolyte layer and so that the thermal production of CO by internal reforming from CH 4 , CO 2 and H 2 O are simultaneously obtained.

Claim 16

The fuel cell for a fuel cell battery according to claim 1, wherein the counterelectrode is deposited directly onto the electrolyte layer by thermal spraying of a powder, and wherein the counterelectrode has a porosity which is a function of at least one of the powder and deposition parameters.

Claim 17

The fuel cell for a fuel cell battery according to claim 15, wherein the counterelectrode has a porosity of 40% and a mean pore size of 25 μm.

Claim 18

The fuel cell for a fuel cell battery according to claim 15, wherein the powder to be thermally sprayed is composed of a mixture of Ni and ZrO 2 , whereby a cermet layer is produced having a percent by volume of Ni ranging between 25 and 75%, and wherein the mixture has a particle size ranging from 6 to 75 μm.

Claim 19

A fuel cell battery, comprising: a frame structure; and a plurality of fuel cells which are interconnected with the frame structure and with one another in a gastight manner, and which are electrically connected to one another in series, each fuel cell being comprised of: an active cell element comprised of a support electrode, a counterelectrode, and an electrolyte layer positioned between the support electrode and the counterelectrode, wherein the support electrode supports the active cell element and includes an edge region, a spring-loaded region, and a porous region provided between the edge region and the spring-loaded region, the support electrode being composed of a metallic substance and the edge region, porous region and spring-loaded region of the support electrode being composed of the same metallic substance, and wherein the support electrode has a thickness effective to provide a transverse electrical conductivity which is effective to produce a uniform electrochemical reaction homogeneously distributed over the electrolyte layer, wherein the spring-loaded region mechanically decouples the active cell element of the fuel cell for a fuel cell battery from frame structure thereby protecting the electrolyte layer from thermally induced mechanical stresses produced by differing coefficients of expansion of materials, wherein the counterelectrode is porous and composed of a metallic substance, and wherein the electrolyte layer is gastight and is composed of an oxide, wherein the spring-loaded region of each fuel cell for a fuel cell battery is connected to the frame structure to provide a mechanical frictional connection therebetween which is decoupled thereby protecting the electrolyte layer from thermally induced mechanical stressed produced by differing coefficients of expansion of materials.

Claim 20

A fuel cell battery, comprising: a frame structure; and a plurality of fuel cells which are interconnected with the frame structure and with one another in a gastight manner, and which are electrically connected to one another in series, each fuel cell being comprised of: an active cell element comprised of a support electrode, a counterelectrode, and an electrolyte layer positioned between the support electrode and the counterelectrode, wherein the support electrode supports the active cell element and includes an edge region, a spring-loaded region, and a porous region provided between the edge region and the spring-loaded region, the support electrode being composed of a metallic substance and the edge region, porous region and spring-loaded region of the support electrode being composed of the same metallic substance, and wherein the support electrode has a thickness effective to provide a transverse electrical conductivity which is effective to produce a uniform electrochemical reaction homogeneously distributed over the electrolyte layer, wherein the spring-loaded region mechanically decouples the active cell element of the fuel cell for a fuel cell battery from frame structure thereby protecting the electrolyte layer from thermally induced mechanical stresses produced by differing coefficients of expansion of materials, wherein the counterelectrode is porous and composed of a metallic substance, and wherein the electrolyte layer is gastight and is composed of an oxide, wherein the spring-loaded region of each fuel cell for a fuel cell battery is connected to the frame structure to provide a mechanical frictional connection therebetween which is decoupled thereby protecting the electrolyte layer from thermally induced mechanical stressed produced by differing coefficients of expansion of materials.

Claim 21

The fuel cell battery according to claim 18, further comprising a plurality of contact assemblies each comprised of a contact part which is metal, an insulating element, and a sprung part, the insulating element connecting the contact part to the sprung part, and wherein each fuel cell for a fuel cell battery is tubular and has an edge region extending from the support electrode, and wherein the edge region of the support electrode of one fuel cell for a fuel cell battery is electrically connected in series with the counterelectrode of a next fuel cell for a fuel cell battery by one contact assembly of the plurality of contact assemblies, the edge region of the support electrode being connected to the contact part of the contact assembly and the counterelectrode contacting the sprung part of the contact assembly, whereby electrical insulation between support electrodes of adjacent fuel cells is provided by the insulating element of respective contact assemblies.

Claim 22

The fuel cell battery according to claim 19, wherein a plurality of chambers are defined within the fuel cell battery through which flow, respectively, a fuel gas and an oxygen-containing gas in a selected mass flow ratio.

Claim 23

The fuel cell battery according to claim 20, wherein the selected mass flow ratio is provided by selecting dimensions of insulating elements, and wherein the insulating elements are dimensioned so that the mass flow ration provides a flow of air which ranges up to ten times the flow of fuel gas.

Claim 24

The fuel cell battery according to claim 18, further comprising a plurality of contact assemblies each comprised of an insulating element and a sprung part connected to one another, each sprung part contacting a counter-electrode and each insulating element contacting an edge region of a support electrode, wherein each fuel cell for a fuel cell battery is planar, and has a shape which is one of round or rectangular, and wherein the plurality of fuel cells are connected together using planar technology so that support electrodes of adjacent fuel cell for a fuel cell battery are electrically connected in series through contact points which are extended outside of the fuel cell battery, the contact points comprising edge regions of support electrodes and sprung parts of contact assemblies, the edge region of the support electrode of one fuel cell for a fuel cell battery being electrically connected in series through a sprung part to the counterelectrode of a next fuel cell for a fuel cell battery.