# US 2017/0288238 A1 · Fuel cell matrix composition and method of manufacturing same

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- Number: US 2017/0288238 A1
- Document ID: US20170288238A1
- Status: Published application
- Kind: A1
- Application number: 15/628,047
- Filed: 2017-06-20
- Published: 2017-10-05
- Earliest claimed: 2014-01-27
- Assignees: FuelCell Energy, Inc.
- Applicants: FuelCell Energy, Inc.
- Inventors: Abdelkader HILMI; Arun SURENDRANATH; Chao-Yi YUH; Mohammad FAROOQUE
- Web page: https://patentgrep.com/patent/US20170288238A1

## CPC

- H01M 8/0295: Matrices for immobilising electrolyte melts
- H01M 8/145: {comprising carbonates}
- H01M 2008/147: {Fuel cells with molten carbonates}
- Y02E 60/50: Fuel cells
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A composition for use in forming a fuel cell matrix includes a support material, an electrolyte material, and an additive material that includes a plurality of flakes having an average length in a range of 5 to 40 micrometers and an average thickness of less than 1 micrometer.

## Claims

### Claim 1

A composition for use in forming a fuel cell matrix, the composition comprising:
a support material,
an electrolyte material, and
an additive material comprising a plurality of flakes having an average length in a range of 5 μm to 40 μm and an average thickness of less than 1 μm.

### Claim 2 (depends on 1)

The composition in accordance with claim 1, wherein the flakes of the additive material have an average Brunauer-Emmett-Teller (BET) surface area from 1 m2/g to 6 m2/g.

### Claim 3 (depends on 1)

The composition in accordance with claim 1, wherein the flakes of the additive material are made of a metal.

### Claim 4 (depends on 3)

The composition in accordance with claim 3, wherein the flakes of the additive material are made of aluminum.

### Claim 5 (depends on 4)

The composition in accordance with claim 4, wherein an amount of the additive material in the composition is between 3 volume percent and 35 volume percent.

### Claim 6 (depends on 1)

The composition in accordance with claim 1, wherein:
the support material comprises lithium aluminum oxide;
the flakes of the additive material are made of aluminum; and
the electrolyte material comprises one or more of carbonate electrolyte and carbonate electrolyte precursor.

### Claim 7 (depends on 1)

The composition in accordance with claim 1, wherein the flakes of the additive material have a leafing value of 70 to 100%.

### Claim 8 (depends on 1)

The composition in accordance with claim 1, wherein the plurality of flakes have an average length in a range of 12 μm to 20 μm.

### Claim 9 (depends on 1)

The composition in accordance with claim 1, wherein the plurality of flakes have an average length in a range of 15 μm to 18 μm.

### Claim 10 (depends on 1)

The composition in accordance with claim 1, wherein the plurality of flakes have an average thickness of less than 0.5 μm.

### Claim 11 (depends on 1)

The composition in accordance with claim 1, wherein the plurality of flakes have an average thickness in a range of 0.1 μm to 0.3 μm.

### Claim 12 (depends on 1)

The composition in accordance with claim 1, wherein the flakes are coated with an acidic compound adapted to prevent re-agglomeration.

### Claim 13 (depends on 12)

The composition in accordance with claim 12, wherein the acidic compound is stearic acid.

### Claim 14 (depends on 1)

The composition in accordance with claim 1, further comprising a binder and a plasticizer.

### Claim 15 (depends on 1)

A green tape cast element formed by tape casting the composition of claim 1.

### Claim 16 (depends on 15)

A conditioned fuel cell matrix formed by conditioning the green tape cast element of claim 15 such that the additive material reacts with the electrolyte material.

### Claim 17 (depends on 16)

The conditioned fuel cell matrix of claim 16, wherein the conditioning is performed by heating the green tape cast element at a temperature of at least 500° C. for at least two hours.

### Claim 18 (depends on 16)

The conditioned fuel cell matrix of claim 16, wherein the conditioning is performed by heating the green tape cast element at a temperature in range of 500 to 650° C. for a time in a range of 2 to 150 hours.

### Claim 19 (depends on 16)

The conditioned fuel cell matrix of claim 16, wherein the conditioned fuel cell matrix has a snap strength of at least 657 PSI.

### Claim 20 (depends on 16)

A fuel cell system comprising one or more fuel cells, each of the fuel cells including an anode electrode, a cathode electrode and a conditioned fuel cell matrix in accordance with claim 16.