Clad Current Carrier for Solid Oxide Fuel Cell
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Solution Overview
Problem
Conventional materials for electric current carriers in solid oxide fuel cell (SOFC) systems suffer from poor electrical conductivity and mechanical instability at high operating temperatures, leading to significant power loss, high cost, and structural issues.
Innovation Solution
A two-component structure comprising a high-conductivity core material like copper, surrounded by a protective jacket of a high-temperature alloy such as stainless steel, with a clamp system using fine silver particles and an organic binder for secure electrical connections, minimizing power loss and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high-temperature alloy current carriers (e.g., Inconel) are used to maintain structural integrity at elevated temperatures, then structural stability is improved, but electrical conductivity deteriorates significantly (resistivity 100 or more times greater than copper)
Solution Approach 1:
The patent applies composite materials by creating a clad structure consisting of a high-conductivity core (copper or copper alloy) metallurgically bonded to a high-temperature alloy jacket (Inconel or similar). This composite structure combines the high electrical conductivity of copper with the structural stability and oxidation resistance of high-temperature alloys, resolving the contradiction between conductivity and structural stability at elevated temperatures.
Solution Approach 2:
The patent uses the nesting principle by placing the high-conductivity core material inside a protective high-temperature alloy jacket. The core is nested within the jacket, allowing the inner core to provide electrical conductivity while the outer jacket provides structural integrity and protection from oxidation at high temperatures.
2Loss of energy
If conventional high-conductivity metals (copper, silver, aluminum) are used as current carriers, then electrical conductivity is improved, but mechanical competence deteriorates at SOFC operating temperatures (copper becomes soft, aluminum becomes liquid, silver becomes extremely soft)
Solution Approach 1:
The patent uses composite materials to combine the high electrical conductivity of conventional metals (copper, silver, aluminum) with the mechanical strength of high-temperature alloys. The core material provides excellent conductivity while the surrounding jacket maintains structural integrity at operating temperatures, preventing the core from deforming despite its softness.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different parts of the current carrier: the core region provides high electrical conductivity while the jacket region provides mechanical strength and oxidation resistance. Each part is optimized for its specific function, resolving the contradiction between conductivity and mechanical competence.
3Loss of energy
If high-temperature alloy current carriers are sized large enough to minimize power loss, then power loss is reduced, but device complexity and fabrication difficulty increase significantly
Solution Approach 1:
The patent uses composite materials to achieve low power loss with smaller, more manageable dimensions. The high-conductivity core allows for reduced cross-sectional area compared to high-temperature alloys, while the jacket provides necessary structural support. This results in a less complex, more fabricable current carrier that still minimizes power loss.
4Loss of energy
If conventional high-conductivity metals are used as current carriers, then electrical conductivity is improved, but chemical stability deteriorates (copper corrodes rapidly by oxidation, leading to disintegration)
Solution Approach 1:
The patent applies composite materials where the high-conductivity core (copper or copper alloy) is protected by an outer jacket of oxidation-resistant high-temperature alloy. This composite structure maintains the electrical conductivity benefits of copper while the jacket prevents oxidation and corrosion, ensuring long-term chemical stability and reliability.
Solution Approach 2:
The high-temperature alloy jacket acts as an intermediary protective layer between the high-conductivity core and the oxidizing environment. This intermediary prevents direct contact between the copper core and oxygen, stopping oxidation before it can damage the conductive material, while still allowing electrical current to flow through the core.
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 reduces the size and cost of current carriers while maintaining high conductivity, allowing for efficient current transmission with minimal power loss and structural competence at elevated temperatures.
Implementation Method 1
The jacket is preferably formed of a high temperature alloy that is highly resistant to chemical attack, such as stainless steel, nickel, or a nickel alloy, and forms a stable, conductive oxide surface layer; the jacket, in turn, protects the core from oxidation or corrosion.
Implementation Method 2
a high-conductivity current-carrying core is formed of metallic material which may be incompetent under the operating temperatures of an SOFC, such as copper, brass, bronze, silver, silver-copper alloys, molybdenum, tungsten, or the like
Implementation Method 3
A protective jacket surrounds the core material and preferably is metallurgically bonded to the core.
Implementation Method 4
At SOFC operating temperatures, the organic binder is destroyed, and the silver particles become very soft and form a diffusion bond between the clamp and the jacket of the current carrier, resulting in an excellent electrical connection with very low loss.
Data Source
AI summary
A current carrier for a solid oxide fuel cell system comprising a current-carrying core formed of a high-conductivity metallic material such as copper, brass, bronze, silver, silver-copper alloys, molybdenum, tungsten, or the like, and a protective jacket surrounding the core material. Preferably, the jacket is metallurgically bonded to the core. The jacket is formed of a high temperature alloy such as stainless steel, nickel, or a nickel alloy. The jacket is structurally competent to maintain the form of the electrical carrier at elevated temperatures at which the core material may be structurally incompetent. The current carrier may be sized comparable to conventional copper cables. The carrier is attached to a fuel cell current collector by a clamp assembly having a large surface contact area. Preferably, a contact paste consisting of fine silver particles forms a diffusion bond between the clamp and the carrier jacket, resulting in a low-loss connection.