Fuel cell matrix composition and method of manufacturing same

1. A method of making a fuel cell matrix for use in a molten carbonate fuel cell, comprising:

providing a first predetermined amount of a support material comprising lithium aluminum oxide, a second predetermined amount of an electrolyte material comprising one or more of a carbonate electrolyte and a carbonate electrolyte precursor, and a third predetermined amount of an additive material comprising aluminum, wherein the additive material that has a shape of a flake and has an average thickness of less than 1 μm, an average length in a range of 5 μm to 40 μm average Brunauer-Emmett-Teller (BET) surface area in a range of 1 m 2 /g to 6 m 2 /g, and a leafing value in a range of 70 to 100%;

processing said support material, electrolyte material and additive material to form the fuel cell matrix, such that the fuel cell matrix includes:

a porous body formed from the support material and the additive material, and

the electrolyte material disposed in pores of the porous body.

2. The method of making a fuel cell matrix in accordance with claim 1 , wherein said processing step comprises:

mixing the first predetermined amount of support material and the second predetermined amount of the electrolyte material to form a first mixture; and

adding the third predetermined amount of the additive material to the first mixture to form a second mixture.

3. The method of making a fuel cell matrix in accordance with claim 2 , wherein the processing step further comprises adding at least one of a binder and a plasticizer to the second mixture to form a third mixture, and forming the fuel cell matrix from said third mixture.

4. The method of making a fuel cell matrix in accordance with claim 3 , wherein said at least one of the binder and the plasticizer comprise about 19 to 20 weight percent of the fuel cell matrix.

5. The method of making a fuel cell matrix in accordance with claim 3 , wherein the forming the fuel cell matrix comprises casting the third mixture and then drying the cast mixture to form a tape element.

6. The method of making a fuel cell matrix in accordance with claim 5 , wherein the casting comprises tape casting.

7. The method of making a fuel cell matrix in accordance with claim 2 , further comprising pre-milling the additive material prior to adding the additive material to the first mixture.

8. The method of making a fuel cell matrix in accordance with claim 7 , wherein the pre-milling of the additive material comprises milling the additive material for a time in a range of 100 to 300 minutes using grinding media having a size in a range of 0.3 mm to 0.6 mm at a speed in a range of 2,000 to 3,000 revolutions per minute.

9. The method of making a fuel cell matrix in accordance with claim 1 , wherein the third predetermined amount of additive material is in a range of 5 to 35 volume percent of the fuel cell matrix.

10. The method of making a fuel cell matrix in accordance with claim 9 , wherein the second predetermined amount of electrolyte material is in a range of 5 to 100 volume percent of the first predetermined amount of support material.

11. The method of making a fuel cell matrix in accordance with claim 2 , wherein the mixing of the support material and the electrolyte material to form the first mixture comprises milling at a speed in a range of 2,000 to 3,000 revolutions per minute using a grinding media having a ball size in a range of 0.3 to 3 mm at a loading in a range of 60 to 80%.

12. The method of making a fuel cell matrix in accordance with claim 11 , wherein the mixing of the support material and the electrolyte material to form the first mixture is performed in a solvent comprising 1 volume percent to 6 volume percent of fish oil to prevent re-agglomeration of the support material and the electrolyte material.

13. A method of making a fuel cell matrix for use in a molten carbonate fuel cell, comprising:

providing a first predetermined amount of a support material comprising lithium aluminum oxide, a second predetermined amount of an electrolyte material comprising one or more of a carbonate electrolyte and a carbonate electrolyte precursor, and a third predetermined amount of an additive particle material comprising aluminum; and

processing a mixture of the support material, the electrolyte material and the additive particle material, the processing including:

converting the additive particle material into an additive flake material that has a shape of a flake and has an average thickness of less than 1 μm, an average length in a range of 5 μm to 40 μm, an average Brunauer-Emmett-Teller (BET) surface area in a range of 1 m 2 /g to 6 m 2 /g, and a leafing value in a range of 70 to 100%, and

forming the fuel cell matrix such that the fuel cell matrix includes:

a porous body formed from the support material and the additive flake material, and

the electrolyte material disposed in pores of the porous body.

14. The method of making a fuel cell matrix in accordance with claim 13 , wherein the processing step comprises:

mixing the support material and the electrolyte material to form a first mixture;

adding the additive particle material to the first mixture to form a second mixture; and

milling the second mixture until the additive particle material is converted to the additive flake material.

15. The method of making a fuel cell matrix in accordance with claim 14 , wherein the processing step further comprises adding at least one of a binder and a plasticizer to the second mixture to form a third mixture and forming the fuel cell matrix from the third mixture.

16. The method of making a fuel cell matrix in accordance with claim 14 , wherein milling the second mixture comprises milling for a time in range of 100 to 300 minutes using grinding media having a size in a range of 0.3 mm to 0.6 mm at a speed in a range of 2,000 to 3,000 revolutions per minute.

17. The method of making a fuel cell matrix in accordance with claim 13 , wherein the third predetermined amount of additive particle material is in a range of 5 to 35 volume percent of the fuel cell matrix.

18. The method of making a fuel cell matrix in accordance with claim 14 , wherein mixing the support material and the electrolyte material to form a first mixture comprises milling at a speed in a range of 2,000 to 3,000 revolutions per minute using a grinding media having a ball size in a range of 0.3 to 3 mm at a loading of 60 to 80%.