Fuel cell devices and systems are provided. In certain embodiments, the devices include a ceramic support structure having a length, a width, and a thickness. A reaction zone positioned along a portion of the length is configured to be heated to an operating reaction temperature, and has at least on
Fuel cell devices and systems are provided. In certain embodiments, the devices include a ceramic support structure having a length, a width, and a thickness. A reaction zone positioned along a portion of the length is configured to be heated to an operating reaction temperature, and has at least one active layer therein comprising an electrolyte separating first and second opposing electrodes, and active first and second gas passages adjacent the respective first and second electrodes. At least one cold zone positioned from the first end along another portion of the length is configured to remain below the operating reaction temperature. An artery flow passage extends from the first end along the length through the cold zone and into the reaction zone and is fluidicly coupled to the active first gas passage, which extends from the artery flow passage toward at least one side. The thickness of the artery flow passage is greater than the thickness of the active first gas passage. In other embodiments, fuel cell devices include an electrolyte having at least a portion thereof comprising a ceramic material sintered from a nano-sized powder. In yet other embodiments, cold zones are provided at each end of the device with the reaction zone therebetween having at least two discrete power sections, each having one or more active layers, the power sections fed by discrete fuel passages to provide a device and system capable of operating at more than one power level.
대표청구항▼
1. A fuel cell device comprising: an elongate substrate having a length that is the greatest dimension whereby the elongate substrate exhibits thermal expansion along a dominant axis that is coextensive with the length, a first cold end region adjacent a first end, a second cold end region adjacent
1. A fuel cell device comprising: an elongate substrate having a length that is the greatest dimension whereby the elongate substrate exhibits thermal expansion along a dominant axis that is coextensive with the length, a first cold end region adjacent a first end, a second cold end region adjacent a second end, and a reaction zone between the first and second cold end regions, wherein the reaction zone is configured to be heated to an operating reaction temperature and is capable of generating a fuel cell reaction, and the first and second cold end regions are configured to remain at a low temperature below the operating reaction temperature when the reaction zone is heated and are incapable of generating a fuel cell reaction;at least two discrete power sections in the reaction zone, each of the at least two discrete power sections comprising one or more active layers each having an anode, an opposing cathode and an electrolyte therebetween for generating the fuel cell reaction at the operating reaction temperature when supplied with heat, fuel and oxidizer, the anode and cathode in each of the one or more active layers in each of the at least two discrete power sections having an electrical pathway extending to the first or second cold end region for electrical connection at the low temperature below the operating reaction temperature;at least two discrete fuel passages in the elongate substrate extending from the first cold end region to the anodes of the respective at least two discrete power sections in the reaction zone; andat least one oxidizer passage in the elongate substrate extending from the second cold end region to the cathodes of the at least two discrete power sections in the reaction zone;wherein the fuel cell device is operable at two or more different power levels by selectively flowing fuel into one or more than one of the at least two discrete fuel passages, and wherein the fuel cell device is operable to receive fuel into one of the at least two discrete fuel passages without receiving fuel in at least one other of the at least two discrete fuel passages such that the two or more different power levels include a low power level in which the fuel cell reaction is generated in fewer than all of the at least two discrete power sections and a high power level in which the fuel cell reaction is generated in all of the at least two discrete power sections. 2. The fuel cell device of claim 1, wherein the at least one oxidizer passage includes at least two discrete oxidizer passages extending to the cathodes of the respective at least two discrete power sections. 3. The fuel cell device of claim 2 wherein the at least two discrete power sections include first and second discrete power sections, the at least two discrete fuel passages include first and second discrete fuel passages, and the at least two discrete oxidizer passages include first and second discrete oxidizer passages, and wherein the first and second cold end regions each comprise a first input section and a second input section, the first and second input sections of the first cold end region providing fuel inputs to the respective first and second discrete fuel passages, and the first and second input sections of the second cold end region providing oxidizer inputs to the respective first and second discrete oxidizer passages, whereby the fuel cell device is operable to receive fuel and air into the first input sections of the first and second cold end regions without receiving fuel into the second input sections of the first and second cold end regions to power the one or more active layers in the first discrete power section without powering the second discrete power section, and whereby the fuel cell device is operable to receive fuel and air into the second input sections of the first and second cold end regions without receiving fuel into the first input sections of the first and second cold end regions to power the one or more active layers in the second discrete power section without powering the first discrete power section, and whereby the fuel cell device is operable to receive fuel and air into both of the first and second input sections of the first and second cold end regions to power the one or more active layers in both the first and second discrete power sections. 4. The fuel cell device of claim 3 wherein the first and second cold end regions each comprise a groove separating the first input section from the second input section. 5. The fuel cell device of claim 3 wherein the second discrete power section comprises a greater number of active layers than the first discrete power section, whereby the fuel cell device is operable to receive fuel and air into the first input sections of the first and second cold end regions without receiving fuel into the second input sections of the first and second cold end regions to power the active layers in the first discrete power section for low power supply, or to receive fuel and air into the second input sections of the first and second cold end regions without receiving fuel into the first input sections of the first and second cold end regions to power the active layers in the second discrete power section for medium power supply, or the fuel cell device is operable to receive fuel and air into the first and second input sections of the first and second cold end regions to power the active layers in both of the first and second discrete power sections for high power supply. 6. A fuel cell system comprising: a hot zone chamber;at least one fuel cell device of claim 3 positioned with the reaction zone in the hot zone chamber and the first and second cold end regions extending outside the hot zone chamber;a heat source coupled to the hot zone chamber and adapted to heat the reaction zone to the operating reaction temperature within the hot zone chamber;a fuel-power plug coupled to the first cold end region having first and second discrete fuel input pathways in fluid communication with the respective first and second discrete fuel passages and first and second conductor elements electrically coupled to the electrical pathways of one of the anodes or cathodes of the respective first and second discrete power sections for collecting power output; andan air-power plug coupled to the second cold end region having first and second discrete air input pathways in fluid communication with the respective first and second discrete oxidizer passages and first and second discrete conductor elements electrically coupled to the electrical pathways of the other one of the anodes or cathodes of the first and second discrete power sections for collecting power output. 7. The fuel cell device of claim 1, wherein the at least one oxidizer passage is fluidicly coupled to the cathodes in each of the at least two discrete power section whereby the fuel cell device is operable at two or more different power levels by flowing air into each of the at least two discrete power sections while selectively flowing fuel into one or more than one of the at least two discrete fuel passages. 8. A fuel cell system comprising: a hot zone chamber;at least one fuel cell device of claim 1 positioned with the reaction zone in the hot zone chamber and the first and second cold end regions extending outside the hot zone chamber;a heat source coupled to the hot zone chamber and adapted to heat the reaction zone to the operating reaction temperature within the hot zone chamber;a fuel-power plug coupled to the first cold end region having at least two discrete fuel input pathways in fluid communication with the respective at least two discrete fuel passages and at least two conductor elements electrically coupled to the electrical pathways of one of the anodes or cathodes of the at least two discrete power sections for collecting power output; andan air-power plug coupled to the second cold end region having at least one air input pathway in fluid communication with the respective at least one oxidizer passage and at least two conductor elements electrically coupled to the electrical pathways of the other one of the anodes or cathodes of the at least two discrete power sections for collecting power output. 9. A fuel cell device comprising: an elongate substrate having a length that is the greatest dimension whereby the elongate substrate exhibits thermal expansion along a dominant axis that is coextensive with the length, a first non-active end region adjacent a first end, a second non-active end region adjacent a second end, and an active zone between the first and second non-active end regions, wherein the first and second non-active end regions are non-active by virtue of being incapable of generating a fuel cell reaction and wherein the active zone is active by virtue of being capable of generating a fuel cell reaction;at least two discrete power sections in the active zone, each of the at least two discrete power sections comprising one or more active layers each having an anode, an opposing cathode and an electrolyte therebetween for generating the fuel cell reaction at an operating reaction temperature when supplied with heat, fuel and oxidizer, wherein the first and second non-active end regions lack the anode and cathode in opposing relation to thereby be incapable of generating the fuel cell reaction and extend away from the active zone without being heated to dissipate heat and to thereby remain at a lower temperature than the active zone when the active zone is supplied with heat, and the anode and cathode in each of the one or more active layers in each of the at least two discrete power sections having an electrical pathway extending to the first or second non-active end region for electrical connection at the lower temperature;at least two discrete fuel passages in the elongate substrate extending from the first non-active end region to the anodes of the respective at least two discrete power sections in the active zone; andat least one oxidizer passage in the elongate substrate extending from the second non-active end region to the cathodes of the at least two discrete power sections in the active zone;wherein the fuel cell device is operable at two or more different power levels by selectively flowing fuel into one or more than one of the at least two discrete fuel passages while further providing oxidizer and heat, and wherein the fuel cell device is operable to receive fuel into one of the at least two discrete fuel passages without receiving fuel in at least one other of the at least two discrete fuel passages such that the two or more different power levels include a low power level in which the fuel cell reaction is generated in fewer than all of the at least two discrete power sections and a high power level in which the fuel cell reaction is generated in all of the at least two discrete power sections. 10. The fuel cell device of claim 9, wherein the at least one oxidizer passage includes at least two discrete oxidizer passages extending to the cathodes of the respective at least two discrete power sections. 11. The fuel cell device of claim 10 wherein the at least two discrete power sections include first and second discrete power sections, the at least two discrete fuel passages include first and second discrete fuel passages, and the at least two discrete oxidizer passages include first and second discrete oxidizer passages, and wherein the first and second non-active end regions each comprise a first input section and a second input section, the first and second input sections of the first non-active end region providing fuel inputs to the respective first and second discrete fuel passages, and the first and second input sections of the second non-active end region providing oxidizer inputs to the respective first and second discrete oxidizer passages, whereby the fuel cell device is operable to receive fuel and air into the first input sections of the first and second non-active end regions without receiving fuel into the second input sections of the first and second non-active end regions to power the one or more active layers in the first discrete power section without powering the second discrete power section, and whereby the fuel cell device is operable to receive fuel and air into the second input sections of the first and second non-active end regions without receiving fuel into the first input sections of the first and second non-active end regions to power the one or more active layers in the second discrete power section without powering the first discrete power section, and whereby the fuel cell device is operable to receive fuel and air into both of the first and second input sections of the first and second non-active end regions to power the one or more active layers in both the first and second discrete power sections. 12. The fuel cell device of claim 11 wherein the first and second non-active end regions each comprise a groove separating the first input section from the second input section. 13. The fuel cell device of claim 11 wherein the second discrete power section comprises a greater number of active layers than the first discrete power section, whereby the fuel cell device is operable to receive fuel and air into the first input sections of the first and second non-active end regions without receiving fuel into the second input sections of the first and second non-active end regions to power the active layers in the first discrete power section for low power supply, or to receive fuel and air into the second input sections of the first and second non-active end regions without receiving fuel into the first input sections of the first and second non-active end regions to power the active layers in the second discrete power section for medium power supply, or the fuel cell device is operable to receive fuel and air into the first and second input sections of the first and second non-active end regions to power the active layers in both of the first and second discrete power sections for high power supply. 14. A fuel cell system comprising: a hot zone chamber;at least one fuel cell device of claim 11 positioned with the active zone in the hot zone chamber and the first and second non-active end regions extending outside the hot zone chamber;a heat source coupled to the hot zone chamber and adapted to heat the active zone to the operating reaction temperature within the hot zone chamber;a fuel-power plug coupled to the first non-active end region having first and second discrete fuel input pathways in fluid communication with the respective first and second discrete fuel passages and first and second conductor elements electrically coupled to the electrical pathways of one of the anodes or cathodes of the respective first and second discrete power sections for collecting power output; andan air-power plug coupled to the second non-active end region having first and second discrete air input pathways in fluid communication with the respective first and second discrete oxidizer passages and first and second discrete conductor elements electrically coupled to the electrical pathways of the other one of the anodes or cathodes of the first and second discrete power sections for collecting power output. 15. The fuel cell device of claim 9, wherein the at least one oxidizer passage is fluidicly coupled to the cathodes in each of the at least two discrete power section whereby the fuel cell device is operable at two or more different power levels by flowing air into each of the at least two discrete power sections while selectively flowing fuel into one or more than one of the at least two discrete fuel passages. 16. A fuel cell system comprising: a hot zone chamber;at least one fuel cell device of claim 9 positioned with the active zone in the hot zone chamber and the first and second non-active end regions extending outside the hot zone chamber;a heat source coupled to the hot zone chamber and adapted to heat the active zone to the operating reaction temperature within the hot zone chamber;a fuel-power plug coupled to the first non-active end region having at least two discrete fuel input pathways in fluid communication with the respective at least two discrete fuel passages and at least two conductor elements electrically coupled to the electrical pathways of one of the anodes or cathodes of the at least two discrete power sections for collecting power output; andan air-power plug coupled to the second non-active end region having at least one air input pathway in fluid communication with the respective at least one oxidizer passage and at least two conductor elements electrically coupled to the electrical pathways of the other one of the anodes or cathodes of the at least two discrete power sections for collecting power output. 17. A fuel cell device comprising: an elongate substrate comprising a ceramic support structure and having a length that is the greatest dimension whereby the elongate substrate exhibits thermal expansion along a dominant axis that is coextensive with the length, a first non-active end region adjacent a first end, a second non-active end region adjacent a second end, and an active zone between the first and second non-active end regions, wherein the first and second non-active end regions are non-active by virtue of being incapable of generating a fuel cell reaction and wherein the active zone is active by virtue of being capable of generating a fuel cell reaction;first and second discrete power sections in the active zone separated by a non-active intermediate region, each of the first and second discrete power sections comprising one or more active layers within the ceramic support structure, each active layer having an anode, a fuel passage adjacent the anode, a cathode opposing the anode, an oxidizer passage adjacent the cathode, and an electrolyte between the opposing anode and cathode for generating the fuel cell reaction at an operating reaction temperature when supplied with heat, fuel and oxidizer, wherein the first and second non-active end regions comprise the ceramic support structure and lack the anode and cathode in opposing relation to thereby be incapable of generating the fuel cell reaction and extend away from the active zone without being heated to dissipate heat and to thereby remain at a lower temperature than the active zone when the active zone is supplied with heat, wherein the non-active intermediate region consists of the ceramic support structure, and the anode and cathode in each of the one or more active layers in each of the first and second discrete power sections having an electrical pathway extending to the first or second non-active end region for electrical connection at the lower temperature;a first input section in each of the first and second non-active end regions, the first input section of the first non-active end region having a first fuel inlet and the first input section of the second non-active end region having a first oxidizer inlet, the first fuel inlet and the first oxidizer inlet coupled to the fuel passages and the oxidizer passages, respectively, in the one or more active layers of the first discrete power section; anda second input section in each of the first and second non-active end regions, the second input section of the first non-active end region having a second fuel inlet and the second input section of the second non-active end region having a second oxidizer inlet, the second fuel inlet and the second oxidizer inlet coupled to the fuel passages and oxidizer passages, respectively, in the one or more active layers of the second discrete power section, wherein the first and second input sections are separated in each of the first and second non-active end regions by the non-active intermediate region and/or by a groove;wherein the fuel cell device is operable in three different power modes including a first power mode, a second power mode and a third power mode, wherein in the first power mode the fuel cell device is operable to receive fuel and air into the first input sections of the first and second non-active end regions without receiving fuel and/or air into the second input sections of the first and second non-active end regions to power the one or more active layers in the first discrete power section without powering the second discrete power section, wherein in the second power mode the fuel cell device is operable to receive fuel and air into the second input sections of the first and second non-active end regions without receiving fuel and/or air into the first input sections of the first and second non-active end regions to power the one or more active layers in the second discrete power section without powering the first discrete power section, and wherein in the third power mode the fuel cell device is operable to receive fuel and air into both of the first and second input sections of the first and second non-active end regions to power the one or more active layers in both the first and second discrete power sections. 18. The fuel cell device of claim 17 wherein the second discrete power section comprises a greater number of active layers than the first discrete power section such that the second power mode has a higher power output capability than the first power mode.
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