1. A solid oxide fuel cell component comprising:
a porous gas permeable support structure having a surface;
at least first, second and third solid oxide fuel cells being arranged in spaced apart relationship on the surface of the porous gas permeable support structure, such that the first cell is adjacent to the second cell, the second cell is adjacent to the third cell, and the cells are arranged in electrical series;
the first, second and third cells each comprising a dense non-porous gas tight electrolyte member, a porous gas permeable anode, and a porous gas permeable cathode;
the anode of the first cell being connected to the cathode of the adjacent second cell by a first dense non-porous and gas tight interconnector;
the first interconnector having a bottom surface contacting the surface of the support, a first side surface contacting the anode of the first cell, a top surface, and a second side surface spaced apart from the anode of the second cell;
the anode of the first cell contacting a portion of the top surface of the first interconnector and the cathode of the second cell contacting another portion of the top surface of the first interconnector;
the anode of the second cell being connected to the cathode of the adjacent third cell by a second dense non-porous and gas tight interconnector;
the second interconnector having a bottom surface contacting the surface of the support, a first side surface contacting the anode of the second cell, a top surface, and a second side surface spaced apart from the anode of the third cell;
the anode of the second cell contacting a portion of the top surface of the second interconnector and the cathode of the third cell contacting another portion of the top surface of the second interconnector; and
the electrolyte member of the second cell being arranged between the anode and cathode of the second cell, a first end of the electrolyte member of the second cell contacting the surface of the support between the second side surface of the first interconnector and a side surface of the anode of the second cell, a second end of the electrolyte member of the second cell contacting the top surface of the second interconnector between the anode of the second cell and the cathode of the third cell, and the electrolyte member of the second cell is spaced apart from the cathode of the third cell by a portion of the top surface of the second interconnector.
2. A solid oxide fuel cell component as claimed in claim 1, further comprising a dense non-porous gas tight peripheral seal member covering at least a portion of the surface of the support structure not covered by the anodes, the interconnectors and the electrolyte members.
3. A solid oxide fuel cell component as claimed in claim 1, further comprising a dense non-porous gas tight seal comprising a seal layer filling an area defined by a side surface of the electrolyte member of the second cell, a side surface of the cathode of the second cell, a side surface of the cathode of the third cell, and the top surface of the second interconnector to reduce leakage of reactant.
4. A solid oxide fuel cell component as claimed in claim 3 wherein the electrolyte member of the second cell and the dense non-porous gas tight seal are arrange to encapsulate the cathode of the second cell except for surfaces of the cathode remote from the electrolyte member of the second cell to reduce leakage of reactant from the cathode.
5. A solid oxide fuel cell component as claimed in claim 1 wherein each of the anodes is arranged in contact with the surface of a current collector, each current collector being arranged in contact with a porous barrier layer, the porous barrier layer being arranged in contact with the surface of the porous gas permeable support structure.
6. A solid oxide fuel cell component as claimed in claim 1, wherein the first, second and third interconnectors each comprises a first layer on the porous gas permeable support structure, a second layer on the first layer, and a third layer on the second layer, the first layer is dense, non-porous gas tight and is electronically and ionically non-conducting, the second layer bonds the third layer to the first layer and the third layer is electronically conducting.
7. A solid oxide fuel cell component as claimed in claim 6 wherein the first layer comprises a ceramic, the second layer comprises lanthanum chromite and the third layer comprises a metal.
8. A solid oxide fuel cell component as claimed in claim 6 wherein the third layer comprises nickel, platinum, palladium, ruthenium and silver.
9. A solid oxide fuel cell component as claimed in claim 6 wherein the first layer comprises yttria stabilized zirconia doped with silicate glass or yttria stabilized zirconia doped with calcium chromate.
10. A solid oxide fuel cell component as claimed in claim 1, wherein the first, second and third interconnectors each comprises a first layer on the porous gas permeable support structure and a second layer on the first layer, the first layer is dense non-porous and is electronically and ionically nonconducting and the second layer is electronically conducting.
11. A solid oxide fuel cell component as claimed in claim 10 wherein the first layer comprises a ceramic and the second layer comprises a metal.
12. A solid oxide fuel cell component as claimed in claim 10 wherein the second layer comprises nickel, platinum, palladium, ruthenium, silver.
13. A solid oxide fuel cell component is claimed in claim 10 wherein the first layer comprises yttria stabilized zirconia.
14. A solid oxide fuel cell component as claimed in claim 13 to wherein the first layer comprises yttria stabilized zirconia doped with silicate glass or yttria stabilized zirconia doped with calcium chromate.
15. A solid oxide fuel cell component as claimed in claim 5 wherein an electronically conducting layer of each of the first, second and third interconnectors is integral with the current collector.
16. A solid oxide fuel cell component as claimed in claim 1 wherein a porous gas permeable barrier layer is arranged between each of the anodes and the surface of the porous gas permeable support structure to prevent chemical interactions between the anodes and the porous gas permeable support structure.
17. A solid oxide fuel cell component as claimed in claim 16, a dense non-porous gas tight peripheral seal extends around a periphery of an area defined by the anodes and the dense non-porous interconnectors.
18. A solid oxide fuel cell component as claimed in claim 17 wherein ends of at least one dense non-porous interconnector contacts a top surface of the dense non-porous gas tight peripheral seal.
19. A solid oxide fuel cell component as claimed in claim in 18 wherein edges of the dense non-porous gas tight electrolyte members contact a top surface of the dense non-porous gas tight peripheral seal.
20. A solid oxide fuel cell component as claimed in claim 16 wherein the dense non-porous gas tight peripheral seal comprises a first layer and a second layer.
21. A solid oxide fuel cell component as claimed in claim 20 wherein the dense non-porous gas tight peripheral seal comprises a ceramic.
22. A solid oxide fuel cell component as claimed in claim to 21 wherein the dense non-porous gas tight peripheral seal comprises yttria stabilized zirconia.
23. A solid oxide fuel cell component as claimed in claim 21 wherein the dense non-porous gas tight peripheral seal comprises yttria stabilized zirconia doped with silicate glass or yttria stabilized zirconia doped with calcium chromate.
24. A solid oxide fuel cell component as claimed in claim 1 further comprising a dense non-porous gas tight peripheral seal member covering at least a portion of the surface of the support structure not covered by the anodes, the interconnectors and the electrolyte members and a dense non-porous gas tight seal comprising a seal layer filling an area defined by a side surface of the electrolyte member of the second cell, a side surface of the cathode of the second cell, a side surface of the cathode of the third cell, and the top surface of the second interconnector, wherein the dense non-porous seal contacts a top surface of the dense non-porous gas tight peripheral seal.
25. A solid oxide fuel cell component as claimed in claim 24 wherein the dense non-porous seal contacts the top surface of the electrolyte member of the second cell.
26. A solid oxide fuel cell component as claimed in claim 3 wherein the dense non-porous gas tight seal comprises a glass ceramic material.
27. A solid oxide fuel cell component as claimed in claim 3 wherein the dense non-porous seal comprises a glass containing barium oxide, silica, alumina and zircon.
28. A solid oxide fuel cell component as claimed in claim 1 wherein a portion of the first end of the electrolyte member of the second cell contacting a top surface of the first interconnector.
29. A solid oxide fuel cell component as claimed in claim 28 wherein the first end of the electrolyte member of the second cell contacts the second side of the first interconnector.
30. A solid oxide fuel cell component as claimed in claim 6 wherein the third layer comprises an alloy of any two or more of nickel, platinum, palladium, ruthenium and silver.
31. A solid oxide fuel cell component as claimed in claim 10 wherein the second layer comprises an alloy of any two or more of nickel, platinum, palladium, ruthenium, and silver.
32. A solid oxide fuel cell component comprising:
a porous gas permeable support structure having a surface;
at least first, second and third solid oxide fuel cells being arranged in spaced apart relationship on the surface of the porous gas permeable support structure, such that the first cell is adjacent to the second cell, the second cell is adjacent to the third cell, and the cells are arranged in electrical series;
the first, second and third cells each comprising a dense non-porous gas tight electrolyte member, a porous gas permeable anode, and a porous gas permeable cathode;
the anode of the first cell being connected to the cathode of the adjacent second cell by a first dense non-porous and gas tight interconnector;
the first interconnector having a bottom surface contacting the surface of the support, a first side surface contacting the anode of the first cell, a top surface, and a second side surface spaced apart from the anode of the second cell;
the anode of the first cell contacting a portion of the top surface of the first interconnector and the cathode of the second cell contacting another portion of the top surface of the first interconnector;
the anode of the second cell being connected to the cathode of the adjacent third cell by a second dense non-porous and gas tight interconnector;
the second interconnector having a bottom surface contacting the surface of the support, a first side surface contacting the anode of the second cell, a top surface, and a second side surface spaced apart from the anode of the third cell;
the anode of the second cell contacting a portion of the top surface of the second interconnector and the cathode of the third cell contacting another portion of the top surface of the second interconnector;
the electrolyte member of the second cell being arranged between the anode and cathode of the second cell, a first end of the electrolyte member of the second cell contacting the surface of the support between the second side surface of the first interconnector and a side surface of the anode of the second cell, a second end of the electrolyte member of the second cell contacting the top surface of the second interconnector between the anode of the second cell and the cathode of the third cell, and the electrolyte member of the second cell is spaced apart from the cathode of the third cell by a portion of the top surface of the second interconnector; and
a dense non-porous gas tight peripheral seal member comprising a seal layer located on the surface of the support structure on the periphery of the area defined by the anode of the second cell and the first and second interconnectors the dense non-porous gas tight peripheral seal member and the second electrolyte members arranged to encapsulate the second anode except for the bottom surface of the second anode facing the surface of the porous gas permeable support structure to reduce leakage of reactant from the second anode.
33. A solid oxide fuel cell component as claimed in claim 1 wherein a pitch of the solid oxide fuel cells is between 5 mm and 20 mm.
34. A solid oxide fuel cell component as claimed in claim 1 wherein the electrolyte member to interconnector aspect ratio is about 3 to 1, the electrolyte member to interconnector aspect ratio is the ratio of the length of the electrolyte member to the length of the interconnector.
35. A solid oxide fuel cell component as claimed in claim 2 wherein the dense non-porous gas tight peripheral seal comprises a first layer and a second layer.
36. A solid oxide fuel cell component as claimed in claim 2 wherein the dense non-porous gas tight peripheral seal comprises a ceramic.
37. A solid oxide fuel cell component as claimed in claim to 36 wherein the dense non-porous gas tight peripheral seal comprises yttria stabilized zirconia.
38. A solid oxide fuel cell component as claimed in claim 36 wherein the dense non-porous gas tight peripheral seal comprises yttria stabilized zirconia doped with silicate glass or yttria stabilized zirconia doped with calcium chromate.
39. A solid oxide fuel cell component comprising:
a porous gas permeable support structure having a surface;
at least first, second and third solid oxide fuel cells being arranged in spaced apart relationship on the surface of the porous gas permeable support structure, such that the first cell is adjacent to the second cell, the second cell is adjacent to the third cell, and the cells are arranged in electrical series;
the first, second and third cells each comprising a dense non-porous gas tight electrolyte member, a porous gas permeable anode, and a porous gas permeable cathode;
the anode of the first cell being connected to the cathode of the adjacent second cell by a first dense non-porous and gas tight interconnector;
the first interconnector having a bottom surface contacting the surface of the support, a first side surface contacting the anode of the first cell, a top surface, and a second side surface spaced apart from the anode of the second cell;
the anode of the first cell contacting a portion of the top surface of the first interconnector and the cathode of the second cell contacting another portion of the top surface of the first interconnector;
the anode of the second cell being connected to the cathode of the adjacent third cell by a second dense non-porous and gas tight interconnector;
the second interconnector having a bottom surface contacting the surface of the support, a first side surface contacting the anode of the second cell, a top surface, and a second side surface spaced apart from the anode of the third cell;
the anode of the second cell contacting a portion of the top surface of the second interconnector and the cathode of the third cell contacting another portion of the top surface of the second interconnector;
the electrolyte member of the second cell being arranged between the anode and cathode of the second cell, a first end of the electrolyte member of the second cell contacting the surface of the support between the second side surface of the first interconnector and a side surface of the anode of the second cell, a second end of the electrolyte member of the second cell contacting the top surface of the second interconnector between the anode of the second cell and the cathode of the third cell, and the electrolyte member of the second cell is spaced apart from the cathode of the third cell by a portion of the top surface of the second interconnector;
a dense non-porous gas tight seal comprising a seal layer filling an area defined by a side surface of the electrolyte member of the second cell, a side surface of the cathode of the second cell, a side surface of the cathode of the third cell, and the top surface of the second interconnector to reduce leakage of reactant; and
a dense non-porous gas tight peripheral seal member covering at least a portion of the surface of the support structure not covered by the anodes, the interconnectors and the electrolyte members.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. An acoustic system for applying vibratory energy, the system comprising:
a horn connected to an ultrasonic energy source, the horn having a length that is other than one half a wavelength of the ultrasonic energy source, wherein at least a leading section and a trailing section of the horn consist essentially of a ceramic material;
wherein the horn is defined by a trailing end and a leading end, and further wherein the ultrasonic energy source includes a mounting component selected from the group consisting of a waveguide and a booster, the trailing end of the horn engaging in an interference fit with the mounting component such that a junction point between the mounting component and the trailing end of the horn is at an anti-node, the horn being secured to the mounting component by a clamping mechanism, wherein the horn is a ceramic cylindrical rod and the mounting component defines a circular bore, wherein the trailing end of the horn is received within the circular bore to provide an interference fit of 0.003 inch at room temperature.
2. The system of claim 1, wherein the mounting component is a waveguide which has a length selected such that a node is maintained at a mid-span of the waveguide and a mid-span of the horn.
3. The system of claim 1, wherein the entirety of the horn consists essentially of a ceramic material.
4. The system of claim 1, wherein the ceramic material includes at least one ceramic selected from silicon nitride, aluminum oxide, sialon, titanium diboride, zirconia, or silicon carbide.
5. The system of claim 1, wherein the horn is a cylindrical rod.
6. The system of claim 1, wherein the horn is adapted for at least partial immersion in a high temperature fluid medium.
7. The system of claim 6, wherein the horn is adapted to transmit ultrasonic energy at a frequency of approximately 20 kHz to a molten metal-based medium and is characterized by a working life of at least 100 hours.
8. The system of claim 7, wherein the horn is characterized by a working life of at least 200 hours when immersed in a molten aluminum-based medium.
9. The system of claim 1, wherein the mounting component is a waveguide comprising titanium.
10. The system of claim 1, further comprising:
a transducer for changing electrical energy into ultrasonic vibration; and
a booster positioned between said transducer and said horn for increasing an amplitude of the vibration; and wherein the mounting component is a waveguide comprising a material other than ceramic for transferring the amplified vibration to the horn.