3D Extrusion Printed Solid Oxide Fuel Cell Interconnects
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Solution Overview
Problem
The fabrication and assembly of solid oxide fuel cells (SOFCs) are inefficient due to structural and material limitations, particularly with traditional metallic components that lead to increased manufacturing time, weight, and cost, as well as challenges in gas sealing and compression, which hinder their adoption in mobile applications.
Innovation Solution
The method involves 3D extrusion printing and 2D casting techniques to form thin, functional ceramic layers in intimate contact, eliminating the need for compression hardware, gas seals, and metallic interconnects by using ceramic particle-laden compositions that can be processed at room temperature and ambient pressure, forming a monolithic structure through co-sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metallic interconnect plates and compression hardware are used, then electrical conductivity and structural support are achieved, but device weight and manufacturing complexity increase
Solution Approach 1:
The patent merges the interconnect plate and electrode functions into a single integrated component. The interconnect plate includes electrode layers formed directly on its surfaces, eliminating the need for separate electrode assemblies and reducing overall device weight while maintaining structural support and electrical conductivity functions
Solution Approach 2:
The interconnect plate is designed to perform multiple functions simultaneously: providing structural support, conducting electricity, distributing gases through manifolds and channels, and serving as a substrate for electrode layers. This multi-functionality reduces the number of separate components needed, thereby reducing weight and manufacturing complexity
2Ease of manufacture
If separate processing and assembly of individual components is used, then manufacturing flexibility is maintained, but manufacturing time and assembly complexity increase
Solution Approach 1:
The patent combines multiple manufacturing steps into integrated processes. The interconnect plate is manufactured with electrode layers, gas channels, and manifolds as part of a single component structure, reducing the number of separate assembly operations required and decreasing overall manufacturing time while maintaining design flexibility through additive manufacturing
3Strength
If thick electrodes are used for handling and assembly, then mechanical strength is improved, but materials cost and concentration polarization losses increase
Solution Approach 1:
The patent applies different thicknesses and material properties to different regions of the electrode layers. The electrodes are formed with varying local densities and compositions to provide sufficient mechanical strength for handling in certain areas while maintaining thin sections in active regions to reduce concentration polarization losses and improve electrochemical performance
4Ease of manufacture
If ferritic steel interconnect plates are used, then cost and machinability are improved, but oxide scale formation and Cr contamination occur
Solution Approach 1:
The patent uses composite interconnect plate structures combining ferritic steel with ceramic coatings or composite materials. This maintains the cost-effectiveness and machinability of steel while the ceramic components prevent oxide scale formation and chromium contamination, resolving the contradiction between manufacturability and chemical stability
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 approach enables rapid device design and fabrication, reduces material costs, and improves scalability, resulting in a lightweight, efficient, and flexible SOFC design suitable for mobile applications by eliminating the need for cumbersome compression hardware and metallic components.
Implementation Method 1
3D extrusion printing a three-dimensional anode comprising a central portion comprising a plurality of spaced-apart, parallel fibers
Implementation Method 2
co-sintering the green body cell
Data Source
AI summary
Solid oxide electrochemical devices, methods for making the electrochemical devices, and methods of using the electrochemical devices are provided. The electrochemical devices comprise a plurality of stacked functional layers that are formed by a combination of three-dimensional (3D) extrusion printing and two-dimensional (2D) casting techniques.