3D SOFC Membrane Structure for High-Density Aircraft Fuel Cells
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Solution Overview
Problem
Current fuel cells for aviation require improvements in energy density, ease of maintenance, and scalability, with existing solid oxide fuel cells facing challenges in current conductivity and mechanical stabilization, particularly in high-temperature applications.
Innovation Solution
A solid oxide fuel cell design featuring a self-supporting membrane structure with triply periodic level surfaces, ion-conductively connecting two open-pored cavities and using 3-D printing for production, allowing for high energy density and reduced electrical losses, with interconnector elements forming helical contacts and gas passage regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If solid oxide fuel cells are used for aviation, then high energy density is achieved, but current conductivity is insufficient at normal operating temperature
Solution Approach 1:
The patent transitions from planar interconnectors to three-dimensional tubular interconnectors with radial gas channels. This dimensional change allows the interconnectors to serve multiple functions simultaneously: providing structural support, conducting electricity, and facilitating gas flow through their hollow core and radial channels, thereby improving current conductivity while maintaining high energy density.
Solution Approach 2:
The patent employs composite material structures where tubular interconnectors are formed from electrically conductive materials that also provide mechanical strength and thermal stability. The combination of conductive materials with optimized microstructures enables both high current conductivity and structural integrity at operating temperatures.
2Productivity
If complex membrane structures are used to improve gas flow distribution, then gas flow efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the gas distribution function into multiple segments: axial gas channels for bulk flow, radial gas channels for distribution, and porous layers for final dispersion. This segmentation allows each component to be optimized independently and manufactured using standard techniques, reducing overall manufacturing complexity while maintaining high gas flow efficiency.
Solution Approach 2:
The patent uses curved and tubular geometries for interconnectors and gas channels rather than flat planar structures. The tubular interconnectors with radial channels provide three-dimensional gas distribution that improves flow efficiency while being amenable to manufacturing via techniques like 3D printing or extrusion processes.
3Reliability
If interconnector elements are added to improve electrical conductivity, then current discharge is improved, but device complexity increases
Solution Approach 1:
The tubular interconnectors are designed to perform multiple functions simultaneously: providing electrical conduction through their conductive material, structural support for the membrane, gas flow distribution through radial and axial channels, and mechanical stabilization. This multi-functionality reduces the need for separate components, thereby improving current conductivity without proportionally increasing device complexity.
Solution Approach 2:
The patent merges the functions of electrical interconnectors, gas distributors, and structural supports into a single integrated tubular component. By combining these previously separate elements into one multi-functional interconnector, the design simplifies the overall structure while enhancing electrical conductivity and gas flow management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances energy density, reduces electrical losses, and extends service life by distributing pressure differences effectively and reducing thermal stresses, while enabling efficient gas flow and easy access to electrical contacts.
Implementation Method 1
the membrane structure ion-conductively connects together a first open-pored cavity and a second open-pored cavity
Implementation Method 2
the membrane structure ion-conductively connects together a first open-pored cavity and a second open-pored cavity and separates them from one another gas-tightly
Implementation Method 3
Solid oxide fuel cells (SOFC) are a type of high-temperature fuel cell which converts a fuel (e.g. hydrogen) and an oxidation agent (e.g. air) into electricity, heat and other by-products such as e.g. water
Implementation Method 4
at least one of the interconnector elements is configured so as to form a linear contact, preferably a helical linear contact, with the membrane structure and/or the anode/cathode layer
Data Source
AI summary
In order to improve usability of hybrid or fully electric aircraft, a fuel cell having improved efficiency and increased volume/weight specific energy density is provided. The fuel cell has a self-supporting membrane structure that is formed as a triply periodic level surface, which separates a first cavity supplied with gaseous fuel from a second cavity supplied with gaseous oxidizer in a gas-sealed manner while connecting the cavities in an ion-conductive manner.