FUEL CELL

Abstract: In a fuel cell according to the present inven­ tion, a plurality of unit cells (l2) each includes an anode (l5) and a cathode (l6), each formed of a porous substrate, and an electrolyte matrix layer (l4) interposed between the anode (l5) and the cathode (l6). A fuel gas channel (25) is formed on one surface of the anode (l5) that is located on the side opposite to the electrolyte matrix layer (l4), and an electrolyte-solution permeable portion (l7-l) is formed on the same surface of the anode. The unit cells (l2) are stacked in layers, and a plurality of separator elements (l3) are interposed between the adjacent unit cells (l2) to form a stacked structure. Each of the separator elements (l3) has a recess (30) formed on its surface that is located on the side facing the anode (l5). The recess (30) serves to store an electrolyte solution and contain the electrolyte-­ solution permeable portion (l7-l). Thus, if an electrolyte solution, with which the electrolyte matrix layer (l3) is impregnated, is reduced, the solution stored in the recess permeates the matrix layer (l3), flowing through the permeable portion (l7-l). As a result, the voltage of the fuel cell is prevented from dropping, thus permitting a prolonged continuous operation of the fuel cell.

Description: The present invention relates to a fuel cell, and more specifically, to a fuel cell having an electrolyte matrix layer impregnated with an electrolyte solution (e.g., phosphoric acid solution). Generally, in fuel cells, an easily oxidizable fuel gas (e.g., hydrogen gas) and an oxidant gas (e.g., oxygen gas) having oxidizing capability are subjected individually to electrode reactions. By these reactions, free energy of Gibbs is released and taken out as electric power. These fuel cells are advantageous in having high power-generation efficiency and in being pollution-free. One such prior art fuel cell comprises a number of unit cells, for use as minimum generator elements, and separator plates electrically connecting the unit cells. In the fuel cell of this type, the unit cells are stacked in layers, and the separator plates are interposed individually between the adjacent unit cells. This configuration is necessary because a number of unit cells must be arranged in series, in order to enable the fuel cell to produce a high electromotive force, since each unit cell can produce an electromotive force of only l V or less. Each unit cell includes an anode and a cathode, each formed of a porous substrate, and an electrolyte matrix layer interposed between them. The matrix layer is impregnated with an electrolyte solution of a very high concentration, e.g., 95-% phosphoric acid solution. An anode catalyst layer is formed on the matrix-side surface of the anode, while a cathode catalyst layer is formed on the matrix-side surface of the cathode. The fuel cell is further provided with a fuel gas channel, used to feed the fuel gas to the anode, and an oxidant gas channel through which the oxidant gas is fed to the cathode. Depending on the locations of these channels, fuel cells are generally classified into the following three types. A first one is a so-called bipolar type, in which a fuel gas channel and an oxidant gas channel are formed individually in two opposite surfaces of a separator plate. A second one is a so-called ribbed-substrate type, in which a fuel gas channel is formed in the separator-side surface of an anode, and an oxidant gas channel is formed in the separator-side surface of a cathode. A third one is a so-called hybrid type, in which a fuel gas channel is formed in the separator-side surface of an anode, and an oxidant gas channel is formed in the cathode-side surface of a separator. Fuel cells of the hybrid type are commonly used, in view of the strength of the stacked structure and the ease of diffusion of the oxidant gas. If the fuel gas and oxidant gas are delivered to the anode and cathode in each unit cell, and brought into contact with the anode and cathode catalyst layers, respectively, the following electrode reactions take place: H₂ → 2H⁺ + 2e ... (l) on the anode side, and ½0₂ + 2H⁺ + 2e → H₂O ... (2) on the cathode side. During these reactions, H⁺ in the electrolyte solution, with which the electrolyte matrix layer is impregnated, functions as a medium for charge transfer. After the electrode reactions, the fuel and oxidant gases are discharged through their respective channels. With the progress of the electrode reaction, as indicated by formula (2), water is produced. The water tends to lower the concentration of the electrolyte solution. In order to prevent the concentration reduction, the water is discharged quickly with the oxidant gas. At the same time, however, some of the electrolyte solution is discharged, so that the solution in the electrolyte matrix layer is reduced. Thus, the matrix layer increases its resistance, thereby lowering the voltage of the fuel cell. In the prior art fuel cells, therefore, if the electrolyte solution is reduced, the electrolyte matrix layer is replenished with electrolyte solution, to prevent the fuel cell voltage from dropping. In the fuel cells of the popular hybrid type, the fuel gas channel of the anode is defined by a plurality of porous ribs, which have been previously impregnated with the electrolyte solution. If the electrolyte solution in the electrolyte matrix layer lessens, the solution in the ribs is delivered to the matrix layer, after permeating the porous anode. Thus, the matrix layer is replenished with the electrolyte solution, thereby maintaining the quantity of the solution therein, so that the voltage of the fuel cell is prevented from dropping. If all the voids of the porous anode are filled up with the electrolyte solution, however, the fuel gas cannot reach its reaction point. Accordingly, the electrolyte solution is reserved only in about 60 % of the voids of the anode. In the conventional fuel cells, therefore, the electrolyte solution cannot be resupplied to a level high enough to permit a continuous operation of the fuel cell for 40,000 hours, which is a commercial power-generating time. Moreover, a bank portion is formed on either side of the fuel gas channel of the anode. It is formed with a channel, capable of storing an electrolyte solution, for use as an alternative solution resupply means. During operation of the fuel cell, the electrolyte solution in this channel permeates the electrolyte matrix layer, so that the matrix layer is replenished. Since the bank portion is relatively small, the channel can store only a relatively small quantity of electrolyte solution. Thus, in the prior art fuel cells, as in the aforementioned case, the electrolyte solution cannot be resupplied to the level for a continuous operation for the commercial power generating time, 40,000 hours. In replenishing the channel with the electrolyte solution, furthermore, the stacked structure must be disassembled. Therefore, the maintenance of the fuel cell requires much time. The object of the present invention is to provide a fuel cell which can be replenished easily with an electrolyte solution, for a prolonged continuous operation. In a fuel cell according to the present invention, a plurality of unit cells each includes an anode and a cathode, each formed of a porous substrate, and an electrolyte matrix layer interposed between the anode and the cathode. The anode has an anode catalyst layer formed on its one surface that is located on the side of the electrolyte matrix layer, and a fuel gas channel formed on its other surface that is located on the opposite side to the electrolyte matrix layer. An electrolyte-solution permeable portion is formed on the other surface of the anode. The cathode has a cathode electrolyte layer formed on its one surface that is located on the side of the electrolyte matrix layer. The unit cells are stacked in layers, and a plurality of separator elements are interposed between the adjacent unit cells to form a stacked structure. Each of the separator element has a recess formed in the anode-side surface thereof. The recess serves to store an electro­ lyte solution and contain the electrolyte-solution permeable portion. Thus, the recess in the separator element is provided with a necessary quantity of electro­ lyte solution for a prolonged continuous operation of the fuel cell. In this arrangement, if an electrolyte solu­ tion, with which the electrolyte matrix layer is impreg­ nated, is reduced, the solution stored in the recess is fed to the matrix layer through the permeable portion. As a result, the electrolyte matrix layer is replenished with the electrolyte solution, thereby maintaining the quantity of the solution therein, so that the voltage of the fuel cell is prevented from dropping. Thus, the fuel cell can be operated continuously for a long time. This invention can be more fully understood from the following detailed description when taken in conjunction with the accompanying drawings, in which: Fig. l is an exploded perspective view of a stacked structure constituting a fuel cell according to the present invention; Fig. 2 is a perspective view, as taken from the bottom side, showing an anode constituting the stacked structure of Fig. l; Fig. 3 is a perspective view, as taken from the top side, showing a separator plate constituting the stacked structure of Fig. l; Fig. 4 is a sectional view of the stacked structure shown in Fig. l; Fig. 5 is a graph showing the relationship between unit cell voltage and operating time, obtained as a result of experiments on a fuel cell according to the invention and a prior art fuel cell; Fig. 6 is a sectional view of a stacked structure constituting a fuel cell according to a second embodiment of the invention; and Fig. 7 is an exploded perspective view of the stacked structure according to a third embodiment of the invention. As shown in Fig. l, stacked structure ll, consti­ tuting a fuel cell, comprises unit cells l2, as minimum generator elements, and separator plates l3 for electri­ cally connecting cells l2. In structure ll, cells l2 are stacked in layers, and one separator plate l3 is inter­ posed between each two adjacent cells l2. The fuel cell of Fig. l is of the so-called hybrid type. In Figs. l to 7, arrows X (X-l, X-2) and Y (Y-l, Y-2) indicate specific directions of stacked structure ll, for the ease of illustration of embodiments of the invention. Each unit cell l2 includes electrolyte matrix layer l4, anode l5 disposed in intimate contact with the lower surface of layer l4, and cathode l6 in intimate contact with the upper surface of layer l4. Matrix layer l4 is formed of a kneaded mixture of silicon-carbide powder, with particle diameter of 3 to 5 µm, and 6 %, by weight, of polytetrafluoroethylene. Layer l4 is impregnated with an electrolyte solution, e.g., 95-% phosphoric acid solution. Anode l5 is formed of a porous carbon substrate shaped like a flat plate. As shown in Fig. 2, a plurality of first ribs l7, extending in the X-direction, are formed on the lower surface of anode l5. Second ribs l7-l, extending in the X-direction, are formed on the respective top faces of ribs l7. Ribs l7-l are housed in recess 30 (mentioned later) of each separator plate l3, and are permeated with the electrolyte solu­ tion, Thus, the second ribs constitute an electrolyte-­ solution permeable portion, through which the solution is supplied to electrolyte matrix layer l4. The top faces of first ribs l7 are formed with stepped portion 23, extending along the periphery of anode l5. Grooves 22, formed between ribs l7, define fuel gas channel 24. Those first and second ribs l7 and l7-l located in the center of anode l5 are formed with communication channels 2l, which connect adjacent grooves 22. Anode catalyst layer 25 is formed on that surface of anode l5 on the side of matrix layer l4. Anode l5 is formed of a porous carbon substrate whose bulk specific gravity ranges from 0.50 to 0.55. Anode catalyst layer 25 is formed of a kneaded mixture of catalyst powder, including fine particles of furnace black and 3 %, by weight, of platinum black, educed thereon, and 8 %, by weight, of polytetrafluoroethylene suspension. The mixture is coated on the matrix-side surface of anode l5. A 30-% suspension of polytetrafluoroethylene is sprayed on the inner surface of fuel gas channel 24 or those of grooves 22, at a rate of 5 to l0 mg per unit area, and is then dried. The dried suspension is heated at 340°C for 5 minutes, for waterproofing. Fluorine-contained elastomer is applied to the separator-side surface of anode l5, in order to prevent oxidant gas from mixing with the fuel cell. Cathode l6 is formed of porous graphitized carbon paper, having a bulk specific gravity of 0.42 to 0.45. The carbon paper is impregnated with a 30-% suspension of polytetrafluoroethylene, for waterproofing. Further, it is dried and sintered at 320°C for l0 minutes. Cathode l6 has cathode catalyst layer 26 formed on its one surface that is located on the side of electrolyte matrix layer l4. Layer 26 is formed of a kneaded mixture of catalyst powder with particle diameter of 3 to 5 µm, including fine particles of carbon and l0 %, by weight, of platinum black, educed thereon, and 8 %, by weight, of polytetrafluoroethylene suspension. The mixture is applied to the matrix-side surface of cathode l6. Separator plate l3 is formed of a powdered mixture of natural graphite powder with a mean particle diameter of about l0 µ m, synthetic graphite, novolac phenol resin, and hexamethylene amine. The mixed powder is heated to a high temperature, and formed into a properly shaped member with density of l.8 to l.9. As shown in Fig. 3, moreover, a plurality of ribs 27, extending in the Y-direction, are formed on the cathode-side surface of separator plate l3. Grooves formed individually between ribs 27 define oxidant gas channel 29, which extends at right angles to fuel gas channel 24. Formed on the anode-side surface of plate l3 is recess 30, in which the electrolyte solution is stored. Bank portion 3l is formed along the periphery of recess 30. When unit cell l2 and separator plate l3 are joined together, second ribs l7-l of anode l5 are fitted in recess 30. In this state, the respective top faces of ribs l7-l are in contact with the bottom surface of recess 30. At the same time, stepped portion 23 of anode l5 is in intimate contact with the top surface of bank portion 3l. Unit cells l2 and separator plates l3 are stacked in layers, in the following manner, thus constituting stack­ ed structure ll. Fifty percent of the voids of first and second ribs l7 and l7-l of anode l5 are impregnated with the electrolyte solution (i.e., 95-% phosphoric acid solution). Anode l5 is laid on top of separator plate l3 so that ribs l7-l are fitted in recess 30. In this state, fuel gas channel 24 of anode l5 is arranged at right angles to oxidant gas channel 29 of plate l3. Electrolyte matrix layer l4 and cathode l6 are arranged on the upper surface of anode l5. In this manner, unit cells l2 are formed by lamination, and separator plate l3 is interposed between each two adjacent cells l2. Thus, stacked structure ll is completed, as shown in Figs. l and 4. In stacked structure ll, the electrolyte solution or 95-% phosphoric acid solution is injected through fuel gas channel 24 into recess 30, at a rate of 0.03 cc/cm². The injected solution spreads all over recess 30 through communication channels 2l in first and second ribs l7 and l7-l. A specific region of structure ll is sealed. A fuel gas manifold (not shown), used to supply fuel gas, is attached to the (X-l)-side face of structure ll. Likewise, an oxidant gas manifold (not shown), used to supply oxidant gas, is attached to the (Y-2)-side face of structure ll. Constructed in this manner, the fuel cell produces electric power as follows. As shown in Fig. 4, the fuel gas, supplied from the fuel gas manifold, advances in fuel gas channel 24. Since anode l5 is porous, the fuel gas is guided through anode l5, thus reaching anode catalyst layer 2, whereupon it undergoes an electrode reaction. After the reaction, the fuel gas flows in the direction of arrow X-2, to be discharged through an exhaust manifold. Meanwhile, the oxidant gas, supplied from the oxidant gas manifold, advances in oxidant gas channel 29. Since cathode l6 is porous, the oxidant gas is guided through cathode l6, thus reaching cathode catalyst layer 26, whereupon it undergoes an electrode reaction. After the reaction, the oxidant gas flows in the direction of arrow Y-2, to be discharged through the exhaust manifold. Water is produced during the electrode reactions, and it is discharged together with unaffected oxidant gas. At the same time, some of the electrolyte solution is discharged with the generated water. Thus, the electrolyte solution in electrolyte matrix layer l4 lessens. The electrolyte solution stored in first and second ribs l7 and l7-l is fed to layer l4 through porous anode l5. If the solution in anode l5 is reduced, the electrolyte solution stored in recess 30 of separator plate l3 permeates second ribs l7-l of anode l5. This solution is fed to layer l4 through first ribs l7. In this manner, matrix layer l4 is replenished with the electrolyte solution, thereby maintaining the quantity of the solution therein, so that the voltage of the fuel cell is prevented from dropping. Thus, the fuel cell can be operated continuously for a long time. Moreover, the electrolyte solution can be filled into recess 30 with only the manifolds removed from the fuel cell, without disassembling the stacked structure. Accordingly, the maintenance of the fuel cell is easy. Products according to the present invention were made on an experimental basis, and were tested. These products have the following measurements. Electrolyte matrix layer l4 is 0.3 mm thick, 600 mm wide, and 600 mm long. Anode l5 is l.8 mm thick, 600 mm wide, and 600 mm long. Grooves 22, defining fuel gas channel 24, have a width of l.6 mm and a depth of l.3 mm, and are arranged at pitches of 3 mm in the Y-direction. Width L of stepped portion 23 is 30 mm, and height H of second ribs l7-l is 0.5 mm. Cathode l6 is 0.4 mm thick, 600 mm wide, and 600 mm long. Separator plate l3 is 3 mm thick, 600 mm wide, and 600 mm long. A fuel cell of this configuration and a conven­ tional hybrid-type fuel cell were operated at 205 °C and 220 mA/cm². In Fig. 5, curve M represents the characteristic of unit cells according to the embodi­ ment of the invention, while curve N indicates the characteristic of prior art unit cells. As seen from Fig. 5, after prolonged operation, the voltage of the unit cells of the invention dropped much less than that of the prior art unit cells did. After 8,000 hours of operation, the unit cell voltage dropped a little. In this case, the operation of the fuel cell was stopped temporarily, an electrolyte solution was resupplied to recess 30 of separator plate l3 in the amount of 0.02 to 0.04 cc/cm². As a result, stable electrode reactions were resumed in the unit cells. The effect of the replenishment was noticed several times, as shown in Fig. 5. Referring now to Fig. 6, a second embodiment of the present invention will be described. In a stacked structure of this embodiment, carbon paper 4l is interposed between the respective top faces of second ribs l7-l of anode l5 and the bottom surface of recess 30 of separator plate l3. Paper 4l has a thickness of 0.2 to 0.3 mm and a porosity of about 80 %. It is highly resistant to acid and heat, and has good electrical conductivity and some elasticity. Therefore, an electrolyte solution can be stored satisfactorily in the carbon paper. Also, the contact between anode l5 and separator plate l3 is improved, thus ensuring higher conductivity. Referring now to Fig. 7, a third embodiment of the present invention will be described. A fuel cell of this embodiment is of the ribbed-substrate type. In this case, cathode 5l is formed with oxidant gas channel 52, and separator plate 53 is formed with recess 54. The fuel cell, comprising a plurality of unit cells and separator plates 53, is operated in the same manner as in the first embodiment. An electrolyte solution stored in recess 54 is supplied to electrolyte matrix layer l4. The present invention is not limited to the embodiments described above. For example, the separator plate may be formed of a carbon plate, which is prepared by binding graphite powder with coal-tar pitch and sintering it, and then impregnating the resulting structure with resor-type phenol resin. The carbon plate, which is highly impermeable to gas, serves to further prevent the fuel gas from mixing with the oxidant gas.

Claims: 1. A fuel cell comprising a plurality of unit cells (l2) stacked in layers, and a plurality of separator elements (l3) formed of a conductive material and interposed between the adjacent unit cells (l2) to form a stacked structure (ll), each unit cell (l2) including an anode (l5) and a cathode (l6), each formed of porous substrate, and an electrolyte matrix layer (l4) interposed between the anode (l5) and the cathode (l6), said anode (l5) having an anode catalyst layer (25) formed on its one surface that is located on the side of the electrolyte matrix layer (l4), a fuel gas channel (24) formed on its other surface that is located the opposite side to the electrolyte matrix layer (l4), said cathode (l6) having a cathode catalyst layer (26) formed on its one surface that is located on the side of the electrolyte matrix layer (l4), an oxidant gas channel (29) formed for supplying the oxidant gas to the cathode (l6), characterized in that an electrolyte-solution permeable portion (l7-l) is formed on one surface of the anode (l5) that surface is located on the side of the separator element (l3), in that the separator element (l3) has a recess (30) formed on its one surface that is located on the side of the anode (l5), and in that the recess (30) is adapted to store an electrolyte solution and contains the electrolyte-solution permeable portion (l7-l). 2. The fuel cell according to claim l, character­ ized in that said electrolyte-solution permeable portion is defined by a plurality of second ribs (l7-l) formed on one surface of the anode facingthe separator element (l3). 3. The fuel cell according to claim l, character­ ized in that said fuel gas channel (24) is defined by grooves between a plurality of first ribs (l7) formed on one surface of the anode (l5) facing the separator element (l3). 4. The fuel cell according to claim 2, charac­ terized by further comprising a communication channel (2l) connecting grooves between the second ribs (l7-l). 5. The fuel cell according to claim 3, character­ ized by further comprising a communication channel (2l) connecting the grooves between the first ribs (l7). 6. The fuel cell according to claim 2, character­ ized in that the respective top faces of said second ribs are in contact with the bottom surface of the recess. 7. The fuel cell according to claim l, character­ ized in that said fuel gas channel (24) and said oxidant gas channel (29) are arranged at right angles to each other. 8. The fuel cell according to claim l, charac­ terized in that said fuel gas channel is defined by grooves between a plurality of first ribs (l7) formed on one surface of the anode facing the separator element (l3), the inner surface of said grooves being waterproofed. 9. The fuel cell according to claim 2, character­ ized by further comprising a porous carbon sheet (4l) interposed between the bottom surface of the recess (30) and the respective top faces of the second ribs (l7-l). l0. The fuel cell according to claim l, character­ ized in that said oxidant gas channel (29) is formed on one surface of the cathode (l6) that surface is located on the side of the separator element (l3). 11. The fuel cell according to claim l0, character­ ized in that said oxidant gas channel (29) is formed on one surface of the separator element (l3) that surface is located on the side of the cathode (l6).

Inventors: SHIROGAMI, TAMOTSU C/O PATENT DIVISION, UENO, MITSUSHI C/O PATENT DIVISION
Applicants: KABUSHIKI KAISHA TOSHIBA
Application year: 1987
Main classification: H01M8
IPC codes: H01M8