Carbon Matrix Composite Interconnect for Lightweight Solid Oxide Fuel Cells
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Solution Overview
Problem
Existing solid oxide fuel cells rely on heavy metal interconnects, which are undesirable in applications requiring lighter weight materials, and existing solutions do not adequately address the need for materials that are both lightweight and thermo-mechanically stable at high temperatures.
Innovation Solution
A carbon matrix composite interconnect is developed, incorporating carbon fibers, metal fibers, ceramic fibers, or a combination thereof, with a porosity gradient and density less than 3.4 grams per cubic centimeter, which is thermo-mechanically stable at temperatures greater than 400°C and has low electrical resistivity, prepared using techniques such as chemical vapor infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal interconnects are used in solid oxide fuel cells, then structural strength and electrical conductivity are ensured, but the weight of the fuel cell increases
Solution Approach 1:
The patent employs a composite interconnect structure consisting of a metal substrate providing structural strength and a ceramic coating layer providing oxidation resistance and thermal stability. This composite approach allows the interconnect to achieve both mechanical integrity and chemical stability at high temperatures without using heavy pure metal materials throughout the entire structure.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the interconnect materials by selecting specific metal alloys with optimized strength-to-weight ratios and applying ceramic coatings with controlled thickness and composition. These parameter changes enable the interconnect to maintain structural strength while reducing overall weight compared to traditional solid metal interconnects.
2Weight of moving object
If lighter weight interconnect materials are used, then the weight of the fuel cell is reduced, but thermo-mechanical stability at high temperatures deteriorates
Solution Approach 1:
The patent uses a composite structure where a lightweight metal substrate is combined with a ceramic coating layer. The metal substrate provides low density and reduced weight, while the ceramic coating provides high-temperature stability and oxidation resistance, achieving both weight reduction and thermo-mechanical stability simultaneously.
Solution Approach 2:
The patent applies different material properties to different regions of the interconnect - the metal substrate provides mechanical strength and weight reduction, while the ceramic coating applied specifically on the surface provides thermal stability and chemical resistance. This local differentiation of material qualities allows the interconnect to meet both weight and stability requirements.
3Weight of moving object
If carbon matrix composite is used to reduce weight, then weight is reduced, but electrical conductivity may deteriorate
Solution Approach 1:
The patent employs a composite interconnect structure consisting of a metal substrate providing structural strength and electrical conductivity, and a ceramic coating layer providing oxidation resistance and thermal stability. This composite approach allows the interconnect to achieve both mechanical integrity and chemical stability at high temperatures without using heavy pure metal materials throughout the entire structure.
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 carbon matrix composite interconnect provides a lightweight, stable, and electrically conductive solution that maintains performance over extended periods at high temperatures, reducing weight and enhancing operational efficiency while resisting corrosion.
Implementation Method 1
thermo-mechanically stable at temperatures greater than 400°C for greater than 100 hours
Implementation Method 2
has an electrical resistivity less than or equal to 0.1 milliohm-cm at 20°C
Data Source
Figure 1
AI summary
Disclosed is a solid oxide fuel cell including an electrode-electrolyte assembly (12) and an interconnect (14) in communication with the electrode-electrolyte assembly, wherein the interconnect comprises a carbon matrix composite.