US 12,136,756 B1
Method of making a fuel cell stack with stress reducing seals
Michael D. Gasda, Sunnyvale, CA (US); Madhuri Nallabolu, Fremont, CA (US); Brian Therault, San Jose, CA (US); Robert Hintz, San Jose, CA (US); Hoa Vo, San Jose, CA (US); Phuc Phan, San Jose, CA (US); Patrick Nikong, Mountain View, CA (US); and Greg Young, Santa Cruz, CA (US)
Assigned to BLOOM ENERGY CORPORATION, San Jose, CA (US)
Filed by BLOOM ENERGY CORPORATION, San Jose, CA (US)
Filed on Mar. 19, 2021, as Appl. No. 17/206,790.
Claims priority of provisional application 63/003,960, filed on Apr. 2, 2020.
Int. Cl. H01M 8/248 (2016.01); H01M 8/0265 (2016.01); H01M 8/0273 (2016.01); H01M 8/0282 (2016.01)
CPC H01M 8/248 (2013.01) [H01M 8/0265 (2013.01); H01M 8/0273 (2013.01); H01M 8/0282 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A method of assembling a fuel cell stack, comprising:
providing a cross-flow first interconnect comprising fuel holes that extend through the interconnect, fuel channels that extend in a first direction between fuel ribs on a fuel side of the interconnect, and air channels that extend on an air side of the interconnect between air ribs in a second direction substantially perpendicular to the first direction;
depositing a glass or glass ceramic seal material on the air side of the first interconnect to form riser seals that surround the fuel holes;
depositing the glass or glass ceramic seal material on the fuel side of the first interconnect to form a perimeter seal that surrounds the fuel channels and the fuel holes;
positioning a first side of a first fuel cell on the air side of the first interconnect in contact with at least a portion of the riser seals;
placing a cross-flow second interconnect into the fuel cell stack facing a second side of the first fuel cell;
positioning a second side of a second fuel cell on the fuel side of the first interconnect in contact with at least a portion of the perimeter seal;
placing a cross-flow third interconnect into the fuel cell stack facing a first side of the second fuel cell; and
sintering the fuel cell stack to reflow the riser seals and the perimeter seal,
wherein the riser seals, the perimeter seal, or both the riser seals and the perimeter seal comprise at least one of at least one support portion or extensions that are formed of the glass or glass ceramic seal material and which are configured to reduce an amount of compressive stress on corners of at least one of the first or second fuel cells in the fuel cell stack, and
wherein:
the riser seals comprise the support portions having a first thickness and base portions having a second thickness that is less than the first thickness;
the support portions at least partially define a pocket region; and
positioning the first side of the first fuel cell comprises disposing the first side of the first fuel cell on the base portions in the pocket region, such that the first fuel cell is partially surrounded by the support portions and opposing edges of the first fuel cell contact the base portions.