Method and apparatus for forming electrode interconnect contacts for a solid-oxide fuel cell stack

Keller, Joseph M.; Haltiner, Karl J.; Mukerjee, Subhasish; England, Diane M.; Reisdorf, Gary F.; Cooper, Steven L.; Vilders, Willem

Title: Method and apparatus for forming electrode interconnect contacts for a solid-oxide fuel cell stack

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Abstract

An electrical interconnect for a solid-oxide fuel cell stack assembly, including a novel sintering paste and an improved manufacturing process for an anode and cathode electrical contacts is disclosed. On the anode side, the paste contains a metallic oxide such as NiO, and an amount of sacrificial pore-forming particles, such as carbon particles or polymer spheres, which are vaporized during sintering of the paste, resulting in a very porous connection having good electrical conductivity and good adhesion. A preferred level of pore-former in the paste is about 40 volume percent. On the cathode side, the paste contains a noble metal such as for example, gold, platinum, palladium or rhodium, and an amount of the sacrificial pore-forming particles. The paste may be applied to the surfaces in a grid pattern or, because the resulting contact is porous after sintering, it may be applied as a continuous layer.

Inventors:: Keller, Joseph M.; Haltiner, Jr., Karl J.; Mukerjee, Subhasish; England, Diane M.; Reisdorf, Gary F.; Cooper, Steven L.; Vilders, III, Willem

Issue Date:: 2010-08-24

Research Org.:: Delphi Technologies, Inc., Troy, MI (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1531648

Patent Number(s):: 7781123

Application Number:: 11/145,647

Assignee:: Delphi Technologies, Inc. (Troy, MI)

Patent Classifications (CPCs):: H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

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H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
H01M8/1246 - the electrolyte consisting of oxides
H01M8/1213 - characterised by the electrode/electrolyte combination or the supporting material
H01M8/0236 - Glass
H01M4/8885 - {Sintering or firing}
H01M8/0297 - Arrangements for joining electrodes, reservoir layers, heat exchange units or bipolar separators to each other

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
Y02P70/50 - Manufacturing or production processes characterised by the final manufactured product

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02E - REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
Y02E60/50 - Fuel cells

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
H01M8/0245 - in the form of layered or coated products
H01M8/0232 - Metals or alloys
H01M4/8621 - {containing only metallic or ceramic material, e.g. made by sintering or sputtering}

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DOE Contract Number:: FC26-02NT41246

Resource Type:: Patent

Resource Relation:: Patent File Date: 2005-06-06

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; 37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY; 30 DIRECT ENERGY CONVERSION

Citation Formats


                    Keller, Joseph M., Haltiner, Jr., Karl J., Mukerjee, Subhasish, England, Diane M., Reisdorf, Gary F., Cooper, Steven L., and Vilders, III, Willem. Method and apparatus for forming electrode interconnect contacts for a solid-oxide fuel cell stack.  United States: N. p., 2010. 
        Web.

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                    Keller, Joseph M., Haltiner, Jr., Karl J., Mukerjee, Subhasish, England, Diane M., Reisdorf, Gary F., Cooper, Steven L., & Vilders, III, Willem. Method and apparatus for forming electrode interconnect contacts for a solid-oxide fuel cell stack.  United States.

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                    Keller, Joseph M., Haltiner, Jr., Karl J., Mukerjee, Subhasish, England, Diane M., Reisdorf, Gary F., Cooper, Steven L., and Vilders, III, Willem. Tue .  
        "Method and apparatus for forming electrode interconnect contacts for a solid-oxide fuel cell stack".  United States.  https://www.osti.gov/servlets/purl/1531648.

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@article{osti_1531648,

  title        = {Method and apparatus for forming electrode interconnect contacts for a solid-oxide fuel cell stack},

  author       = {Keller, Joseph M. and Haltiner, Jr., Karl J. and Mukerjee, Subhasish and England, Diane M. and Reisdorf, Gary F. and Cooper, Steven L. and Vilders, III, Willem},

  abstractNote = {An electrical interconnect for a solid-oxide fuel cell stack assembly, including a novel sintering paste and an improved manufacturing process for an anode and cathode electrical contacts is disclosed. On the anode side, the paste contains a metallic oxide such as NiO, and an amount of sacrificial pore-forming particles, such as carbon particles or polymer spheres, which are vaporized during sintering of the paste, resulting in a very porous connection having good electrical conductivity and good adhesion. A preferred level of pore-former in the paste is about 40 volume percent. On the cathode side, the paste contains a noble metal such as for example, gold, platinum, palladium or rhodium, and an amount of the sacrificial pore-forming particles. The paste may be applied to the surfaces in a grid pattern or, because the resulting contact is porous after sintering, it may be applied as a continuous layer.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2010},

  month        = {8}

}

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