Fuel Cell Layer Laser-Absorbing Interconnector

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Solution Overview

Problem

In planar fuel cell configurations, the narrow regions of discontinuity formed by laser processing can lead to unwanted transmission through the fuel cell layer, causing burn-through and hydrogen leakage, which complicates the miniaturization of fuel cells and increases ohmic losses.

Innovation Solution

The use of a composite layer with gas-impermeable regions made of dielectric materials, including epoxy resin with additives that absorb or scatter laser beams, and a conductive gas-impermeable region to prevent laser transmission and connect anode and cathode cells, reducing the frequency of discontinuity and hydrogen leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the spacing between adjacent fuel cells is reduced to miniaturize the fuel cell, then the integration density is improved, but laser beam transmission through narrow discontinuity regions causes burn-through and hydrogen leakage

Engineering Contradiction:

Improvefuel cell sizeVSAvoidgas leakage prevention

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

A laser-absorbing layer is introduced as an intermediary component between the anode and cathode discontinuity regions. This layer absorbs the laser beam energy that would otherwise transmit through the narrow spacing and cause burn-through, thereby preventing hydrogen leakage while allowing tight spacing for miniaturization

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The physical and chemical properties of the discontinuity region are changed by introducing a laser-absorbing material with specific optical absorption characteristics. This material is designed to absorb laser beams at the operating wavelength while maintaining gas impermeability, transforming the region from a potential failure point to a protective barrier

Inventive Principle:

Principle #35Parameter changes

2Power

If the number of cells connected in series is increased to obtain necessary voltage, then the voltage output is improved, but the total active area decreases due to space overhead of interconnect regions

Engineering Contradiction:

Improvevoltage outputVSAvoidtotal active area

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

The interconnector structure is designed with thin-film and planar geometries, using flexible sealing layers and compact conductive paths. This reduces the vertical and lateral footprint of interconnect regions, minimizing the space overhead and maximizing the total active area available for power generation

Inventive Principle:

Principle #30Flexible shells and thin films

3Loss of energy

If the cell pitch is reduced to decrease resistive electrical losses, then the ohmic losses are improved, but the spacing between cells becomes too narrow causing laser transmission and burn-through

Engineering Contradiction:

Improveresistive electrical lossesVSAvoidlaser burn-through

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The laser-absorbing layer serves as a mediator that decouples the relationship between cell pitch and laser transmission. It allows the cell pitch to be reduced for lower ohmic losses while the intermediary layer independently handles the laser absorption function, preventing burn-through despite narrow spacing

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively minimizes laser burn-through and hydrogen leakage, allowing for a higher integration density of planar fuel cells while maintaining efficient power generation by narrowing the spacing between cells without increasing ohmic losses.

Implementation Method 1

a first gas-impermeable interface region and a second gas-impermeable interface region each comprising a dielectric material which has been constructed to block the transmission of laser beam

Methodology Applied

Scientific EffectLaser beam absorption: Absorption (EM radiation)

Implementation Method 2

dielectric material which has been constructed to block the transmission of laser beam

Methodology Applied

Scientific EffectLaser beam scattering: Scattering

Implementation Method 3

A fuel cell is a device that generates electricity from hydrogen and oxygen

Methodology Applied

Scientific EffectElectrochemical reaction: Fuel Cell

Implementation Method 4

a plurality of ion conducting components, positioned between the interconnectors; and a first plurality of electrode coatings disposed on the first surface to form anodes; and a second plurality of electrode coatings disposed on the second surface to form cathodes, each of the first and second plurality of electrode coatings in ionic contact with one of the ion conducting components

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Data Source

PatentUS8795919B2Fuel cell layer

Publication Date: 2014.08.05 SANYO ELECTRIC CO LTD

AI summary

MEAs are formed in regions corresponding to openings provided in a substrate. Each MEA includes an electrolyte membrane, an anode catalyst layer, and a cathode catalyst layer. The substrate has a first gas-impermeable region and a second gas-impermeable region between adjacent MEAs. A third gas-impermeable region is provided between the first gas-impermeable region and the second gas-impermeable region. The third gas-impermeable region having conductive property constitutes a part of interconnector.