Fuel Cell Stack Seals for Lower Corner Compressive Stress

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Solution Overview

Problem

Fuel cell stacks face challenges such as compressive stress on fuel cell corners, which can lead to damage and reduced performance, due to the use of conventional seals and fuel manifolds.

Innovation Solution

The method involves using stress-reducing seals with support portions and extensions on cross-flow interconnects, which are sintered to reflow and provide uniform contact with fuel cells, reducing compressive stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional seals are used in fuel cell stacks, then the sealing function is achieved, but compressive stress on fuel cell corners increases leading to damage

Engineering Contradiction:

Improvefuel cell integrityVSAvoidcompressive stress on fuel cell corners

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The seal is divided into multiple functional regions: a first region that provides sealing against the fuel cell and a second region that provides structural support. This segmentation allows the seal to simultaneously achieve sealing functionality while distributing compressive stress to protect fuel cell corners from damage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the seal are designed with different properties: the first region is optimized for sealing contact with the fuel cell, while the second region is optimized for providing structural support and stress distribution. This local differentiation enables the seal to address both sealing and stress reduction requirements effectively.

Inventive Principle:

Principle #3Local quality

2Reliability

If stress-reducing seals with support portions are used, then compressive stress on fuel cells is reduced, but device complexity increases

Engineering Contradiction:

Improvefuel cell protectionVSAvoidseal structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sealing function and structural support function are merged into a single integrated seal component. The first region provides sealing while the second region provides support, combining multiple functions into one part rather than requiring separate sealing and support components, thereby reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The seal is designed as a multi-functional component that simultaneously performs sealing, stress distribution, and structural support. This universal design eliminates the need for multiple separate components, reducing assembly complexity while maintaining fuel cell protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 minimizes damage to fuel cells by reducing compressive stress, enhances uniform fuel distribution, and improves the overall performance and yield of the fuel cell stack.

Implementation Method 1

sintering the fuel cell stack to reflow the riser seals and the perimeter seal

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS20250038242A1Method of making a fuel cell stack with stress reducing seals

Publication Date: 2025.01.30 BLOOM ENERGY CORP

AI summary

A method of assembling a fuel cell stack includes depositing a liquid seal material on an interconnect, pressing a fuel cell into the liquid seal material, and solidifying the liquid seal material after pressing the fuel cell into the liquid seal material. The seal material may also include a support portion or extensions which are configured to reduce an amount of compressive stress on corners of the fuel cell in the fuel cell stack.