The invention relates to compression of cell stacks, more specifically to a force distributor for fuel cell stacks or electrolysis cell stacks in particular for Solid Oxide Fuel Cell (SOFC) stacks or Solid Oxide Electrolysis Cell stacks (SOEC).
In the following the invention will be explained in relation to SOFC stacks. The force distributor according to the invention can however, also be used for other types of fuel cells such as Polymer Electrolyte Fuel cells (PEM), Molten Carbonate Fuel Cells (MCFC) or Direct Methanol Fuel Cells (DMFC). Further, the invention can also be used for electrolysis cells such as Solid Oxide Electrolysis Cells and such cell stacks.
The electro-chemical reactions and the function of a fuel cell or an electrolysis cell is not the essence of the present invention, thus this will not be explained in detail, but considered known for a person skilled in the art.
To increase the voltage produced by the SOFC, several cell units are assembled to form a stack and are linked together by interconnects. These layers of the stack are sealed together with a gas tight and temperature resistant seal such as glass along some or all edges. The interconnects serve as a gas barrier to separate the anode (fuel) and cathode (air/oxygen) sides of adjacent cell units, and at the same time they enable current conduction between the adjacent cells, i.e. between an anode of one cell with a surplus of electrons and a cathode of a neighbouring cell needing electrons for the reduction process. The current conduction between neighbouring electrodes through the interconnect separating the electrodes, is enabled via a plurality of contact points throughout the area of the interconnect. The contact points can be formed as protrusions on both sides of the interconnect. The efficiency of the fuel cell stack is dependant of good contact in these points, and therefore it is crucial that a suitable compression force is applied to the fuel cell stack. This compression force must be large enough and evenly distributed throughout the area of the fuel cell to ensure electrical contact, but not so large that it damages the electrolyte, the electrodes, the interconnect or impedes the gas flow over the fuel cell. The compression of the fuel cell is also vital for the seal between the layers of the stack to keep the stack gas tight. Further, different areas of the cell stack may require different compression forces, the electro chemical active area of the cell stack may require a lower compression force than the sealing areas. Hence, not only must the compression force be evenly distributed over some areas, there can also be a need to tailor the compression force such that a compression force of a first magnitude is evenly applied to some surface areas of the cell stack, but a compression force of a second, third and more magnitudes is evenly applied to other surface areas of the cell stack according to the specific compression requirements of the area in question.
A solution to this problem has been proposed in WO 2008089977 describing how the fuel cell stack has thermally insulating end blocks having one rectangular planar side facing the stack and an opposing side of convex shape. Springs tighten a flexible sheet against the convex shaped face of the end blocks, whereby the spring force is evenly distributed over the stack end areas.
In DE 10250345 a housing surrounding a SOFC is provided and a compressible mat between the stack and the housing provides a compression force to the cells both radially and axially.
WO 2005045982 describes how a multi-function end plate assembly may be used to preferentially compress a region of the fuel cell stack.
In WO 2008003286 a stack is compressed by thermally insulating elements, which are pressed against the stack by an elastic sleeve. The sleeve can for instance be made of silicone or natural caoutchouc.
Yet another stack compression principle is shown in DE 19645111.
The presented known art disclose solutions to compression problems of a fuel cell stack. They address the problems of force providing, but not force distribution as does the present invention. Accordingly all of them have some of the inherent problems:
It is an object of the present invention to solve the mentioned problems by providing a new force distributor for a cell stack.
More specifically, it is an object of the invention to provide a force distributor which compensates for any impurities, roughness, lacking flatness and lacking stiffness of the force provider.
An object of the invention is also to provide a force distributor which allows the force provider to be less heavy, voluminous and expensive.
It is a further object of the invention to provide a force distributor which protects the components of a cell stack against damage.
It is further an object of the invention to provide a force distributor which provides an evenly distributed compression force from a force provider to a cell stack.
It is yet a further object of the invention to provide a force distributor which tailors the compression force to the requirements of local surface areas of a cell stack.
A further object of the invention is to provide a force distributor which enables a cell stack assembly to have quick thermal response relative to state of the art, heavy endplate cell stacks.
A further object of the invention is to provide a force distributor which integrates the sealing of a side gas manifold to at least a part of the force distributor.
A further object of the invention is to provide a force distributor which provides vibration damping and protection of a cell stack.
These and other objects are achieved by the invention as described below.
According to the above objectives of the invention a force distributor is provided for a cell stack. The force distributor is located on at least one end of the cell stack in-between the end face of the cell stack and an end plate which serves as a force provider, providing compression force to the cell stack. The force provider can have a range of forms such as tightening rods in connection with flat steel end plates, it can be in the form of a frame compressing one or more stacks, it can be a manifold or tightening clamps, another adjacent stack, another adjacent force distributor etc. The force provider is defined as anything providing compression force for the cell stack.
The force distributor can be located at both ends of the cell stack: between a bottom end plate and the bottom end of the stack and between a top end plate and the top end of the stack. It is also possible to locate the force distributor within the stack between separate cells of the stack or to combine having the force distributor located on one or two ends of the cell stack as well as on one or more positions within the cell stack. In some embodiments the force distributor itself serves as an end plate to the cell stack, which means the end plate and the force distributor can be one integral unit. For example, the force distributor can have a flat face oriented towards the cell stack and a convex opposite face in connection with force providing tightening clamps or a force providing flexible mat surrounded by a sheet of for instance steel.
The force distributor comprises an at least partially flexible plate or body, optionally with protruding contact areas on at least the face of the plate oriented towards the cell stack. The necessity of the protruding contact areas depends on the partial flexibility of the force distributor. They are necessary if the force distributor face oriented towards the cell stack is so flexible that the force would otherwise be distributed to areas with gas flow channels with the risk of clogging of the gas channels and damage to the cell parts. Flexible is defined as having an E-module less than the E-module of the force provider of the cell stack. The E-module relates in this context to the entire flexible part of the plate, not to the flexible materials components themselves which individually seen as particles can have larger E-modules.
The force distributor can in one embodiment comprise at least two layers, a first layer which is flexible and a second layer which is rigid. Flexible is defined as above and rigid as having a higher E-module than the flexible layer as a whole. The flexible layer faces the force provider. The surface of the force provider, which faces the force distributor (and further on faces the cell stack) is ideally a plane surface. However the force provider is manufactured with geometrical tolerances, which entails deviation from the absolute ideal plane surface. Also roughness, impurities and deflection of the force provider due to thermo-mechanical tensions or uneven force transmitting, results in deviation from the ideal plane surface of the force provider. Also vibrations from the force provider or physical movements in any directions for instance due to thermo mechanical tensions in the force providing structure poses potentially critical problems for the cell stack. The flexible layer of the force distributor is able to absorb these deviations, vibrations and movements, and thus receive the relative unevenly distributed compression force from the force provider and transmit it further on to the second rigid layer as a relative more evenly distributed compression force. The second rigid layer of the force distributor passes the compression force on to the cell stack. The face of the second layer of the force distributor which faces the cell stack can be a plane surface. Because of the limited thickness of the second layer it is possible to manufacture the second layer with a face with more narrow geometrical tolerances. Also thermo-mechanical tensions are less in the thin second layer of the force distributor than in conventional thick endplates. But preferably the face of the force distributor which faces the cell stack comprises protruding contact areas to transmit the compression force, thus tailoring the compression force to the requirements of the cell stack.
In an embodiment of the invention, the first layer of the force distributor can be integral with or serve as an endplate as explained above, which can reduce manufacturing and handling costs. In another embodiment of the invention, the first layer of the force distributor can be integral with the second layer of the force distributor.
In a further embodiment of the invention, the face towards the cell stack of the force distributor second layer can comprise protruding force distributor contact areas. In this embodiment, the compression force will only be distributed to the underlying cell stack at areas with protruding contact areas. Thus, the compression force can be omitted in some areas, such as reaction gas flow channel areas in the cell stack, whereas seal areas and the interconnect contact areas will receive a compression force. The protruding contact areas can even vary in area and height to tailor the compression force to certain areas of the underlying cell stack. E. g. the protruding areas can have a larger area and protrude more where the underlying cell stack has seal areas.
In a further embodiment of the invention, the face towards the force provider of the force distributor second layer can comprise protruding force distributor contact areas. On this face of the force distributor the design of the surface can also be tailored to the compression requirements of the cell stack, because it is possible to vary the relative height of the protruding force distributor contact areas. Accordingly, the seal areas which typically require the largest compression force can receive a larger compression force than the cell stack contact points, by making the corresponding contact areas of the force distributor areas above the sealing areas higher than the force distributor areas above the contact areas of the cell stack. Highest compression force will be distributed from the first flexible layer of the force distributor to the second rigid layer in areas where the protruding contact areas are highest, because those areas will give the highest local compression of the first layer.
A further embodiment of the invention combines the two aforementioned embodiments into a force distributor with protruding force distributor contact areas on both faces of the second rigid layer. The space which forms between the protruding contact areas in any of the embodiments having such protruding areas can be adapted to correspond to gas flow channels of the interconnects, which ensures these gas flow channels are not impeded. Also, said spaces can be adapted to contain sensors, cooling or heating channels.
In one embodiment of the invention, the second layer of the force distributor can be electrically conducting, whereby components and costs can be saved as the current collector plate of the cell stack can be omitted or supported. In case this embodiment is cooperated with the embodiment where the first layer of the force distributor is integrated with the pressure plate, the advantages of the force distributor can be achieved without a greater number of components than in a conventional cell stack.
The first force distributor layer can be made of calcium silicate, micro porous insulation, mica, metal or a fibre mat. The first force distributor layer is flexible, but further the material characteristics of this layer can also be utilised to provide vibration damping of the cell stack and sealing of a reaction gas side manifold to the cell stack. The second force distributor layer can be made of metal alloy or ceramic or other known suitable materials.
1. Force distributor for at least one cell stack, said cell stack comprises
wherein said force distributor comprises an at least partially flexible body with the flexible part oriented towards the at least one force provider.
2. Force distributor according to feature 1, wherein the at least partially flexible body comprises protruding contact areas on at least the face of the plate oriented towards the cell stack.
3. Force distributor according to any of the preceding features, wherein said force distributor comprises a convex face oriented towards the force provider.
4. Force distributor according to any of the preceding features, wherein said force distributor comprises a first and a second force distributor layer, each layer has a first and a second force distributor face, said first force distributor layer is a flexible layer and said second force distributor layer is a rigid layer.
5. Force distributor according to any of the preceding features, wherein said first force distributor layer has an E-module which is higher than the E-module of the force provider.
6. Force distributor according to any of the preceding features, wherein said force distributor is located on at least one of the following positions: between said cell stack top face and said at least one force provider or between said cell stack bottom face and said at least one force provider, and said force distributor is positioned with the second force distributor layer facing the cell stack.
7. Force distributor according to any of the preceding features, wherein at least one of said force distributor is located within said cell stack.
8. Force distributor according to any of the preceding features, wherein said at least one force provider is integral with the first force distributor layer.
9. Force distributor according to any of the preceding features, wherein the protruding contact areas corresponds at least one of: the sealing areas of the cell stack or the interconnect contact areas.
10. Force distributor according to any of the preceding features, wherein at least one of the spaces formed between said protruding contact areas is adapted to contain sensors.
11. Force distributor according to any of the preceding features, wherein at least one of the spaces formed between said protruding contact areas is adapted to form cooling or heating channels.
12. Force distributor according to any of the preceding features, wherein said second force distributor layer is electrically conducting.
13. Force distributor according to any of the preceding features, wherein the force distributor comprises at least one of: calcium silicate, micro porous insulation, mica, metal, a fibre mat, refractory ceramic fibre or glass fibre, magnesia-silica fibre, alumina fibre containing an amount of silica, low alkali aluminosilicate compositions containing one or more of the following oxides: zirconia, chromia or titania or vermiculite.
14. Force distributor according to any of the preceding features, wherein the force distributor comprises at least one of: metal alloy or ceramic.
15. Force distributor according to any of the preceding features, wherein at least a part of said force distributor forms a seal between said cell stack and at least one of: a side inlet gas manifold or a side outlet gas manifold.
16. A Cell stack comprising at least one force distributor according to any of the preceding features, wherein said cell stack is a Solid Oxide Fuel Cell stack or a Solid Oxide Electrolysis Cell stack.
The invention is further illustrated by the accompanying drawings showing examples of embodiments of the invention.
In the Figs. explained below, the details of roughness and deviation from the plane surface (unevenness) is somewhat exaggerated for the sake of understanding.
Referring to
In
A further embodiment is shown in
In a further embodiment (not shown) the face of the second force distributor layer towards the cell stack can be plane, i.e. without protruding areas whereas the face towards the first force distributor layer can have protruding areas similar to the embodiment shown in
In
In
In
For first (flexible) layer of the force distributor:
Fibre mats known as “catalytic converter mats”. E.G. refractory ceramic fibre or glass fibre, preferably magnesia-silica fibre, alumina fibre containing an amount of silica, low alkali aluminosilicate compositions containing one or more of the following oxides: zirconia, chromia or titania or vermiculite.
“CC-Max® 4 HP substrate support mat from Unifrax” is an example of a suitable commercial mat. The elasticity of the mat is described in
Porous material made of calcium silicate which has an E-module of approximately 10 GPa or porous material made of exfoliated vermiculite.
High temperature gasket materials. Gaskets materials can be based on vermiculite, mica, mineral wool, woolastonite, calcium silicate, or other or a mixture of several of the mentioned.
For second (rigid) layer of the force distributor:
An example for the rigid part is a ferritic steel with an E-modulus of around 140 GPa and a thermal expansion coefficient which matches the stack's thermal expansion coefficient.
Number | Date | Country | Kind |
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PA 2010 00532 | Jun 2010 | DK | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2011/002604 | 5/26/2011 | WO | 00 | 12/17/2012 |