Solid oxide fuel cell stack with reduced-leakage unit cells

Solid oxide fuel cell stacks and methods of sealing a planar solid oxide fuel cell. Unit cells within the stack each include a metal frame with a periphery that can both provide a support surface for a membrane electrode assembly, as well as form a fluid-tight seal with a bonded separator plate. The separator plate includes a peripheral lip that bounds a cell-receiving cavity such that a volumetric region is formed within the separator plate to receive at least a portion of the membrane electrode assembly to create a fluid-tight pathway for at least one of the reactants that is being introduced to a corresponding anode layer or cathode layer of the membrane electrode assembly.

BACKGROUND

The present disclosure relates generally to a solid oxide fuel cell (SOFC), and more particularly to a stack of SOFC fuel cells where each individual unit includes a metal frame that allows a corresponding membrane electrode assembly (MEA) to be sealingly bonded to an adjacent flow separator plate as a way to reduce reactant leakage.

SUMMARY

A planar SOFC stack is made up of multiple unit cells placed on top of one another where each unit cell includes an anode, a cathode and a solid oxide electrolyte sandwiched together as an MEA. The individual unit cells are physically separated from one another by a separator plate that in addition to providing an electrical connection between two individual unit cells includes passages for receiving reactants in the form of air or fuel. With regard to the reactant flow, neither the fuel nor the air should be mixed with one another prior to the introduction of each reactant to a respective one of the anode or cathode of the MEA, as this may adversely affect the performance of the fuel cell. To prevent such mixing and related leakage, a metal frame with an MEA mounted thereon is bonded to an adjacent separator plate to avoid the use of glass sealants or other materials that have a tendency to crack when subjected to minor vibrations or impact, as well as lower-temperature sealant materials (such as polymer-based ones) that cannot withstand typical SOFC operating temperatures.

According to one embodiment of the present disclosure, an SOFC stack includes numerous unit cells aligned along a stacking dimension or axis. Each of the unit cells includes a metal frame made up of a mounting surface upon which an MEA is secured to form a metal supported cell (MSC), as well as numerous fluidly separate reactant passageways to allow the conveyance of fuel through the MEA anode layer and air through the MEA cathode layer, respectively. Each of the unit cells additionally includes a separator plate that has a peripheral lip that bounds a cavity such that at least the anode layer of the MEA is received within a volumetric region that is defined by the cavity and the peripheral lip. At least a portion of the mounting surface of the metal frame is bonded to the peripheral lip such that a fluid-tight seal is formed between them. Additional components, such as stack upper and lower setter plates may be made cooperative with one another to exert a fixing pressure on the various unit cells along the stacking dimension in order to form the SOFC stack.

According to another embodiment of the present disclosure, a method of sealing a planar SOFC includes arranging a metal frame to have a mounting surface, placing an MEA to fit substantially within an aperture defined by the mounting surface, and connecting a separator plate such that the mounting surface of the metal frame is bonded to a peripheral lip of the separator plate in order to form a fluid-tight seal between them. The separator plate includes a peripheral lip that bounds a cavity such that at least an anode layer of the MEA is received within a volumetric region that is defined by the cavity and the peripheral lip.

Additional features and advantages of the embodiments described herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.

DETAILED DESCRIPTION

Embodiments of the present disclosure are directed to an improved SOFC where a bonded connection allows a fluid-tight seal to be formed between a metal frame-supported MEA and an adjacent-facing separator plate in order to substantially prevent air—such as that from the ambient environment or from the cathode flowpath of the MEA—from mixing with the fuel in the region around the anode layer of the MEA. In this way, air leakage can be minimized, which in turn promotes reduction-oxidation stability of the anode layer of the MEA, which in turn reduces the likelihood of anode layer damage. In particular, the bonded connection uses metal structure that through one or both of similar coefficient of thermal expansion (CTE) or thermochemical compatibility achieves a fluid-tight seal that is generally impervious to physical and thermal impact in order to improve long-term stack durability. Furthermore, such bonding may also simplify the manufacturing processes associated with forming the SOFC stack.

Referring first toFIG. 1, an exploded view of an SOFC stack10is shown in a notional two-cell plate-type configuration. Accordingly, two unit cells20include a substantially planar (that is to say, flat) profile that are stacked on top of one another along a Y-axis (that is to say, vertical) stacking dimension in Cartesian space. Within the present context, reference to a particular stacking, location or dimension direction will be understood to be within the context of the Cartesian coordinates depicted inFIG. 1, and that slight deviations from the same due to minor misalignment relative to such spatial reference system are permissible without any loss in generality. Furthermore, as used within the present disclosure, recourse to a particular component or feature as having upper or lower directional attributes will be understood to be based on the depiction of the Cartesian coordinates ofFIG. 1, so that a component exhibiting so-called “upper” attributes will be understood to be father away from the Cartesian axis origin along the positive Y-axis shown than a component exhibiting so-called “lower” attributes. For example, although the SOFC stack10is notionally shown as being built up along the vertical Y-axis; it will be appreciated that the SOFC stack10may be oriented in any suitable orientation, and that any discussion of Cartesian or other directional attributes associated with such orientation will be similarly attributed to the corresponding surfaces, components or other parts of the SOFC stack10. Moreover, although the stack10is shown as containing two unit cells20(as discussed in more detail as follows), it will be appreciated that a greater number of unit cells may be provided, and that all such variants are deemed to be within the scope of the present disclosure.

Each of the first and second unit cells20are spaced apart from one another along the stacking dimension of the Y-axis. Additional interspersed components include intermediate separator plate30, end separator plates40, stack upper and lower setter plates50, metal frames60, MEAs70, channel plates80, gaskets90, gasket rings100, MSC110that is an assembly formed by the joining of a metal frame60to a corresponding MEA70and reactant passageways120, all as will be discussed in more detail elsewhere in this disclosure.

It will be appreciated that the electrochemical interactions using fuel as one reactant and air as the other reactant take place in the MEAs70, and that these interactions in turn provide power in the form of electric current for use by a load, such a motor, auxiliary power unit (APU) or the like. It will likewise be appreciated that the MEAs70are shown inFIG. 1as having a monolayer structure for simplicity, but that in fact are made up of a three-layer structure (such as shown inFIGS. 4B and 4C) with generally planar major surfaces and edgewise minor surfaces where an electrolyte layer74is sandwiched between electrodes in the form of an anode layer72and a cathode layer76such that O2−ions generated at the cathode layer76flow through the electrolyte layer74and react with the fuel (such as H2or CO) air at the anode layer72, while electric current generated by the flow of free electrons produced at the cathode layer76from the reduction of oxygen within the air and consumed during the oxidation of the fuel at the anode layer72can be used to power one or more external device loads. Within the present context, the terms “major” and “minor”—when used to describe a surface—refer to the amount of surface area rather than the relative importance of such surface to the structure or operation of the SOFC stack10in general or one of its components in particular. As such, those surfaces that project a larger surface area (such as the planar surfaces of the anode layer72or cathode layer76of the MEA70that forms a facingly adjacent relationship with either the separator plates30,40) is deemed to be a major surface such as that to which other components or features may be mounted, affixed or otherwise secured, while those that project a smaller area (such as those that correspond to the edges that are formed on MEA70or metal frame60) are deemed to be minor surfaces. As such, terms such as “generally planar”, “edge” or the like will be understood within the present context to be respectively interchangeable with terms describing such major and minor surfaces.

The remaining components that make up SOFC stack10are used to provide mechanical, electrical or fluid-conveying support to the MEAs70. For example, the immediate structural coupling of each MEA70takes place through the metal frame60such that when joined to one another they form a substantially unitary structural coupling in the form of the assembled MSC110. Likewise, the conveyance of reactants to and from each of the MEAs70may take place through the aligned reactant passageways120. In one form, the reactant passageways120are defined as an alignable set of apertures that are formed in the respective intermediate separator plate30, end separator plates40, gaskets90and gasket rings100and that will be described in more detail in conjunction withFIGS. 2A, 2B, 2C and 5. In such form, the reactants may be made to flow along the stacking dimension through the passageways120such that they act as a vertical manifold. In another form, rather than being formed by the integrated assembly of the various aligned and stacked components, the reactant passageways may be situated outside of the SOFC stack10, such as in the form of structurally decoupled conduit. It will be appreciated that these and other configurations on the degree of structural integration between the reactant passageways120and the remainder of SOFC stack10are all deemed to be within the scope of the present disclosure. In the form depicted inFIG. 1, the alignment of these reactant passageways120is such that each pair (formed for example by the fluid joining of opposing corner sections into a fluidly-continuous couplet) promotes a fluidly separate way to respectively convey fuel through the anode layer72and air through the cathode layer76of the MEAs70. By keeping them fluidly separate, the chances of inadvertent mixing of the different reactants is minimized. In one form, the reactant passageways120project predominantly along the stacking dimension in order to convey sufficient quantities of the respective reactant (that is to say, fuel for the anode layer72of the MEAs70and air for the cathode layer76of the MEAs70). This is depicted notionally by the flowpaths corresponding to “fuel in” and “fuel out”, and “air in” and “air out” ofFIG. 1. As will be discussed in more detail in conjunction withFIGS. 2C, 4A through 4C and 5, the reactant passageways120also include laterally-directed branched gates130that allow the diversion of at least some of each of the reactants from the main portion of the passageways120to a corresponding one of the anode layer72or cathode layer76side of each of the MEAs70. Within the present context, a lateral direction for the flow of a reactant is one that proceeds along the X-axis or Z-axis (or along a plane formed by the X-Z axes) relative to the SOFC stack10.

As will be discussed in conjunction withFIGS. 2C(for intermediate separator plate30) and2D and4A through4C (for the end separator plates40), peripheral lips34,44form upstanding walls that project upwardly from generally planar major surfaces36,46to define trough-like volumetric region38,48with which to accept placement of a major surface of a corresponding MSC110. This volumetric region38,48is formed as a generally U-shaped receiving cavity in one of the major surfaces46(in the end separator plates40) or both of the major surfaces36(in the intermediate separator plates30). As will be discussed elsewhere in this disclosure, the volumetric regions38,48are where one of the reactants (that is to say, the fuel or air) flow into and out of as part of their interactions with one another to produce electric current in the MEA70. In one form, the laterally-directed branched gates130are formed as relatively small cutouts in one or more of the upstanding peripheral lips34,44of the respective separator plates30,40that bound the volumetric regions38,48in order to allow the lateral introduction of the reactants from the reactant passageways120and into the volumetric regions38,48. In one form as shown inFIG. 1, these laterally-directed branched gates130cause the corresponding reactant to flow in the X-Z plane that is orthogonal to the flow of the reactants through the main part of the reactant passageways120.

Depending on the diametric size of the flowpath formed by the reactant passageways120, the gasket rings100may be sized to fit within the portion of the passageway120that is defined by the apertures32,42or92of the corresponding intermediate separator plate30, end separator plate40or gasket90such that they may rest upon a lip, ledge or related support structure that may be formed in such apertures32,42or92. By not having the same lateral cutouts or related breeches in their periphery as the laterally-directed branched gates130of the intermediate separator plate30or end separator plate40, the gasket90and gasket rings100inhibit radially-directed flow out of the corresponding passageway120that in turn helps to provide enhanced sealing between the reactant passageways120and the adjacent volumetric regions38,48while preserving reactant flow through the stacking dimension of the reactant passageways120. In addition, the gaskets90may define a full-perimeter structure of a size and shape (for example, having the same general rectangular footprint) as the intermediate separator plate30or end separator plate40. In this way, when compressed between adjacently-facing surfaces of one or more stacked intermediate separator plates30and end separator plates40, the gaskets90help to further reduce any leakage of reactants, as well as of byproduct fluids and air from the ambient environment. The gaskets90may be constructed of a non-conductive compressible material. In one form, the sandwich-like alignment and compliant cooperation between the gaskets90, gasket rings100and the intermediate separator plates30and end separator plates40can be provided through a compressive clamping force from a bolted connection action of the stack upper and lower setter plates50. The gasket rings100may be fabricated from any of a variety of conventional or yet to be developed materials suitable for use in fuel cell assemblies including, for example, glass, glass-ceramics, alumina-felt, ceramic-ceramic, metal-ceramic, mica, and Thermiculite.

In addition to providing a compliant interface between adjacent components as a way to compensate for manufacturing tolerances by providing a minimum fixed distance between such components, the gaskets90may also provide electrical isolation between such components. In fact, maintaining a minimum fixed distance between adjacently facing components helps ensure such electrical isolation, where in one particular form, the minimum fixed distance may prevent the respective separator plates30,40from making electrical contact with one another. Of course, the compressing action produced on the SOFC stack10and the gaskets90should not be greater than their compression limit in order to avoid excessive or unwanted plastic deformation of the material that makes up the gaskets90, as such excessive deformation could lead to—among other things—such a loss in electrical isolation.

The construction as shown for the intermediate separator plate30may allow it to act as a boundary between the two adjacently-stacked unit cells20. In such a configuration, the intermediate separator plate30may act as a bipolar plate in that the volumetric region38can be formed on both opposing side major surfaces36. Furthermore, each opposing side and companion volumetric region38cooperates with a corresponding one of the metal frames60and MEAs70of the MSCs110in order to control the delivery to and removal from the corresponding volumetric region38of a first reactant (such as fuel) on one side and a second reactant (such as air) on the other in a manner understood by those skilled in the bipolar plate art. In one form, the intermediate separator plate30and the end separator plates40are constructed of an electrically conductive material and act as a physical barrier between the unit cells20, while external circuits may also electrically connect an upper one of the unit cells20to a lower one of the unit cells20using a suitable series or parallel connection. Similarly-configured volumetric regions48of the end separator plates40may also be provided on the major surface that is arranged to be facingly adjacent to the corresponding one of the metal frames60and inserted MEAs70of the MSCs110.

The channel plates80may be placed in a facingly adjacent relationship relative to the cathode layer of the MEAs70such that they are disposed between the MEAs70and a corresponding one of the intermediate separator plate30or end separator plate40. The channel plates80are each positioned adjacent a corresponding surface (such as the anode or cathode surfaces) of one of the MSCs110. In one form, the channel plates80may each include one or more respective serpentine channels as shown to help promote the flow of the air to the cathode layer (which will be discussed in greater detail in conjunction withFIGS. 4B and 4C). Although a serpentine configuration is illustrated inFIG. 1, it should be appreciated that this is merely exemplary in nature, and that other configurations, such as a parallel channel arrangement, are also deemed to be within the scope of the present disclosure. In one form, the channel plates80may instead be formed with a porous, foam-like or mesh-like construction in order to promote porosity which in turn facilitates the flow of air from the corresponding reactant passageway120to the cathode layer of each MEA70. In addition, the channel plates80may be used in order to establish electrical continuity with an external load or other electrical circuit for the conveyance of electric current from the unit cell20.

In one form, the SOFC stack10may experience relatively high operating temperatures (that is to say, up to about 1000° C.). It should be appreciated that various components of the SOFC stack10may undergo thermal expansion when subjected to relatively high operating temperatures, which may result in deformation of one or more of the first and second unit cells20and their corresponding supporting components. The upper and lower setter plates50may create a fixing pressure upon the unit cells20to reduce or substantially eliminate the thermal expansion of the unit cells20. More specifically, the upper and lower setter plates50may each exert a compressive force along the stacking dimension through the use of bolts or other fastening or securing means. The amount of fixing pressure exerted upon the various unit cells20may be based on a vertical height the SOFC stack10which in turn may depend upon the number of unit cells20. More specifically, the fixing pressure required to reduce or substantially eliminate the thermal expansion of the SOFC stack10may increase as a height of the SOFC stack10increases. In other words, increasing the number of unit cells20results in a higher fixing pressure required by the SOFC stack10to reduce or substantially eliminate the effects of thermal expansion. Similarly, decreasing the number of unit cells20results in a lower fixing pressure required by the SOFC stack10.

Referring next toFIGS. 2A through 2D, perspective isolated views of each of the gasket90(FIG. 2A), upper end separator plate40(FIG. 2B), intermediate separator plate30with inserted gasket90(FIG. 2C) and lower end separator plate40(FIG. 2D) are shown. Referring with particularity toFIG. 2A, a body94of the gasket90may be shaped to define a central void96and a plurality of conduit-like apertures92that upon aligned stacking correspond to the reactant passageways120. In one form, the conduit-like apertures92are disposed on each of the four corners of the rectangular-shaped body94. Referring with particularity toFIG. 2B, the upward-facing major surface of the upper end separator plate40defines a generally smooth, planar configuration in order to promote low-profile joining to the adjacent stack upper setter plate50. The thickness of the upper end separator plate40along the stacking dimension can be seen edgewise along the peripheral lip44. In addition, a notch N may be integrally formed as part of the upper end separator plate40to promote aligned stacking of it with the upper setter plate50and other components within the SOFC stack10. In one form, a pin or other alignment securing member may be placed within numerous ones of the aligned notches N that may likewise be formed on various other components such as intermediate separator plate30, lower end separator plates40, gaskets90or the like. Referring with particularity toFIG. 2C, the intermediate separator plate30shows the lateral diversions within part of the apertures32and the reactant passageways120in the form of the laterally-directed branched gates130that allow for the introduction and subsequent removal of at least some of each of the reactants from the main portion of one set of coupled sections of the passageways120. The recessed, trough-like nature of the volumetric region38that is formed as a cavity by the peripheral lip34and lower surface36can also be seen. Referring with particularity toFIG. 2D, the upward-facing major surface of the lower end separator plate40defines a cavity and corresponding volumetric region48generally similar in construction to the intermediate separator plate30ofFIG. 2Cthrough the cooperation of the peripheral lip44and lower surface46as a way to form cooperative planar surfaces between the lower end separator plate40and the MSC110as a way to form a fluid-tight seal SF(as will also be discussed in conjunction withFIGS. 4B and 4C). Similarly, the laterally-directed branched gates130act as lateral diversions within part of the apertures42to allow for the introduction and subsequent removal of at least some of each of the reactants from the main portion of one set of coupled sections of the passageways120.

Referring next toFIG. 3, a perspective view is shown of the assembly of the MSC110that is formed by the deposition or other placement of the MEAs70onto a planar major surface62of the metal frame60that defines a substantially planar profile. It will be appreciated that the relative thicknesses of the MEA70and metal from60are not shown to scale, as the edge that corresponds to the minor surface64of the metal frame60is sometimes on the order of 100 μm to 5000 μm or, more narrowly, 100 μm to 300 μm, while that of the deposited anode, cathode and electrolyte layers is sometimes on the order of 50 μm to 100 μm or, more narrowly, about 200 μm. These dimensions are presented as examples only, for context, and should not be used to limit the scope of the present disclosure or claims. The immediate structural coupling of each MEA70takes place through the metal frame60; when joined to one another, each MEA70and corresponding metal frame60forms a substantially unitary structural coupling in the form of the assembled MSC110. Although the MSC110is shown as defining a rectangular shape, it should be appreciated that other shapes that form any number of closed polygons (such as a square, rounded rectangles or the like) may also be used, and that all variants are deemed to be within the scope of the present disclosure. In one form, the metal frame60is made from a gas-permeable metallic foam (such as those with chromium-rich iron-based alloys) in a manner similar to the foam-based or mesh-based variant of the channel plate80to allow for the reactant air ingress to, as well as the egress from, the cathode layer76. Such porous material or metal foam may be produced by known methods, such as powder metallurgy, where sintering may be used as part of the overall powder metallurgy process to control the amount of such porosity. By using powder metals, the metal frame60may avoid some of the durability issues that hamper ceramics. In one form, the cross-sectional surface area of the MEA70is such that it fits on a planar major surface62that acts like a mounting surface of the metal frame60while leaving a peripheral boundary region66that extends beyond the surface area footprint defined by the MEA70uncovered. Within the present context, components such as the metal frame60and channel plate80that exhibit porous structure, construction or related properties are those that allow a flow of reactants (such as fuel) in a gaseous form to travel through the thickness of such components in an amount sufficient to allow the MEA70to perform is electrical current-generating function in the manner for which it is designed.

Referring next toFIGS. 4A through 4C, various views showing the cooperation between one of the separator plates40and the MSC110is shown. Referring with particularity toFIG. 4A(where an optional upper-surface channel plate80that may form part of the unit cell20ofFIGS. 1, 4B and 4Chas been shown in exploded view for clarity), placement of the MSC110onto the separator plate40is such that at least a lower-facing surface of the metal frame60(or optional channel plate (not presently shown)) is disposed within the volumetric region48of an adjacently-facing lower end separator plate40. An elevational perspective view shows the stacked and partially nested relationship between the lower end separator plate40and the MSC110, as well as a substantially planar ledge that defines an upper surface of the peripheral lip44upon which sealed bonding takes place between the separator plate40and a tab68that defines at least a portion of the planar major surface62of the peripheral boundary region66of metal frame60. Although shown presently with an end separator plate40and the MSC110, and as disclosed elsewhere, the present discussion also applies to the bonding, joining or otherwise affixing of the MSC110to one of the intermediate separator plates30.

Referring with particularity toFIGS. 4B and 4C, details associated with the MSC110and the lower end separator plate40both in exploded view ofFIG. 4Bthat is prior to bonding, and the as-assembled view ofFIG. 4Cafter the two components have been bonded are shown. The elevational cutaway view shows the various layers of the MEA70, as well as how the MEA70may be secured to an upper surface of the metal frame60in order to form the MSC110. In one form, the metal frame60may be made to include the tab68by compressing at least a portion of the peripheral boundary region66that forms a part of the planar major surface62. In particular, the porous metal structure of the material making up the metal frame60is amenable to such compression along the stacking dimension, thereby allowing the formation of a location where a thin, flat bonding surface B with which to attach to the corresponding upper surface of the peripheral lip44of the lower end separator plate40. In such construction, the tab66has a thinner profile along the stacking dimension than the central section that forms the planar major surface62. As previously mentioned, the MEA70includes a three-layer structure where a major surface of the anode layer72is placed on one major surface of the electrolyte layer74, while a major surface of cathode layer76is placed on the opposing major surface of the electrolyte layer74. In one form, the anode layer72, electrolyte layer74and cathode layer76are typically made of a porous material in order to promote the relatively free flow of the reactants that are in gaseous form. For example, and not by way of limitation, the electrolyte layer74may be made from zirconia-based electrolytes or ceria-based electrolytes. In specific embodiments, the zirconia-based electrolyte layer74may be selected from yttria stabilized ZrO2(YSZ), scandia stabilized ZrO2(ScSZ), calcia stabilized ZrO2(CSZ) and combinations thereof. Alternatively, the ceria-based electrolyte layer74may comprise rare earth doped ceria. For example, the ceria-based electrolyte layer74may be selected from the group consisting of gadolinium doped ceria (GDC), yttria doped ceria (YDC), samarium doped ceria (SmDC) and combinations thereof. Likewise, the cathode layer76may be made from any material that exhibits low O2(g) reduction overpotential at the higher operating temperature range of an SOFC while having negligible interactions with the electrolyte layer74. For example and not by way of limitation, the cathode layer76may be made up of doped lanthanum-based perovskites and related substances, such as lanthanum strontium cobalt ferrite (LSCF), lanthanum strontium manganite (LSM), yttria stabilized ZrO2/lanthanum strontium manganite (YSZ-LSM) and combinations thereof. Furthermore, the anode layer72may be made up of ceramic-metallic mixtures (that is to say, cermets) such as those based on metallic nickel with a YSZ skeletal structure. High porosity of the anode layer72helps facilitate the relatively free flow of the fuel (when in gaseous form) that is delivered through its respective reactant passageway120. In one form, the anode layer72and cathode layer76may be made by screen printing, plasma spraying or the like, while the electrolyte layer74may be made by plasma spraying, physical vapor deposition (PVD), sintering, sol-gel, screen printing, wet powder spraying or other known thin-film processes. Additional layers, such as diffusion barrier layers (for example, a cerium-gadolinium oxide (CGO), doped lanthanum-based perovskites or the like) may be used in interfacial regions between the various layers, such as in an electrolyte-to-cathode interface or an anode-to metal substrate layer, where the metal substrate that makes up the metal frame60may be in the form of sintered powder or other structure that may be made to have a measure of porosity that could be used to promote reactant permeability. Such diffusion barrier layers may be formed from known techniques, such as PVD or the like.

Regardless of which form of separator plates30,40are employed, the fluid-tight seal SFformed at the bonding surface B between it and the metal frame60extends over at least some—if not all—of the common contact area of their surface widths within the plane formed by the X-Z axes. In one form, such common contact area extends from the peripheral lip44of the separator plate40to at least a portion of the overlapping outward-extending tabs68of the metal frame60. In one form, the horizontal fluid-tight seal SFextends around the entire perimeter of the upper surface the peripheral lip44of the lower end separator plate40, and at least along the portion of the stacking dimension within the apertures42and accompanying passageways120of the respective intermediate separator plate30that are not occupied by the laterally-directed branched gates130.

The volumetric region48acts as the previously-discussed trough-like receiving cavity, as well as how a formed reactant flow vertical gap GVpermits the flow of a reactant (specifically, fuel as shown) to encounter the channel plate80on its way to the metal frame60and then on to the lower-facing major surface of anode layer72of the MEA70. Although the passageways120and laterally-directed branched gates130that permit the diversion of some of the fuel from the main portion of the passageways120are not shown inFIGS. 4B and 4C, it will be understood from recourse to the rest of the present disclosure that the conveyance of fuel—also referred to as fuel flow F—extends horizontally in the reactant flow vertical gap GVthat is formed between a downward-facing major surface of the channel plate80, the and the upward-facing lower surface46of the lower end separator plate40after having been introduced through laterally-directed branched gates130that permit the diversion of some of the fuel flow F from the main portion of the passageways120.

The tab68that forms the outer perimeter of the metal frame60may be bonded to the peripheral lip44such that the fluid-tight seal SFis formed horizontally between them when assembled together. Such bonding may be in the form of a weld, braze, fastened joint, adhesive or the like. The fluid-tight seal SFsubstantially prevents the outward leakage into the ambient environment of introduced fuel flow F, and also substantially prevents the inward flow of air from the ambient environment into the anode layer72side of the MEA70. In forms where the adjacently-facing surface of the separator plate40is bonded to the metal frame60via weld, the material making up the metal frame60is substantially resistant to deformation during welding. Likewise, the metal frame60and the bonded separator plate40may be constructed of the same electrically conductive material such as, for example, a metal or a metal alloy. In one form, the separator plate40and bonded metal frame60may be constructed of dissimilar electrically conductive materials that both include a similar CTE as a way to help avoid the formation of cracks or other deformities during welding. In a more particular form, the CTE between the separator plate40and the metal frame60(as well as between the anode layer72of the MEA70and the metal frame60) can be tailored in order to be substantially identical, where (for example) the previously-discussed diffusion barrier layers may be used in order to inhibit the interdiffusion of alloy components between adjacent layers.

Although not shown inFIG. 4B, it will be appreciated by those skilled in the art that in situations where the separator plate is configured as an intermediate separator plate30, there is a substantially mirror-image lower-facing structure such that the intermediate separator plate30has bipolar plate features. Likewise, in situations where the separator plate is configured as shown as one or the other of the upper or lower end separator plates40, no such substantially mirror-image opposing surface structure or related bipolar plate features are needed, and that both construction variants will be both understood from the context and within the scope of the present disclosure. Regardless of whether the separator plate is an intermediate separator plate30or one of the end separator plates40, the nesting nature of the placement of the MSC110into the volumetric regions38,48formed within the respective separator plates30,40can be seen. The nested stacking of the MSC110and the adjacent one of the separator plates30,40is such that upon being bonded together (such as by welding or the like as discussed previously), the thickness along the stacking dimension is not significantly greater than that of the separator plate30,40alone. As such, in configurations where the SOFC stack10is made up of numerous unit cells20, the vertical height of the SOFC stack10can be reduced relative to an arrangement where no such nesting is present, thereby allowing for more unit cells20to be packed within a given amount of SOFC stack10height; it will be appreciated that such overall thickness reduction of the unit cells20is particularly beneficial in transportation-based applications (such as the previously-mentioned APU) where packaging and volumetric constraints are particularly acute. Regardless of the manner in which the metal frame60is coupled to the MEA70in the MSC110, the planar major surface62may also provide the stiffness required in order to substantially prevent flexing or bowing of the MEA70.

The MSC110is oriented with respect to the lower separator plate40such that a substantially porous reactant flow continuum is formed by the exposure of the fuel flow F that is traveling along the upward-facing lower surface46of the lower separator plate40in the reactant flow vertical gap GV. Such continuum means that the fuel flow F will encounter—in succession—the anode layer72, planar major surface62of the metal frame60and optional channel plate80. In one form, the reactant flow vertical gap GVis less than about one millimeter in thickness (that is to say, along the stacking dimension). By such sizing, the reactant flow vertical gap GVallows for the fuel flow F to be generally laminar across the receiving lower-facing major surface of the channel plate80and the upward-facing lower surface46of the lower end separator plate40. As such, fuel flow F is made to contact as much of a reactant-facing surface as possible. In one form, a reactant-facing surface is that which first encounters the respective flow of air or fuel. For example, as shown the channel plate80projects downwardly from the remainder of the MSC110such that it extends into the volumetric region48of the separator plate40to be the first part being exposed to the fuel flow F. Likewise, in configurations where the channel plate80may not be present on the fuel side of the unit cell20, the anode layer72projects downwardly from the remainder of the MSC110such that it extends into the volumetric region48of the separator plate40to be the first part of MEA70to be exposed to the fuel flow F.

In addition, a minimum laterally inward distance along the X-axis as shown is between the edges of MEA70and the fluid-tight seal SFso as to provide a thermal barrier horizontal gap GHthat is used to substantially prevent or reduce any thermal shock or related excessive heat transfer that may be experienced by the MEA70as the fluid-tight seal SFis formed. In such a form, the MEA70is inwardly spaced from the tab68of the metal frame60in the plane formed by the X-Z axes to define the thermal barrier horizontal gap GHFor example, if welding is used to create the fluid-tight seal SF, then the thermal barrier horizontal gap GHhelps ensure a low thermal conductivity gas-rich “dead zone” that reduces the edgewise conductance of heat being generated during the welding or other bonding process into the MEA70. In some embodiments, the thermal barrier horizontal gap GHmay extend laterally inward at least about five millimeters, while the length of the bonding line that makes up the fluid-tight seal SFis at least about four millimeters, both in the plane formed in the X-Z axes. Thus, in one form, the ratio of the width of the common seating area that includes the bonding line that makes up the fluid-tight seal SFrelative to the thermal barrier horizontal gap GHis about 0.8, although any lateral width ratio from about 0.5 to about 1.0 is also within the scope of the present disclosure.

Referring next toFIG. 5in conjunction withFIGS. 4B and 4C, an elevated perspective view of an uppermost unit cell20of a portion of the SOFC stack10in an assembled state is shown, where the stack upper setter plate50ofFIG. 1is presently removed for clarity. In particular, the aligned placement of the upper separator plate40is stacked on top of the gasket90that in turn is stacked upon the intermediate separator plate30. In one form, and assuming a vertically-upward movement of fuel being delivered to the various MEAs70of stack10, the fuel flow F may traverse an inlet portion120Iand corresponding outlet portion120Othat are formed at opposite corners of the stack10by the various apertures42,92and32of the respective upper end separator plate40, gaskets90and intermediate separator plate30. It will be appreciated that a comparable flow pattern takes place through the other two inlet and outlet portions120I,120Othat are formed in the opposing corners for the other reactant (air). The fuel flow F initially traverses upward along the stacking dimension through the passageway120and into its inlet portion120Iand then through the various laterally-directed branched gates130that correspond to each of the respective intermediate separator plate30and upper end separator plate40. The fuel flow F may then pass horizontally through the various vertical gaps GVas shown, where the size and shape of this reactant flow vertical gap GVhelps promote the previously-discussed generally laminar flow. Lastly, the portion of the fuel flow F that has not diffused through the anode layer72and electrolyte layer74in order to react with air that has been conveyed in a similar manner to the cathode layer76traverses through the laterally-directed branched gates130at the opposite corner of the upper separator plate40and then downward along the stacking dimension through the outlet portion120O.

It should be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modifications and variations come within the scope of the appended claims and their equivalents.