Electrochemical Cell Sealing Structure for High-Temperature Gas Tightness

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Solution Overview

Problem

Existing fuel cell stack devices face challenges in durability due to issues with bonding and gas sealing, particularly at high temperatures, leading to potential leakage and reduced performance.

Innovation Solution

The implementation of an electrochemical cell design that includes a chromium-containing interconnector with an intermediate material having varying surface roughness and thickness at different positions, along with specific metal element content rates at boundaries, enhances adhesiveness and reduces chromium desorption, thereby improving durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal member containing chromium is used for the interconnector, then electrical conductivity and structural strength are improved, but chromium desorption occurs at high temperatures leading to reduced durability

Engineering Contradiction:

Improvestructural strengthVSAvoiddurability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

An intermediate material layer is introduced between the chromium-containing metal member and the sealing material. This intermediate layer acts as a mediator that prevents direct contact and chemical reaction between chromium and the sealing material, thereby preventing chromium desorption while maintaining the structural strength and electrical conductivity of the metal member.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sealing structure uses a composite material system consisting of the chromium-containing metal member, the intermediate material layer, and the sealing material. This composite structure combines the advantages of each material while mitigating their individual disadvantages, particularly the chromium desorption issue.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If a uniform sealing structure is used, then manufacturing simplicity is maintained, but gas leakage occurs at high temperatures due to insufficient adhesiveness

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidgas sealing performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The intermediate material layer has different properties at different positions: it has higher adhesiveness to the sealing material at the sealing interface and appropriate thermal stability near the chromium-containing metal member. This local differentiation of material properties ensures effective gas sealing at critical interfaces while preventing chromium desorption in other regions.

Inventive Principle:

Principle #3Local quality

3Device complexity

If the intermediate material has uniform thickness and surface roughness, then manufacturing complexity is reduced, but adhesiveness between the sealing material and metal member is insufficient

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidadhesiveness

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The intermediate material layer exhibits local quality variations with different surface roughness and thickness at different positions. The surface facing the sealing material has higher roughness and appropriate thickness to maximize mechanical interlocking and adhesiveness, while other regions have different properties optimized for their specific functions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The surface roughness and thickness of the intermediate material layer are varied as key parameters to optimize adhesiveness. By changing these physical parameters locally, the bonding strength between the sealing material and metal member is significantly enhanced without requiring complex multi-layer structures.

Inventive Principle:

Principle #35Parameter changes

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

This configuration enhances the durability of the electrochemical cell and the overall cell stack device by minimizing gas leakage and maintaining performance under high-temperature conditions.

Implementation Method 1

The intermediate material includes two or more portions having different surface roughnesses or different thicknesses at different positions

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The intermediate material is located between the metal member and the sealing material

Methodology Applied

Scientific EffectMechanical interlocking:

Implementation Method 3

the surface roughness of a first interface of the intermediate material facing the sealing material is different from a surface roughness of a second interface of the intermediate material facing the metal member

Methodology Applied

Scientific EffectDesorption prevention: Desorption

Data Source

PatentUS20250219109A1Electrochemical cell, electrochemical cell device, module and module housing device

Publication Date: 2025.07.03 KYOCERA CORP

AI summary

An electrochemical cell includes a porous portion, a metal member, a sealing material, and an intermediate material. The porous portion is electrically conductive. The metal member contains chromium. The sealing material is located on the porous portion and on the metal member. The intermediate material is located between the metal member and the sealing material. The intermediate material includes two or more portions having different surface roughnesses or different thicknesses at different positions.