Method for making a fuel cell stack

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a method for manufacturing solid oxide fuel cell (SOFC) stacks with enhanced in-line quality control. The core approach is to test individual fuel cell 'half-cells'—which include a substrate, anode, and electrolyte—before completing the full cell or assembling the stack. The process includes reducing the anode, measuring electrolyte leak-tightness or the cell resistance, and only using cells that meet quality standards for final assembly. The cathode is coated onto the cell and sintered when the stack is first started up, ensuring compatibility and minimizing cell damage. This enables early identification and exclusion of defective cells, improving the quality and reliability of the final fuel cell stack.

Use CasesContent extracted from patent full text and abstract with AI.

• Production lines for solid oxide fuel cell (SOFC) stacks in industrial settings
• Quality control steps during the manufacture of fuel cells for residential or commercial energy systems
• Automated or robotic fuel cell assembly plants where rapid, in-line inspection is valuable
• Large-scale research and pilot plants developing advanced fuel cell technology
• Manufacturing of fuel cell backup power systems for critical infrastructure

BenefitsContent extracted from patent full text and abstract with AI.

• Enables non-destructive, in-line testing of fuel cells during production for key quality attributes (like leak-tightness and electrical performance)
• Early identification and removal of defective cells—reducing waste, costs, and risk of assembling faulty stacks
• Improves reliability and long-term performance of SOFC stacks by ensuring only cells that meet strict criteria are used
• Reduces quality control costs by avoiding destructive tests and enabling automated or high-throughput screening
• Facilitates scalability and uniformity in mass production of fuel cell stacks
• Allows for lower-temperature sintering of cathode materials, which helps preserve the integrity of the anode and substrate during final assembly

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Patent Abstract

The method involves manufacturing a half fuel cell with a substrate, anode arranged on the substrate and an electrolyte arranged on the anode, where the anode is made of nickel-containing cermet. The half cell is reduced, and a value for leak-tightness of the electrolyte or a value for cell resistance is determined for the half cell. The half cell is coated with a cathode, and the manufactured fuel cell and another fuel cell are built into a fuel cell stack. The cathode of the former fuel cell is sintered during starting the stack.