Corrugated Solid Oxide Cell Stack for Higher Power Density
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Solution Overview
Problem
Current solid oxide cell (SOC) stack designs face challenges in achieving high volumetric power density and mechanical strength due to the use of flat cells with gas distribution channels in metal interconnects, which result in significant electrochemically inactive surfaces and volume, limiting power density and durability.
Innovation Solution
A solid oxide cell stack design comprising a corrugated ceramic cell with a sealing frame and gas distribution channels, combined with a flat metallic interconnect, manufactured using 3D printing technologies, which enhances the active area and reduces interconnect volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat cells with gas distribution channels in metal interconnects are used, then the structure is simple to manufacture, but the volumetric power density and mechanical strength are limited due to significant electrochemically inactive surfaces and volume
Solution Approach 1:
The patent introduces corrugation in the ceramic cell membrane, transforming a flat two-dimensional structure into a three-dimensional corrugated structure. This dimensional change increases the active surface area within the same footprint, thereby improving volumetric power density without complicating the manufacturing process. The corrugated membrane maintains compatibility with existing tape-casting and hot-pressing techniques.
Solution Approach 2:
The corrugated membrane incorporates curved surfaces instead of flat planes, creating a wavy or undulated structure. This curvature increases the effective active area for electrochemical reactions while maintaining a compact overall volume, directly addressing the limitation of low volumetric power density in flat-cell designs.
2Ease of manufacture
If flat cells with gas distribution channels in metal interconnects are used, then the structure is simple to manufacture, but the mechanical strength is limited
Solution Approach 1:
The corrugated membrane structure provides enhanced mechanical strength through its curved geometry. The undulations create structural rigidity and resistance to deformation, improving the overall mechanical strength of the stack while maintaining manufacturing simplicity through compatibility with existing ceramic processing techniques.
3Strength
If thicker electrolyte layers are used to support the cell mechanically, then the mechanical strength is improved, but the ohmic losses increase
Solution Approach 1:
The corrugated membrane structure allows the electrolyte layer to achieve mechanical strength through its three-dimensional geometry rather than relying solely on increased thickness. The corrugations provide structural support while maintaining a thin electrolyte layer, thereby reducing ohmic losses while preserving mechanical integrity.
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 design achieves a significant increase in volumetric power density and mechanical strength, simplifying interconnection and reducing the overall stack thickness, while maintaining efficient gas distribution and current density.
Implementation Method 1
a ceramic cell with a corrugated membrane
Implementation Method 2
solid oxide cell (SOC) stack made of single repeating units (SRU), each of which comprising a ceramic cell with a corrugated membrane and a sealing frame with gas distribution holes and channels, and a flat metallic interconnect
Data Source
AI summary
The present invention relates to a solid oxide cell (SOC) stack made of single repeating units (SRU), each of which comprising: —a ceramic cell with a corrugated membrane and a sealing frame with gas distribution holes and channels, and—a flat metallic interconnect.