Compliant Contact Ink for Fuel Cell Interconnect Resistance
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Solution Overview
Problem
Existing fuel cell technologies face challenges in achieving low resistance electrical contacts between electrodes and interconnects due to rigid or difficult-to-print contact materials, which can lead to failure modes and increased manufacturing costs.
Innovation Solution
A compliant contact material is developed using an electrically conductive print ink containing a plasticizer, binder, and solvent, allowing for flexible application and conformation around surface irregularities, thereby reducing pressure on delicate fuel cell components and enhancing interface continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid contact material is used, then electrical contact resistance is reduced, but manufacturing difficulty and failure risk increase
Solution Approach 1:
The patent modifies the physical and chemical parameters of the contact material by incorporating organic binders and plasticizers, transforming rigid inorganic materials into a compliant, printable formulation that maintains electrical conductivity while enabling flexible application methods
Solution Approach 2:
The invention creates a composite contact material system combining electrically conductive inorganic particles (such as metal powders or conductive ceramics) with organic binding agents and plasticizers, achieving a balance between electrical performance, mechanical compliance, and printability
2Ease of manufacture
If compliant contact material is used, then ease of printing and conformation improve, but contact resistance may increase
Solution Approach 1:
The patent optimizes the formulation parameters including plasticizer content, binder type, and particle size distribution to achieve the right balance between compliance for easy printing and sufficient electrical conductivity for low contact resistance
Solution Approach 2:
The organic binder and plasticizer act as intermediary substances that facilitate the printing and conformation of the contact material while the conductive particles maintain the electrical pathway, mediating between the conflicting requirements of compliance and conductivity
3Reliability
If pressure is applied to ensure contact, then electrical contact improves, but damage to delicate fuel cell components increases
Solution Approach 1:
The patent employs a compliant contact material formulation that acts as a flexible interface layer, conforming to surface irregularities and achieving reliable electrical contact without requiring high pressing forces that could damage delicate fuel cell components
Solution Approach 2:
By changing the mechanical parameters of the contact material through plasticizer addition, the material becomes sufficiently compliant to deform and conform under low pressure, ensuring good electrical contact while minimizing stress on fragile components
Data Source
AI summary
A method of making a fuel cell stack includes applying an electrically conductive, compliant contact print ink containing an electrically conductive material, a plasticizer, a solvent, and a binder to at least one of a surface of an electrode of a fuel cell or a surface of an interconnect, and placing the fuel cell and the interconnect in the fuel cell stack such that the compliant contact print ink is located between the electrode of the fuel cell and the interconnect.