Internally Manifolded Interconnect Layout for Uniform Fuel Distribution

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Solution Overview

Problem

Conventional fuel cell interconnects face challenges such as complex fuel distribution systems, reduced active area due to internal fuel risers, and density variations leading to topographical issues and reduced stack performance.

Innovation Solution

The interconnect design includes alternating air channel ribs of different lengths, recessed seal gutters on the fuel side, and fuel inlet and outlet plenums that extend perpendicular to fuel channels, enhancing fuel distribution and interconnect density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If internal fuel risers are used to distribute fuel to each cell, then fuel distribution is achieved, but the active area of the fuel cells is reduced

Engineering Contradiction:

Improvefuel distributionVSAvoidactive area

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The patent removes the internal fuel riser structure from the fuel cell stack design. Instead of having fuel risers penetrate through the fuel cells, the system uses external manifolding where fuel is distributed through channels in the manifold housing that is positioned outside the stack. This extraction of the fuel distribution system from the internal structure eliminates the displacement of active area while maintaining fuel distribution capability.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If conventional interconnect designs are used, then structural support is provided, but density variations cause topographical issues and reduced stack performance

Engineering Contradiction:

Improvestructural supportVSAvoiddensity uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent modifies the manufacturing parameters and material composition of the interconnects to achieve more uniform density throughout the structure. This involves controlling sintering parameters, material distribution, and processing conditions to minimize density variations. The result is interconnects with consistent topography that maintain structural support while eliminating the performance reduction caused by density non-uniformity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If seal gutters are positioned at the same level as the perimeter seal surface, then sealing is achieved, but seal material overflow blocks air channel inlets

Engineering Contradiction:

ImprovesealingVSAvoidair channel blockage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent introduces an asymmetric vertical positioning of the seal gutters relative to the perimeter seal surface. The seal gutters are recessed below the level of the perimeter seal surface, creating a depth difference that allows seal material to be contained within the gutters without overflowing into the air channel inlets. This asymmetric design maintains the sealing function while eliminating the harmful blockage effect.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS20250118773A1Internally manifolded interconnects and electrochemical cell column including same

Publication Date: 2025.04.10 BLOOM ENERGY CORP

AI summary

An interconnect for an electrochemical stack includes at least one of alternating air channel ribs of different length, seal gutters recessed relative to a perimeter seal surface on a fuel side of the interconnect, or fuel inlet and outlet plenums which extend perpendicular to fuel channels.