Flat Multilayered Ceramic Fuel Cell Sealing

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Solution Overview

Problem

Existing electrochemical energy converters face challenges in achieving a favorable power-to-volume ratio and are sensitive to temperature shocks, requiring special high-temperature-resistant gaskets and complex sealing mechanisms, which complicates maintenance and repair.

Innovation Solution

A flat multilayered ceramic structure with buried metallic conductive structures and porous cermet layers, featuring nickel nanotubes or meshes, allows for efficient fuel and electrical connections outside the high-temperature zone, using low-melting metal or polymer seals for easy disassembly and repair, and employing ceramic channels formed through machining, laser ablation, or photoforming methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a tubular ceramic supporting structure is used, then sealing reliability is improved, but power-to-volume ratio deteriorates

Engineering Contradiction:

Improvesealing reliabilityVSAvoidpower-to-volume ratio

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The fuel cell assembly is divided into multiple planar cells stacked together, with each cell being a separate functional unit. This segmentation allows for compact stacking arrangements that achieve high power density while maintaining reliable sealing at each interface between cells through gasket-based sealing solutions.

Inventive Principle:

Principle #1Segmentation

2Productivity

If plate structures with thin electrolyte layers are used, then power-to-volume ratio is improved, but sensitivity to temperature shocks worsens

Engineering Contradiction:

Improvepower-to-volume ratioVSAvoidsensitivity to temperature shocks

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The fuel cell employs a composite structure combining thin electrolyte layers with robust support plates and gasket materials. The electrolyte layer is supported by mechanically stronger materials that provide thermal mass and structural integrity, reducing sensitivity to temperature shocks while maintaining the high power-to-volume ratio enabled by the thin electrolyte configuration.

Inventive Principle:

Principle #40Composite materials

3Reliability

If special high-temperature-resistant gaskets are used, then sealing performance is improved, but device complexity worsens

Engineering Contradiction:

Improvesealing performanceVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The gasket material is designed to have thermal expansion properties matched to the adjacent ceramic components, creating a homogeneous thermal response across the sealing interface. This reduces differential thermal stress and maintains sealing effectiveness without requiring complex multi-material constructions or additional compensation mechanisms.

Inventive Principle:

Principle #33Homogeneity

4Reliability

If complex sealing mechanisms are used, then sealing reliability is improved, but ease of repair worsens

Engineering Contradiction:

Improvesealing reliabilityVSAvoidease of repair

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The fuel cell assembly is divided into modular planar cells with standardized sealing interfaces. Each cell can be independently removed and replaced, allowing for simple repair procedures where only the defective cell needs to be replaced rather than the entire assembly. The gasket-based sealing at each interface maintains reliability while enabling easy module replacement.

Inventive Principle:

Principle #1Segmentation

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 design enhances the power-to-volume ratio, minimizes connection degradation, and facilitates easy cell disconnection and repair, while maintaining high thermal and electrical conductivity, thus extending the operational life of the converters.

Implementation Method 1

At high temperature the zirconium ceramics exhibits strong ionic conductivity. Since only the oxygen ions can move through the ceramic layer

Methodology Applied

Scientific EffectIonic conductivity: Conduction (electrical)

Implementation Method 2

the electrolyte is polarised due to oxygen pressure drop across the electrolyte

Methodology Applied

Scientific EffectOxygen pressure drop: Pressure Gradient

Implementation Method 3

High-temperature fuel cells provide high efficiency in the process of converting chemical energy into electrical energy

Methodology Applied

Scientific EffectElectrochemical reaction: Fuel Cell

Implementation Method 4

ceramic channels formed through machining, laser ablation, or photoforming methods

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS8968959B2Method for fabrication of electrochemical energy converter and the electrochemical energy converter

Publication Date: 2015.03.03 HYDROGENTECH SPOLKA Z OGRANICZONA ODPOWIEDZIALNOSCIA

AI summary

In a method for fabrication of an electrochemical energy converter, cermet composition layers (2A), (2B) are applied on both sides of a central ceramic plate (1), channels (3A), (3B) are made in the cermet composition layers (2A), (2B), then the channels (3A), (3B) on both sides of the plate are covered with cermet composition layers (4A), (4B). Afterwards, both sides of the ceramic structure are overlaid with conductive structures (5A), (5B) and then with subsequent layers of the cermet composition (6A), (6B) containing nickel, then both sides of the ceramic structure are overlaid with: layers constituting the solid electrolyte (7A), (7B), layers constituting electrodes (8A), (8B) and contact layers (9A), (9B).