Wet seal caulk with enhanced chemical resistance

Patent metadata

Field	Value
Publication number	US-2019280312-A1
Application number	US-201815916029-A
Country	US
Kind code	A1
Filing date	Mar 8, 2018
Priority date	Mar 8, 2018
Publication date	Sep 12, 2019
Grant date	—

Abstract

A caulk composition includes at least one powder component and at least one binder component, such that the powder component has a particle size distribution in the range of 95% less than 25 μm and 90% greater than 1 μm. A molten carbonate fuel cell (MCFC) includes a fuel cell stack, a manifold, and the caulk composition disposed in between the fuel cell stack and the manifold.

First claim

What is claimed is:

1 . A caulk composition comprising:
at least one powder component and at least one binder component, wherein the powder component has a particle size distribution in the range of 95% less than 25 μm and 90% greater than 1 μm.

2 . The caulk composition of claim 1 , wherein the powder component is a ball-milled powder component comprising at least one of ceria, zirconia, alumina, or combinations thereof.

3 . The caulk composition of claim 2 , wherein the powder component is zirconia.

4 . The caulk composition of claim 3 , wherein the zirconia powder component is present in a concentration range of 65 wt % to 75 wt %.

5 . The caulk composition of claim 1 , wherein the powder component is a heat-treated powder component.

6 . The caulk composition of claim 5 , wherein the heat-treated powder component is heated at a temperature of at least 1500° C.

7 . The caulk composition of claim 1 , wherein the powder component has a concentration in the range of 50 wt % to 80 wt %.

8 . The caulk composition of claim 1 , wherein the binder component comprises at least one of ceria or zirconia.

9 . The caulk composition of claim 8 , wherein the binder component is zirconia.

10 . The caulk composition of claim 9 , wherein the zirconia binder component is present in a concentration range of 25 wt % to 35 wt %.

11 . The caulk composition of claim 1 , wherein the binder component has a concentration in the range of 20 wt % to 35 wt %.

12 . The caulk composition of claim 1 , further comprising pores having a pore diameter in a range of about 1 nm to about 50 nm.

13 . The caulk composition of claim 1 , further comprising pores having a first pore diameter, wherein the pores have a cumulative pore area of at most about 1 m 2 /g.

14 . The caulk composition of claim 1 , wherein the at least one powder component and the at least one binder component do not include ceria.

15 . A molten carbonate fuel cell (MCFC) comprising:
a fuel cell stack; a manifold; and a caulk between the fuel cell stack and the manifold, the caulk comprising at least one powder component and at least one binder component, wherein the powder component has a particle size distribution in the range of 95% less than 25 μm and 90% greater than 1 μm.

16 . The MCFC of claim 15 , wherein the fuel cell stack comprises a plurality of fuel cells, with each fuel cell including a cathode, an anode, an electrically conductive separator plate, corrugated current collectors, and an electrolyte matrix.

17 . The MCFC of claim 16 , wherein the caulk is positioned on a first portion of each fuel cell formed by the electrolyte matrix and on a second portion of each fuel cell formed by the separator plate.

18 . The MCFC of claim 17 , wherein the separator plate comprises a weld bead positioned between a top trough and a bottom trough of the separator plate and wherein the weld bead remains uncovered from the caulk to form a discontinuity.

19 . The MCFC of claim 15 , wherein the caulk is positioned discontinuously over the fuel cell stack.

20 . The MCFC of claim 15 , wherein the MCFC is configured to minimize electrolyte migration from a positive end of the fuel cell stack to a negative end of the fuel cell stack.

Assignees

• Fuelcell Energy Inc

Inventors

• Snider Matthew T
• Yuh Chao-Yi

Classifications

• C04B2235/3244

  Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof · CPC title

• C04B2235/3229

  Cerium oxides or oxide-forming salts thereof · CPC title

• H01M8/0282 Primary

  Inorganic material · CPC title

• C04B35/488

  Composites · CPC title

• H01M2008/147

  Fuel cells with molten carbonates · CPC title