Electrochemical cell stack assembly

Abstract

Multiple stacks of tubular electrochemical cells having a dense electrolyte disposed between an anode and a cathode preferably deposited as thin films arranged in parallel on stamped conductive interconnect sheets or ferrules. The stack allows one or more electrochemical cell to malfunction without disabling the entire stack. Stack efficiency is enhanced through simplified gas manifolding, gas recycling, reduced operating temperature and improved heat distribution.

What is claimed is:  
     
         1 . An electrochemical cell stack assembly, comprising: 
 a plurality of conductive interconnect plates;    each said interconnect plate having a plurality of apertures; and    a plurality of tubular electrochemical cells disposed and sealed between said interconnect plates;    wherein a said tubular electrochemical cell is oriented over a corresponding said aperture to form a gas passageway.    
     
     
         2 . An electrochemical stack assembly as recited in  claim 1 , wherein a said tubular electrochemical cell comprises: 
 a porous cathode;    a substantially gas impermeable ion conducting electrolyte; and    a porous anode.    
     
     
         3 . An electrochemical stack assembly as recited in  claim 2 , wherein said porous cathode of said tubular electrochemical cell is dimensioned to support an electrolyte layer and an anode layer.  
     
     
         4 . An electrochemical stack assembly as recited in  claim 3 , wherein said cathode comprises a porous support with a thickness between approximately 100 μm and approximately 3000 μm.  
     
     
         5 . An electrochemical stack assembly as recited in  claim 3 , wherein said cathode comprises a porous support with a thickness between approximately 150 μm and approximately 2000 μm.  
     
     
         6 . An electrochemical device assembly as recited in  claim 2 , wherein said cathode comprises a material selected from the group consisting essentially of LSM, LSC, LSF and Lanthium Strontium Cobalt Ferrite.  
     
     
         7 . An electrochemical stack assembly as recited in  claim 2 , wherein said electrolyte of said tubular electrochemical cell is dimensioned to support a cathode layer and an anode layer.  
     
     
         8 . An electrochemical stack assembly as recited in  claim 3 , wherein said electrolyte comprises a thin film of electrolyte with a thickness between approximately 1 μm and approximately 50 μm applied to said cathode support.  
     
     
         9 . An electrochemical device assembly as recited in  claim 2 , wherein said electrolyte comprises a material selected from the group consisting essentially of doped Zirconia, doped Ceria and doped Lanthanum Gallate.  
     
     
         10 . An electrochemical stack assembly as recited in  claim 8 , wherein said anode comprises a thin film applied to said thin film of electrolyte, said anode having a thickness within the range of approximately 50 μm to approximately 500 μm.  
     
     
         11 . An electrochemical stack assembly as recited in  claim 8 , wherein said anode comprises a thin film with a thickness between approximately 150 μm and approximately 300 μm applied to said electrolyte layer.  
     
     
         12 . An electrochemical stack assembly as recited in  claim 2 , wherein said porous anode of said tubular electrochemical cell is dimensioned to support an electrolyte layer and a cathode layer.  
     
     
         13 . An electrochemical stack assembly as recited in  claim 12 , wherein said anode comprises a porous support with a thickness between approximately 250 μm and approximately 2500 μm.  
     
     
         14 . An electrochemical device assembly as recited in  claim 2 , wherein said anode comprises a material selected from the group consisting essentially of Ni—YSZ and NI—CGO.  
     
     
         15 . An electrochemical cell stack assembly as recited in  claim 1 , wherein said tubular electrochemical cells are between 1 cm and 10 cm in length.  
     
     
         16 . An electrochemical cell stack assembly as recited in  claim 2 , said electrochemical cells further comprising: 
 a porous metal support;    wherein said cathode, electrolyte and anode are disposed on said porous metal support.    
     
     
         17 . An electrochemical cell stack assembly as recited in  claim 1 , wherein each of said interconnects comprises a metal sheet.  
     
     
         18 . An electrochemical cell stack assembly as recited in  claim 1:   wherein each said interconnect further comprises a plurality of stamped ridges at the periphery of each aperture in said interconnect; and    wherein said ridges configured to engage said corresponding electrochemical cell.    
     
     
         19 . An electrochemical cell stack assembly as recited in  claim 1 , further comprising at least one seal between said tubular electrochemical cell and said interconnect plate.  
     
     
         20 . An electrochemical cell stack assembly as recited in  claim 19 , wherein said seal between said electrochemical cell and said interconnect comprise an electrically conducting seal.  
     
     
         21 . An electrochemical cell stack assembly as recited in  claim 19 , wherein said seal between said electrochemical cell and said interconnect comprise an electrically insulating seal.  
     
     
         22 . An electrochemical device assembly as recited in  claim 19 , wherein said seal comprises a material selected from the group consisting essentially of a braze, weld, ceramic, glass ceramics, ceramic-metal composite and a metal.  
     
     
         23 . An electrochemical cell stack assembly as recited in  claim 1 , further comprising a gas conducting manifold configured to direct gas through said passageways of said stacked electrochemical cells.  
     
     
         24 . An electrochemical cell stack assembly as recited in  claim 23 , further comprising 
 means for preheating gases before entry into said first manifold.    
     
     
         25 . An electrochemical cell stack assembly as recited in  claim 23 , further comprising a second gas conducting manifold configured to receive gas from said passageways of said stacked electrochemical cells.  
     
     
         26 . An electrochemical cell stack assembly as recited in  claim 25 , wherein said second gas manifold is operably connected to a gas purifier configured to separate reaction products from unreacted gas.  
     
     
         27 . An electrochemical cell stack assembly as recited in  claim 1 , further comprising: 
 means for removing excess heat from the stack.    
     
     
         28 . An electrochemical cell stack assembly as recited in  claim 27 , wherein said means for removing excess heat from the stack comprises a heat exchanger operably coupled to said interconnect plates.  
     
     
         29 . An electrochemical cell stack assembly, comprising: 
 a base conductive plate having a plurality of apertures;    a first row of tubular electrochemical cells, each said cell having a central channel oriented over corresponding apertures of said base plate and corresponding apertures of a first conductive interconnect plate, said first row of tubular cells electrically coupled and sealed to said base plate and said first conductive interconnect plate; and    a second row of tubular electrochemical cells having a central channel oriented over corresponding apertures of said first conductive plate, said cells electrically coupled and sealed to said first conductive interconnect plate, said second row of tubular cells oriented over corresponding apertures in a top conductive plate and sealed to said top conductive plate;    wherein said central channels of said first row and said second row of tubular electrochemical cells form gas passageways.    
     
     
         30 . An electrochemical stack assembly as recited in  claim 29 , wherein each said tubular electrochemical cell comprise: 
 a porous cathode;    a substantially gas impermeable ion conducting electrolyte; and    a porous anode.    
     
     
         31 . An electrochemical cell stack assembly as recited in  claim 30 , wherein each said electrochemical cell further comprises: 
 a porous metal support;    said cathode, electrolyte and anode disposed on said porous metal support.    
     
     
         32 . An electrochemical stack assembly as recited in  claim 31 , wherein said porous metal support comprises a sintered powdered metal.  
     
     
         33 . An electrochemical stack assembly as recited in  claim 30 , wherein said porous cathode of said tubular electrochemical cell is dimensioned to support an electrolyte layer and an anode layer.  
     
     
         34 . An electrochemical stack assembly as recited in  claim 30 , wherein said porous anode of said tubular electrochemical cell is dimensioned to support an electrolyte layer and a cathode layer.  
     
     
         35 . An electrochemical cell stack assembly as recited in  claim 29 , wherein said base plate, said interconnect plate and said top plate comprise metal sheets.  
     
     
         36 . An electrochemical cell stack assembly as recited in  claim 29:   wherein said base plate, said interconnects and said top plate further comprise stamped ridges at the periphery of said apertures therein; and    wherein said ridges are configured to engage said plurality of electrochemical cells.    
     
     
         37 . An electrochemical cell stack assembly as recited in  claim 29 , further comprising at least one seal between said tubular electrochemical cell and said base plate, said interconnect plate or said top plate.  
     
     
         38 . An electrochemical cell stack assembly as recited in  claim 37 , wherein said seal between said electrochemical cell and said plates comprise an electrically conducting seal.  
     
     
         39 . An electrochemical cell stack assembly as recited in  claim 37 , wherein said seal between said electrochemical cell and said interconnect comprise an electrically insulating seal.  
     
     
         40 . An electrochemical device assembly as recited in  claim 37 , wherein said seal comprises a material selected from the group consisting essentially of a braze, weld, ceramic, glass ceramics, ceramic-metal composite and a metal.  
     
     
         41 . An electrochemical cell stack assembly as recited in  claim 30 , wherein said cathodes of said first row of electrochemical cells is electrically coupled to said interconnect plate and said anodes from said second row of electrochemical cells is electrically coupled to said interconnect plate.  
     
     
         42 . An electrochemical cell stack assembly as recited in  claim 30 , wherein said anodes of said first row of electrochemical cells is electrically coupled to said interconnect plate and said cathodes from said second row of electrochemical cells is electrically coupled to said interconnect plate.  
     
     
         43 . An electrochemical cell stack assembly, comprising: 
 a plurality of tubular electrochemical cells, each said cell having an anode contact end and a cathode contact end;    a plurality of ferrules, each of said ferrules configured to electrically couple with a corresponding anode contact end of a first electrochemical cell and a corresponding cathode contact end of a second electrochemical cell; and    a plurality of interconnect plates;    each said interconnect plate having a plurality of apertures;    wherein said plurality of ferrules and said plurality electrochemical cells are oriented over said apertures and mounted to said interconnect plates.    
     
     
         44 . An electrochemical device assembly as recited in  claim 43 , wherein said ferrules comprise a material selected from the group consisting essentially of a NI, Cu, Au and stainless steel.  
     
     
         45 . An electrochemical device assembly as recited in  claim 43 , wherein said plurality of ferrules and said plurality of interconnect plates consist of different conductive materials.  
     
     
         46 . An electrochemical device assembly as recited in  claim 45 , wherein said plurality of ferrules and said plurality of interconnect plates consist of different conductive materials that have matched thermal expansion characteristics.  
     
     
         47 . An electrochemical stack assembly as recited in  claim 43 , wherein each said tubular electrochemical cell comprises: 
 a porous cathode;    a substantially gas impermeable ion conducting electrolyte; and    a porous anode.    
     
     
         48 . An electrochemical cell stack assembly as recited in  claim 47 , wherein each said electrochemical cell further comprises: 
 a porous metal support;    said cathode, electrolyte and anode disposed on said porous metal support.    
     
     
         49 . An electrochemical stack assembly as recited in  claim 48 , wherein said porous metal support comprises a sintered powdered metal.  
     
     
         50 . An electrochemical stack assembly as recited in  claim 47 , wherein said porous cathode of said tubular electrochemical cell is dimensioned to support an electrolyte layer and an anode layer.  
     
     
         51 . An electrochemical stack assembly as recited in  claim 50 , wherein said cathode comprises a porous support with a thickness between approximately 100 μm and approximately 3000 μm.  
     
     
         52 . An electrochemical stack assembly as recited in  claim 50 , wherein said cathode comprises a porous support with a thickness between approximately 150 μm and approximately 2000 μm.  
     
     
         53 . An electrochemical device assembly as recited in  claim 47 , wherein said cathode comprises a material selected from the group consisting essentially of LSM, LSC, LSF and Lanthium Strontium Cobalt Ferrite.  
     
     
         54 . An electrochemical stack assembly as recited in  claim 47 , wherein said electrolyte of said tubular electrochemical cell is dimensioned to support a cathode layer and an anode layer.  
     
     
         55 . An electrochemical stack assembly as recited in  claim 47 , wherein said electrolyte comprises a thin film of electrolyte with a thickness between approximately 1 μm and approximately 50 μm applied to said cathode support.  
     
     
         56 . An electrochemical device assembly as recited in  claim 47 , wherein said electrolyte comprises a material selected from the group consisting essentially of doped Zirconia, doped Ceria and doped Lanthanum Gallate.  
     
     
         57 . An electrochemical stack assembly as recited in  claim 55 , wherein said anode comprises a thin film applied to said thin film of electrolyte, said anode having a thickness within the range of approximately 50 μm to approximately 500 μm.  
     
     
         58 . An electrochemical stack assembly as recited in  claim 55 , wherein said anode comprises a thin film with a thickness between approximately 150 μm and approximately 300 μm applied to said electrolyte layer.  
     
     
         59 . An electrochemical stack assembly as recited in  claim 47 , wherein said porous anode of said tubular electrochemical cell is dimensioned to support an electrolyte layer and a cathode layer.  
     
     
         60 . An electrochemical stack assembly as recited in  claim 59 , wherein said anode comprises a porous support with a thickness between approximately 250 μm and approximately 2500 μm.  
     
     
         61 . An electrochemical device assembly as recited in  claim 47 , wherein said anode comprises a material selected from the group consisting essentially of Ni—YSZ and NI—CGO.  
     
     
         62 . An electrochemical cell stack assembly as recited in  claim 43 , wherein said tubular electrochemical cells are between approximately 1 cm and approximately 10 cm in length.  
     
     
         63 . An electrochemical cell stack assembly as recited in  claim 43 , wherein each of said interconnects comprise a metal sheet.  
     
     
         64 . An electrochemical cell stack assembly as recited in  claim 43:   wherein each said interconnect further comprises a plurality of stamped ridges at the periphery of said apertures therein; and    wherein said ridges are configured to engage said plurality of electrochemical cells.    
     
     
         65 . An electrochemical cell stack assembly as recited in  claim 43 , further comprising at least one seal between said tubular electrochemical cell and said interconnect plate.  
     
     
         66 . An electrochemical cell stack assembly as recited in  claim 65 , wherein said seal between said electrochemical cell and said interconnect comprise an electrically conducting seal.  
     
     
         67 . An electrochemical cell stack assembly as recited in  claim 65 , wherein said seal between said electrochemical cell and said interconnect comprise an electrically insulating seal.  
     
     
         68 . An electrochemical device assembly as recited in  claim 65 , wherein said seal comprises a material selected from the group consisting essentially of a braze, weld, ceramic, glass ceramics, ceramic-metal composite and a metal.  
     
     
         69 . An electrochemical cell stack assembly as recited in  claim 43 , further comprising a gas conducting manifold configured to direct gas through said passageways of said stacked electrochemical cells.  
     
     
         70 . An electrochemical cell stack assembly as recited in  claim 69 , further comprising: 
 means for preheating gases before entry into said first manifold.    
     
     
         71 . An electrochemical cell stack assembly as recited in  claim 69 , further comprising a second gas conducting manifold configured to receive gas from said passageways of said stacked electrochemical cells.  
     
     
         72 . An electrochemical cell stack assembly as recited in  claim 71 , wherein said second gas manifold is operably connected to a gas purifier configured to separate reaction products from unreacted gas.  
     
     
         73 . An electrochemical cell stack assembly as recited in  claim 43 , further comprising: 
 means for removing excess heat from the stack.    
     
     
         74 . An electrochemical cell stack assembly as recited in  claim 73 , wherein said means for removing excess heat from the stack comprises a heat exchanger operably coupled to said interconnect plates.  
     
     
         75 . A module for a modular assembly of electrochemical cells, comprising: 
 a first set of tubular electrochemical cells, each said cell having an anode contact end and a cathode contact end;    a second set of tubular electrochemical cells, each said cell having an anode contact end and a cathode contact end; and    an electrically conductive interconnect sheet with a plurality of apertures and top and bottom sides, said top side of said interconnect sheet configured to electrically couple with said anode contact ends of said first set of electrochemical cells, said bottom side of said interconnect sheet configured to electrically couple with said cathode contact ends of said second set of electrochemical cells;    wherein said first and second set of electrochemical cells are aligned over the apertures of the interconnect sheet forming gas passageways through said electrochemical cells and said interconnect sheet.    
     
     
         76 . A module as recited in  claim 75 , further comprising: 
 a third set of tubular electrochemical cells, said cells coupled to said first set of electrochemical cells with a ferrule.    
     
     
         77 . A module as recited in  claim 75 , further comprising: 
 a fourth set of tubular electrochemical cells coupled to said first set of electrochemical cells with a ferrule.    
     
     
         78 . A module as recited in  claim 75 , further comprising at least one seal between each of said tubular electrochemical cells and said interconnect sheet.  
     
     
         79 . A module as recited in  claim 78 , wherein said seal between said electrochemical cell and said interconnect comprise an electrically conducting seal.  
     
     
         80 . A module as recited in  claim 78 , wherein said seal between said electrochemical cell and said interconnect comprise an electrically insulating seal.  
     
     
         81 . A module as recited in  claim 78 , wherein said seal comprises a material selected from the group consisting essentially of a braze, weld, ceramic, glass ceramics, ceramic-metal composite and a metal.  
     
     
         82 . A module as recited in  claim 75 , further comprising: 
 a plurality of ferrules, each said ferrule coupled to a corresponding anode contact end and a corresponding cathode contact end of an electrochemical cell.    
     
     
         83 . A module as recited in  claim 82 , further comprising at least one seal between each of said tubular electrochemical cells and said ferrules.  
     
     
         84 . A module as recited in  claim 83 , wherein said seal between said electrochemical cell and said ferrules comprise an electrically conducting seal.  
     
     
         85 . A module as recited in  claim 83 , wherein said seal between said electrochemical cell and said ferrules comprise an electrically insulating seal.