Layered Conductive Member for Durable Fuel Cell Bonding

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Solution Overview

Problem

Fuel cell stack devices face challenges in durability due to the bonding of conductive members, which affect the overall performance and longevity of the electrochemical cells.

Innovation Solution

A conductive member with a layered structure comprising a base material, a first layer of conductive oxide particles with open pores, and a second layer of smaller conductive oxide particles, along with a third layer for bonding to the air electrode, enhances the bonding strength and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a conductive member with a layered structure is used to bond electrochemical cells, then the bonding strength between layers is improved, but the device complexity increases due to multiple layers and particle size variations

Engineering Contradiction:

Improvebonding strengthVSAvoidlayered structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The conductive member is divided into multiple layers (first layer, second layer, third layer) with progressively smaller particle sizes. This segmentation allows each layer to perform specific functions: the first layer provides base conductivity, the second layer with smaller particles fills pores and enhances bonding, and the third layer provides additional bonding capability. This resolves the contradiction by improving bonding strength through layered segmentation while managing complexity through functional differentiation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the conductive member have different particle sizes and properties. The first layer contains larger first particles, the second layer contains smaller second particles that can enter pores of the first layer, and the third layer contains third particles for bonding. This local quality variation optimizes bonding strength at each interface while maintaining overall structural integrity, addressing the contradiction between improved bonding and controlled complexity.

Inventive Principle:

Principle #3Local quality

2Strength

If smaller second particles are used in the second layer to enhance bonding, then the bonding strength is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvebonding strengthVSAvoidparticle size control precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent systematically varies the particle size parameter across layers: first particles have a certain size range, second particles have smaller sizes to enter pores of the first layer, and third particles have sizes suitable for bonding. This controlled parameter change improves bonding strength while establishing clear manufacturing specifications for each layer, thereby managing the precision requirements through defined parameter ranges rather than uniform high precision across all layers.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260038849A1Conductive member, electrochemical cell device, module, and module housing device

Publication Date: 2026.02.05 KYOCERA CORP

AI summary

A conductive member includes a base material containing chromium, a first layer including first particles each of which is a conductive oxide, and a second layer including second particles each of which is a conductive oxide. The first layer is located on the base material. The second layer is located on the first layer. The first layer has open pores that open to an interface with the second layer. The second particles include particles having a particle diameter smaller than a diameter of the open pores.