USH16H — Fuel cell electrode and method of preparation

Claim 1

Independent Claim 82 words

An electrode for a molten carbonate fuel cell comprising: a generally incompressible porous plaque having interconnecting porosity for gas passage throughout the length and breadth thereof, and; a coherent layer of particulate, electrochemically active catalyst material impregnated and sinter bonded into only one surface section of said plaque thickness leaving a major fraction of said plaque thickness open for gas flow into contact with said coherent layer, said porous plaque extending through the thickness of said coherent layer to restrain compressive creep.

Claim 2

Dependent Claim 82 words

An electrode for a molten carbonate fuel cell comprising: a generally incompressible porous plaque having interconnecting porosity for gas passage throughout the length and breadth thereof, and; a coherent layer of particulate, electrochemically active catalyst material impregnated and sinter bonded into only one surface section of said plaque thickness leaving a major fraction of said plaque thickness open for gas flow into contact with said coherent layer, said porous plaque extending through the thickness of said coherent layer to restrain compressive creep.

Claim 3

Dependent Claim 43 words

The electrode of claim 1 wherein a sheet of electrically conductive, gas impermeable material is bonded to a major surface opposite to said impregnated surface section to define a channel for gas flow into contact with the catalyst material of said coherent layer.

Claim 4

Dependent Claim 34 words

The electrode of claim 1 wherein said porous plaque exhibits general incompressibility by compressing less than 1% in thickness under 90-400 kPa pressure, for 100-500 hours at temperatures of 650° C. to 700° C.

Claim 5

Dependent Claim 30 words

The electrode of claim 1 wherein said porous plaque comprises an electrically conductive metal foam of about 60-99% porosity with a pore size distribution of about 100 to 300 microns.

Claim 6

Dependent Claim 18 words

The electrode of claim 4 wherein said porous plaque is an electrochemically formed skeleton of nickel chromium alloy.

Claim 7

Dependent Claim 42 words

The electrode of claim 1 wherein said porous plaque includes interstitial passages throughout its length and breadth and wherein said coherent layer of catalyst material includes sinter bonded particles within the interstitial passageways of the porous plaque at said one surface section.

Claim 8

Dependent Claim 21 words

The electrode of claim 1 wherein said coherent layer includes electrochemically deposited material within the interconnecting porosity of said porous plaque.

Claim 9

Dependent Claim 29 words

The electrode of claim 1 wherein said coherent layer includes catalytic materials selected from the group consisting of Ni, NiO, lanthium containing oxygenates, lithium containing oxygenates, zirconates and ferrates.

Claim 10

Dependent Claim 45 words

The electrode of claim 1 wherein said porous plaque includes a first thickness of first pore size for receiving particulate catalytic material and a second thickness of smaller pore size for restricting entry of catalytic material while permitting reactant gas distribution to the catalytic material.

Claim 11

Dependent Claim 47 words

The electrode of claim 1 wherein a first pair of opposing edge surfaces are sealed against reactant gas passage and a second pair of opposing edge surfaces are open to permit reactant gas passage, said first opposing pair are aligned generally perpendicular to the second opposing pair.

Claim 12

Dependent Claim 151 words

A fuel cell including a first electrode having a first catalyst for electrolytic reaction of fuel gas and means for admitting fuel gas into contact with said first catalyst, a second electrode having a second catalyst for electrolytic reaction of oxidant gas and means for admitting oxidant gas into contact with said catalyst and a porous matrix containing a molten carbonate electrolyte capable of ionic conduction between said first and said second electrodes wherein at least one of said electrodes comprises a porous plaque of generally incompressible electrically conductive material having a coherent layer of one of said catalysts embedded into only one major surface section of the plaque thickness leaving a major fraction of said plaque thickness with open interconnecting intersticies throughout for passage of reactant gas into contact with said catalyst, said porous plaque extending through the thickness of said one catalyst layer to said molten carbonate electrolyte-containing matrix.

Claim 13

Dependent Claim 151 words

A fuel cell including a first electrode having a first catalyst for electrolytic reaction of fuel gas and means for admitting fuel gas into contact with said first catalyst, a second electrode having a second catalyst for electrolytic reaction of oxidant gas and means for admitting oxidant gas into contact with said catalyst and a porous matrix containing a molten carbonate electrolyte capable of ionic conduction between said first and said second electrodes wherein at least one of said electrodes comprises a porous plaque of generally incompressible electrically conductive material having a coherent layer of one of said catalysts embedded into only one major surface section of the plaque thickness leaving a major fraction of said plaque thickness with open interconnecting intersticies throughout for passage of reactant gas into contact with said catalyst, said porous plaque extending through the thickness of said one catalyst layer to said molten carbonate electrolyte-containing matrix.

Claim 14

Dependent Claim 43 words

The fuel cell of claim 11 wherein said first and second electrodes each comprise a porous plaque of generally incompressible electrically conductive material, each with a major surface section containing embedded catalysts disposed at opposite surfaces of and facing said porous electrolyte matrix.

Claim 15

Dependent Claim 146 words

The fuel cell of claim 12 wherein said porous plaques of both said first and second electrodes having sealed edge surfaces at two generally opposing edges and two open edge surfaces at two generally opposing edges, the open edges are generally perpendicular to the sealed edges and wherein a plurality of said first electrodes, the porous matrices and the second electrodes are assembled into a stack of fuel cells with the sealed edges of said first electrodes in alignment with the open edges of said second electrodes and the open edges of said first electrode in alignment with the sealed edges of said first electrode for coupling to separate supply and discharge manifolds of fuel and oxidant gases and wherein each of said electrodes having a gas impermeable sheet bonded to the major surface of said porous plaque opposite to the surface section containing said catalyst.

Claim 16

Dependent Claim 32 words

The fuel cell stack of claim 13 including porous plaques that exhibit a compressibility of less than 1% in height after about 500 hours duration, 100-400 kPa load and 650°-700° C. temperature.

Claim 17

Dependent Claim 20 words

The fuel cell of claim 11 wherein the one catalyst is embedded particulate material in said one major surface section.

Claim 18

Dependent Claim 33 words

The fuel cell of claim 11 wherein said one catalyst is electrochemically deposited material in said one major surface section and wherein there is included electrochemically deposited reforming catalyst in said porous plaque.

Claim 19

Independent Claim 109 words

A method of preparing an electrode component for a fuel cell comprising: providing a generally incompressible porous plaque of electrically conductive material having interconnecting interstices throughout; impregnating a section contiguous to only one major surface with a catalyst having electrochemical activity while leaving an adjacent section contiguous to the opposite major surface unfilled to permit passage of reactant gas through said porous plaque; sealing opposing edges of said porous plaque to bar reactant gas entry or discharge while leaving alternate opposing edges open to admit and discharge reactant gases, and; affixing a gas impermeable sheet to the major surface opposite to said impregnated surface section of said porous plaque.

Claim 20

Independent Claim 109 words

A method of preparing an electrode component for a fuel cell comprising: providing a generally incompressible porous plaque of electrically conductive material having interconnecting interstices throughout; impregnating a section contiguous to only one major surface with a catalyst having electrochemical activity while leaving an adjacent section contiguous to the opposite major surface unfilled to permit passage of reactant gas through said porous plaque; sealing opposing edges of said porous plaque to bar reactant gas entry or discharge while leaving alternate opposing edges open to admit and discharge reactant gases, and; affixing a gas impermeable sheet to the major surface opposite to said impregnated surface section of said porous plaque.

Claim 21

Dependent Claim 43 words

The method of claim 17 wherein particles of solid electrochemical catalyst are blended with a polymeric binder into a paste, the paste is formed into a sheet and pressed into a section of said porous plaque contiguous with only one major surface thereof.

Claim 22

Dependent Claim 27 words

The method of claim 18 wherein said particles of electrochemical catalyst are sinter bonded together within intersticies of said porous plaque while driving off said polymeric binder.

Claim 23

Dependent Claim 49 words

The method of claim 17 wherein said catalyst is electrochemically deposited into said porous plaque and wherein a gas impermeable sheet is bonded to the major surface opposite to said impregnated surface section and additional gas impermeable sheet sections are bonded to the opposing edges of said porous plaque.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1989-01-06	1989-07-08	1990-01-07	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1993-01-06	1993-07-08	1994-01-07	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1997-01-06	1997-07-08	1998-01-07	$7700.00	Window Closed / Lapsed

Fuel cell electrode and method of preparation

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag