Clad Copper Wire for Fuel Cell Current Collectors
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Solution Overview
Problem
Current collectors and wire interconnects in fuel cells face challenges in maintaining conductivity and environmental protection when exposed to varying environments, such as reducing and oxidizing gases, requiring multiple metal compositions that increase complexity and cost.
Innovation Solution
A current collector design featuring a high conductivity metal core with an environmentally isolating outer cladding, such as copper with Crofer 22 APU, allows for use in both oxidizing and reducing environments, reducing complexity and cost by eliminating the need for multiple materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple metal compositions are used in different portions of the interconnect and current collector system, then environmental protection against varying conditions is improved, but device complexity increases
Solution Approach 1:
The patent applies composite materials by creating a clad wire structure with a copper core and Crofer 22 APU alloy cladding. This composite structure combines the high electrical conductivity of copper with the environmental resistance of the ferritic stainless steel alloy, allowing a single wire to perform multiple functions that previously required different metal compositions in different locations.
Solution Approach 2:
The clad wire structure achieves universality by designing a single wire composition that can be utilized in a variety of different environments including both oxidizing and reducing conditions. This multi-functional wire eliminates the need for multiple specialized materials, reducing device complexity while maintaining environmental protection across all fuel cell components.
2Reliability
If multiple metal compositions are used in different portions of the interconnect and current collector system, then environmental protection against varying conditions is improved, but manufacturing cost increases
Solution Approach 1:
The clad wire structure combines copper and Crofer 22 APU alloy in a single manufactured product, achieving environmental protection without requiring multiple separate materials. The composite structure is manufactured as an integrated component, simplifying the supply chain and reducing the costs associated with handling, installing, and maintaining multiple different metal compositions.
Solution Approach 2:
By creating a universal wire composition that performs both electrical conduction and environmental protection functions across all fuel cell locations, the patent reduces manufacturing costs. This single wire type can be produced in volume and installed throughout the system, eliminating the need to manufacture and manage multiple specialized materials.
3Device complexity
If a single wire composition is used throughout the system, then device complexity and manufacturing cost are reduced, but conductivity maintenance in varying environments deteriorates
Solution Approach 1:
The clad wire structure uses a copper core to maintain high electrical conductivity while the Crofer 22 APU alloy cladding provides environmental protection. This composite design allows the wire to maintain its conductivity function in varying environments without requiring multiple different wire compositions, thus reducing device complexity while preserving electrical performance.
4Ease of manufacture
If a single wire composition is used throughout the system, then manufacturing cost is reduced, but environmental protection against varying conditions deteriorates
Solution Approach 1:
The clad wire structure combines copper and Crofer 22 APU alloy to create a single wire composition that provides both electrical conductivity and environmental protection. This composite material approach maintains manufacturing simplicity while achieving the environmental resistance that would otherwise require multiple specialized materials, thus resolving the contradiction between manufacturing ease and environmental protection.
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 solution provides improved conductivity and environmental protection, extending fuel cell operation endurance to nearly 1000 hours without significant degradation, as seen in the use of copper core with Crofer cladding, which maintains low resistivity and resistance to environmental conditions.
Implementation Method 1
at least one wire having an inner core of high conductivity metal
Implementation Method 2
outer cladding of an environmentally isolating material
Implementation Method 3
resistance to environmental conditions
Data Source
AI summary
A current collector for a fuel cell that includes at least one wire having an inner core of high conductivity metal and an outer cladding of an environmentally isolating material. The current collector may be utilized in both an oxidizing and reducing environment.