High-Volume-Manufacture Fuel Cell Arrangement and Method for Production Thereof

Abstract

A fuel cell which is producible in high volume with electrolyte, positive electrode, and negative electrode components, which incorporate structure, external electrical connections, internal fuel and oxidizer distribution and an exhaust passage to form a simple assembly which can be formed into a stack. The fuel cell can utilize either a rigid or flexible electrolyte.

1 . A fuel cell, consisting of:
 (a) a fuel distributor,   (b) an oxidizer distributor,   (c) a solid electrolyte operatively arranged between the fuel distributor and the oxidizer distributor, wherein   the elements (a), (b) and (c) are configured for selectively forming either a fuel cell with a rigid solid electrolyte or a flexible solid electrolyte.   
     
     
         2 . A fuel cell, consisting of:
 (a) a fuel distributor,   (b) an oxidizer distributor, and   (c) a solid electrolyte operatively arranged between the fuel distributor and the oxidizer distributor, wherein the solid electrolyte comprises a central portion having a positive electrode material and catalyst applied to a first side of the central portion, and a negative electrode material and catalyst applied to a second side of the central portion with fuel feed, oxidizer feed, return and exhaust passages arranged in the frame.   
     
     
         3 . The fuel cell according to  claim 2 , wherein the oxidizer distributor is arranged on the one side of the solid electrolyte and has alternately arranged fuel conduits and exhaust conduits therein congruent with the fuel feed and exhaust passages of the solid electrolyte, fuel and oxidizer vias congruent with solid electrolyte vias, and a plurality of members defining passage areas for the oxidizer, said oxidizer distributor serving as a structural support and as an electrical interconnect for the oxidizer side of the solid electrolyte, incorporating electrical contact lugs extending outwardly thereof. 
     
     
         4 . A fuel cell, consisting of:
 (a) a fuel distributor,   (b) an oxidizer distributor, and   (c) a solid electrolyte operatively arranged between the fuel distributor and the oxidizer distributor, wherein the solid electrolyte comprises a frame with an ion-permissive central portion with fuel feed, oxidizer feed, return and exhaust passages arranged in the frame.   
     
     
         5 . The fuel cell according to  claim 4 , wherein the oxidizer distributor is arranged on one side of the solid electrolyte and comprises an outer frame having alternately arranged fuel conduits and exhaust conduits therein congruent with the fuel and exhaust conduits of the solid electrolyte frame, fuel and oxidizer vias congruent with solid electrolyte vias, and a plurality of members extending between the frame and the vias to define passage areas for the oxidizer; the oxidizer distributor serving as a structural support and as the electrical interconnect for the oxidizer side of the electrolyte, and incorporating electrical contact lugs extending outwardly from the frame, and being composed of nonconductive material with conductive and catalytic material applied on both sides, or of conductive material to which catalytic material is applied on both sides, thus serving, on one hand, as an oxidizer distributor and an electrode, and, on the other hand, as a positive electrode with internal oxidizer distribution. 
     
     
         6 . The fuel cell according to  claim 4 , wherein the fuel distributor is arranged on an opposed side of the central portion and comprises an outer frame having alternately arranged fuel conduits and exhaust conduits therein congruent with the fuel and exhaust conduits of the solid electrolyte frame, fuel and oxidizer vias congruent with the solid electrolyte vias, and a plurality of members extending between the frame and the vias to define permissible areas for the fuel, the fuel distributor serving as a structural support and as an electrical interconnect for a fuel side of the solid electrolyte, incorporating electrical contact lugs which extend outwardly from the frame, and being composed of nonconductive material with conductive and catalytic material applied on both sides, or of conductive material to which catalytic material is applied on both sides, thus serving, on one hand, as a fuel distributor and an electrode and, on the other hand, as a negative electrode with internal fuel distribution. 
     
     
         7 . The fuel cell according to  claim 3 , wherein the components have a central area of material which is the same as, or compatible with, material of the frame and are configured to permit a flow of fuel or oxidizer. 
     
     
         8 . The fuel cell according to  claim 5 , wherein the components have a central area of material which is the same as, or compatible with, material of the frame and are configured to permit a flow of fuel or oxidizer. 
     
     
         9 . The fuel cell according to  claim 6 , wherein the components have a central area of material which is the same as, or compatible with, material of the frame and are configured to permit a flow of fuel or oxidizer. 
     
     
         10 . The fuel cell according to  claim 5 , wherein the oxidizer distributor with electrode or the positive electrode with the internal oxidizer distribution is comprised of three separate components, namely a first oxidizer plate, a second oxidizer plate identical with the first oxidizer plate, and an oxidizer distribution plate operatively arranged between the first and second oxidizer plates, the three separate components being configured to be joined together so as to form a modular oxidizer distributor and electrode assembly or modular positive electrode assembly with internal oxidizer distribution. 
     
     
         11 . The fuel cell according to  claim 6 , wherein the fuel distributor with electrode or negative electrode with internal fuel distribution is comprised of three separate components, namely a first fuel plate, a second fuel plate identical with the first fuel plate, and a fuel distribution plate operatively arranged between the first and second fuel plates; the three separate components being configured to form together a modular fuel distributor and electrode assembly or modular negative electrode assembly with internal fuel distribution. 
     
     
         12 . The fuel cell according to  claim 5 , wherein the oxidizer distributor with electrode, or the positive electrode with internal oxidizer distribution, includes contact shelves on both sides thereof to provide an alternative attachment option for the solid electrolytes. 
     
     
         13 . The fuel cell according to  claim 6 , wherein the fuel distributor electrode, or the negative electrode with internal fuel distribution, includes contact shelves on both sides, thereof providing an alternative attachment for the solid electrolytes. 
     
     
         14 . The fuel cell according to  claim 4 , wherein a combination of electrolyte, distributor and electrolyte contact plates, or a combination of electrolyte and positive and negative electrodes with internal oxidizer and fuel distribution, can be stacked to produce complete modular, fuel cell assemblies. 
     
     
         15 . The fuel cell according to  claim 2 , wherein the oxidizer and fuel distributors are non-conductive. 
     
     
         16 . A fuel cell, consisting of:
 (a) a fuel distributor,   (b) an oxidizer distributor and   (c) a solid electrolyte operatively arranged between the fuel distributor and the oxidizer distributor, wherein the solid electrolyte comprises a frame with an ion permissive central portion having all fuel feed, oxidizer feed, return and exhaust passages arranged entirely within the frame and congruent with corresponding elements of associated cell components to enable an internal plate-to-plate and cell-to-cell passage of fuel, oxidizer and exhaust and to eliminate a need for external inlets and outlets as well as associated external piping to and from each cell or cell component and wherein the cell-to-cell and outside interconnecting passages for the fluid inputs and outputs are integrated.   
     
     
         17 . The fuel cell according to  claim 16 , wherein the distributors have cross and diagonal members which define working areas for a radially outward flow of fuel and oxidizer across the distributors. 
     
     
         18 . A fuel cell, comprising:
 (a) a fuel distributor,   (b) an oxidizer distributor,   (c) a rigid or flexible electrolyte operatively arranged between the fuel distributor and the oxidizer distributor, wherein   the elements (a), (b) and (c) together, by themselves, form a complete fuel cell with a rigid solid electrolyte or a flexible solid electrolyte.   
     
     
         19 . A fuel cell, comprising:
 (a) a fuel distributor,   (b) an oxidizer distributor, and   (c) a solid or flexible electrolyte operatively arranged between the fuel distributor and the oxidizer distributor,   wherein the solid electrolyte comprises a central portion having electrode material and catalyst applied to first and second sides of the central portion, and electrode material and catalyst applied to a second side of the central portion, with fuel feed, oxidizer feed, return and exhaust passages arranged in the frame so as to define with elements (a) and (b) a complete fuel cell.   
     
     
         20 . A fuel cell, comprising:
 (a) a fuel distributor,   (b) an oxidizer distributor, and   (c) an electrolyte operatively arranged between the fuel distributor and the oxidizer distributor,   wherein the electrolyte has a frame with an ion permissive central portion with fuel feed, oxidizer feed, return and exhaust passages arranged entirely within the frame and congruent with corresponding fuel feeds, oxidizer feeds, returns, and exhaust passages of associated cell components to define a complete fuel cell with assembly of components to define a complete fuel cell with assembly of components (a), (b), and (c) thereby to enable an internal plate-to-plate and cell-to-cell passage of fuel, oxidizer, and exhaust among the components (a), (b), and (c) and to eliminate external inlets and outlets as well as associated external piping to and from each cell or cell component.