Boron phosphate matrix layer

Patent metadata

Field	Value
Publication number	US-2018062184-A1
Application number	US-201615244328-A
Country	US
Kind code	A1
Filing date	Aug 23, 2016
Priority date	Aug 23, 2016
Publication date	Mar 1, 2018
Grant date	—

Abstract

An illustrative example embodiment of a fuel cell includes a cathode electrode, an anode electrode, and a porous matrix layer between the electrodes. The porous matrix layer includes pores and solids. The solids comprises at least 90% boron phosphate. A phosphoric acid electrolyte is within the pores of the matrix layer.

First claim

I claim:

1 . A fuel cell, comprising:
a cathode electrode; an anode electrode; a porous matrix layer between the cathode electrode and the anode electrode, the porous matrix layer including pores and solids, the solids of the porous matrix layer comprising at least 90% boron phosphate; and a phosphoric acid electrolyte within the pores of the matrix layer.

2 . The fuel cell of claim 1 , wherein
the boron phosphate has an average particle size between 0.5 μm and 4 μm.

3 . The fuel cell of claim 2 , wherein the average particle size is approximately 2 μm.

4 . The fuel cell of claim 1 , wherein
the matrix layer has a thickness that is between 10 μm and 100 μm.

5 . The fuel cell of claim 3 , wherein the thickness is approximately 50 μm.

6 . The fuel cell of claim 1 , wherein the matrix layer comprises between 90% and 99% boron phosphate.

7 . The fuel cell of claim 1 , wherein the matrix layer comprises a coating on at least one of the electrodes.

8 . The fuel cell of claim 1 , wherein
the cathode electrode and the anode electrode each comprises a catalyst layer; each catalyst layer is surrounded by a porous filler band layer; and each porous filler band layer comprises boron phosphate.

9 . The fuel cell of claim 6 , wherein the filler band layers have a different composition than the matrix layer.

10 . The fuel cell of claim 1 , wherein
the anode electrode and the cathode electrode are supported on respective substrate layers; the respective substrate layers comprise an edge seal; and the respective edge seals comprise boron phosphate.

11 . A method of making a fuel cell, the method comprising:
establishing a cathode layer; establishing an anode layer; establishing a porous matrix layer between the cathode layer and the anode layer, the porous matrix layer including pores and solids, the solids comprising at least 90% boron phosphate; and disposing phosphoric acid electrolyte in the pores of the porous matrix layer.

12 . The method of claim 11 , wherein establishing the porous matrix layer comprises
mixing a slurry comprising boron phosphate particles, a surfactant, a thickening agent, and a binder; depositing a coating of the mixed slurry on at least one of the cathode layer or the anode layer; and drying the deposited coating, wherein the resulting coating is at least part of the matrix layer.

13 . The method of claim 12 , comprising
depositing a coating of the mixed slurry on each of the cathode layer and the anode layer; and removing the solvent, and wherein the deposited coatings collectively establish the matrix layer.

14 . The method of claim 12 , wherein
the boron phosphate particles have an average particle size between 0.5 μm and 4 μm.

15 . The method of claim 14 , wherein the average particle size is approximately 2 μm.

16 . The method of claim 11 , wherein
the matrix layer has a thickness that is between 10 μm and 100 μm.

17 . The method of claim 16 , wherein the thickness is approximately 50 μm.

18 . The method of claim 11 , wherein the matrix layer comprises between 90% and 99% boron phosphate.

19 . The method of claim 11 , comprising surrounding the cathode layer and the anode layer respectively with a filler band layer that comprises boron phosphate.

20 . The method of claim 11 , comprising
establishing the cathode layer on a first substrate layer; establishing the anode layer on a second substrate layer; providing a first edge seal on the first substrate layer; and providing a second edge seal on the second substrate layer, wherein the first and second edge seals comprise boron phosphate.

Assignees

• Doosan Fuel Cell America Inc

Inventors

• Arpin Kevin A

Classifications

• H01M8/0293 Primary

  Matrices for immobilising electrolyte solutions · CPC title

• H01M2300/0008

  Phosphoric acid-based · CPC title

• H01M8/086

  Phosphoric acid fuel cells [PAFC] · CPC title

• Y02E60/50

  Fuel cells · CPC title