Composite Electrical Conductor for High-Temperature Electrolyser

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Solution Overview

Problem

High-temperature electrochemical devices, such as solid oxide fuel cells and electrolyzers, face significant thermal losses and oxidation issues due to the high electrical resistance of current lead rods, particularly at temperatures above 600°C, where standard materials like stainless steel are inefficient and copper oxidizes quickly, leading to increased ohmic losses and poor mechanical resistance.

Innovation Solution

A copper rod is protected with a stainless metal sheath using the Hot Isostatic Compression (CIC) process for diffusion welding, creating a robust and oxidation-resistant electrical conductor that minimizes Joule effect losses and withstands thermal cycling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If copper is used as current lead rod material, then electrical resistance is reduced and Joule losses are minimized, but oxidation resistance deteriorates quickly at temperatures above 600°C

Engineering Contradiction:

ImproveJoule lossesVSAvoidoxidation resistance

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent applies composite materials by combining copper core (for low electrical resistance) with stainless steel sheath (for oxidation resistance). This composite structure allows the current lead rod to simultaneously achieve low Joule losses through the copper conductor and high oxidation resistance through the protective stainless steel envelope, resolving the contradiction between energy efficiency and reliability at high temperatures.

Inventive Principle:

Principle #40Composite materials

2Reliability

If stainless steel is used as current lead rod material, then oxidation resistance is maintained, but electrical resistance increases and Joule losses worsen

Engineering Contradiction:

Improveoxidation resistanceVSAvoidJoule losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent uses composite materials with copper core and stainless steel sheath to resolve this contradiction. The copper core provides low electrical resistance for minimal Joule losses, while the stainless steel sheath provides the necessary oxidation resistance, allowing the system to maintain both reliability and energy efficiency simultaneously.

Inventive Principle:

Principle #40Composite materials

3Loss of energy

If copper rod is used without protection, then electrical conductivity is maximized, but mechanical resistance and durability deteriorate under high-temperature oxidation conditions

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmechanical resistance

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The patent applies composite materials where the copper core maintains high electrical conductivity while the stainless steel sheath provides mechanical strength and oxidation resistance. This composite structure allows the current lead rod to withstand high-temperature oxidation conditions while maintaining excellent electrical conductivity, resolving the contradiction between electrical performance and mechanical durability.

Inventive Principle:

Principle #40Composite materials

4Loss of energy

If the length of current lead rod is reduced, then Joule losses are minimized, but adaptability to different stack configurations deteriorates

Engineering Contradiction:

ImproveJoule lossesVSAvoidstack configuration adaptability

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The patent applies parameter changes by modifying the material composition (copper core with stainless steel sheath) rather than changing geometric parameters like length. This allows the current lead rod to maintain optimal length for minimal Joule losses while the enhanced material properties provide adaptability to different stack configurations and installation requirements.

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

The solution significantly reduces ohmic losses and ensures mechanical and oxidation resistance, maintaining electrical conductivity and durability even under extreme high-temperature conditions, addressing the limitations of existing materials in high-temperature electrochemical systems.

Implementation Method 1

A copper rod is protected with a stainless metal sheath using the Hot Isostatic Compression (CIC) process for diffusion welding

Methodology Applied

Scientific EffectDiffusion welding: Diffusion Welding

Implementation Method 2

using the Hot Isostatic Compression (CIC) process for diffusion welding

Methodology Applied

Scientific EffectHot isostatic compression: Hot Isostatic Pressing

Implementation Method 3

creating a robust and oxidation-resistant electrical conductor

Methodology Applied

Scientific EffectOxidation resistance: Oxidation

Implementation Method 4

significantly reduces ohmic losses

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 5

minimizes Joule effect losses

Methodology Applied

Scientific EffectElectrical resistance: Electrical Resistance

Data Source

PatentEP3098889B1Device for supplying electric current to an electrolyser or a high-temperature fuel cell

Publication Date: 2023.03.15 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

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Figure 3~4
Figure 5~8C

AI summary

An electrical conductor comprises a rod (74) made of a first metallic material and a sheath (76) completely covering the rod and made of a second stainless metallic material with an electrical resistivity lower than that of the first metallic material. The rod (74) and the sheath (76) are welded to each other using hot isostatic compression.