Metal-Supported SOFC Segments Without Heavy Bipolar Plates
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Solution Overview
Problem
Planar solid oxide fuel cells (SOFCs) have a low gravimetric power density due to heavy bipolar plates and high thermal stress, making them unsuitable for mobile applications where weight reduction is critical.
Innovation Solution
A metal-supported fuel cell structure comprising multiple fuel cell segments arranged side-by-side with each segment having an anode, cathode, electrolyte, and metal-support, where the metal-supports provide mechanical support and act as current collectors, eliminating the need for heavy bipolar plates and allowing for serial connection of fuel cell segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy bipolar plates are used in planar SOFC design, then mechanical strength and structural stability are improved, but gravimetric power density deteriorates
Solution Approach 1:
The patent removes the heavy bipolar plates from the fuel cell stack design entirely. Instead, metal supports are used to provide mechanical strength and structural stability, while serving dual functions as current collectors and gas distribution components. This extraction of the bipolar plate function resolves the contradiction by eliminating the weight penalty while maintaining necessary mechanical properties.
Solution Approach 2:
The metal supports in the patent perform multiple functions simultaneously: they provide mechanical strength and structural stability, act as current collectors for electrical conduction, and serve as gas distribution channels. This multi-functionality replaces the specialized bipolar plates, achieving weight reduction while maintaining all necessary structural and functional properties.
2Reliability
If planar SOFC design with perpendicular current transfer is used, then electrical connection between cells is achieved, but interconnector weight increases stack weight
Solution Approach 1:
The metal supports serve as current collectors that provide electrical connection between adjacent fuel cell segments. By integrating this electrical conduction function into the structural metal supports, the patent eliminates the need for separate heavy interconnectors, thereby maintaining reliable electrical connections while significantly reducing overall stack weight.
3Weight of moving object
If tubular cell design with longitudinal current collection is used, then interconnector weight is reduced, but current losses increase
Solution Approach 1:
The patent adopts the tubular cell configuration with longitudinal current collection approach, where current is collected along the length of the cell rather than perpendicular to it. This design copies the successful weight reduction strategy from tubular to planar metal-supported cells, achieving low interconnector weight while the metal support structure minimizes current path length to reduce resistive losses.
4Strength
If metal-supports are arranged adjacent to each other, then mechanical support is provided, but electrical isolation between segments is required
Solution Approach 1:
The fuel cell stack is divided into multiple segments, each with its own metal support. The segmentation allows adjacent metal supports to be electrically isolated from each other through insulation layers or design features, while still providing continuous mechanical support across the entire stack. This segmentation resolves the contradiction by enabling electrical isolation without compromising mechanical integrity.
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
The metal-supported fuel cell structure achieves a high gravimetric power density and mechanical strength while reducing manufacturing challenges, enabling efficient power generation with fast startup times and improved current density at low operating temperatures.
Implementation Method 1
The oxygen reduction reaction occurs in the porous cathode by accepting electrons and producing oxide ions, which transfer through the gas tight electrolyte to the anode interface
Implementation Method 2
The hydrogen fuel gets oxidized at the anode interface by accepting oxide ions and producing electrons, which pass to the cathode side through an external circuit
Implementation Method 3
The metal-support layer provides a mechanical support for the fuel cell structure
Implementation Method 4
The corresponding metal-supports of neighboring fuel cell segment within the metal-support layer are electrically isolated from each other
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
According to an aspect, a metal-supported fuel cell structure (100) is provided. The fuel cell structure comprises at least a two fuel cell segments (150, 160, 170, 180). Each of the at least two fuel cell segments are arranged neighboring each other. Each of the at least two fuel cell segments comprises an anode (111, 112, 113, 114), a cathode (121, 122, 123, 124), an electrolyte (131, 132, 133, 134) interposed between the corresponding anode and the corresponding cathode, and a metal-support (141, 142, 143, 144). The anodes together build an anode layer (110). The corresponding anodes of neighboring fuel cell segments are electrically isolated from each other. All the cathodes together build a cathode layer (120). The corresponding cathodes of neighboring fuel cell segment (150, 160) are electrically isolated from each other. All the metal-supports together build a mechanically stabilizing metal-support layer (140). The corresponding metal-supports of neighboring fuel cell segment are electrically isolated from each other. The anode layer, the cathode layer and the electrolyte layer are disposed on a surface of the metal-support layer. At least one cathode is electrically interconnected, via at least one electrical interconnector, with at least one anode and/or metal-support of a neighboring fuel cell segment, thereby establishing a serial connection between the at least two fuel cell segments.