Bulk Metallic Glass Separator Plate for Fast-Start SOFC Stacks

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Solution Overview

Problem

Current solid oxide fuel cell (SOFC) systems have low power densities and slow startup times, which are inadequate for aircraft applications requiring high power density and rapid power generation.

Innovation Solution

The use of a separator plate made from bulk metallic glass material with defined anode and cathode flow channels, which is thermoplastically formed to increase contact area and conductivity, and optionally coated for corrosion resistance, to enhance fuel cell performance and reduce startup times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If conventional SOFC systems are used, then electrical efficiency of 60% or greater is achieved, but power density remains low (less than 500 W/kg)

Engineering Contradiction:

Improvepower densityVSAvoidpower output per unit mass

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The patent changes the material parameter of the separator plate from conventional metals to bulk metallic glass, which has superior electrical conductivity and corrosion resistance. This material parameter change enables higher power density by improving electron transport and reducing degradation, directly addressing the contradiction between maintaining efficiency and increasing power density

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a composite structure where bulk metallic glass is combined with functional coatings (such as corrosion-resistant or catalytic coatings) on the separator plate. This composite approach leverages the high conductivity of metallic glass while adding protective or functional properties through coatings, thereby increasing power density without sacrificing durability

Inventive Principle:

Principle #40Composite materials

2Speed

If conventional SOFC systems are used, then operational stability is achieved, but startup time exceeds 30 minutes

Engineering Contradiction:

Improvestartup speedVSAvoidstartup time

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

The bulk metallic glass separator plate changes the thermal and electrical parameters of the fuel cell system. Its superior electrical conductivity accelerates charge distribution during startup, while its thermal properties enable faster temperature equilibration, reducing startup time from over 30 minutes to a significantly shorter duration while maintaining operational stability

Inventive Principle:

Principle #35Parameter changes

3Reliability

If separator plate contact area with cathode is increased, then electrical conductivity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidseparator plate configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The separator plate is designed with a flexible or conformable structure that dynamically adapts to the cathode surface geometry. This dynamic configuration allows the plate to maximize contact area with the cathode under operational conditions, improving electrical conductivity without requiring complex rigid structures or precise manufacturing tolerances

Inventive Principle:

Principle #15Dynamics

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 solution achieves higher power densities exceeding 500 W/kg and significantly reduces startup times, enabling efficient and lightweight fuel cell configurations suitable for aircraft applications.

Implementation Method 1

The separator plate is heated to a temperature greater than a glass transition temperature of the bulk metallic glass material, a compressive load is applied to the plurality of fuel cell layers, and the bulk metallic glass material is thermoplastically flowed thereby increasing a contact area of the separator plate to the cathode of the adjacent fuel cell layer

Methodology Applied

Scientific EffectThermoplastic flow: Viscoelasticity

Implementation Method 2

an electrical conductivity of the separator is attained via crystallization of the bulk metallic glass material

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS12068509B2Bulk metallic glass interconnect for high power density fuel cell

Publication Date: 2024.08.20 HAMILTON SUNDSTRAND CORP

AI summary

A solid oxide fuel cell or solid oxide electrolyzer includes a plurality of fuel cell layers stacked along a stacking axis. Each fuel cell layer including a stacked arrangement of elements including a cathode, an anode, an electrolyte located between the anode and the cathode, a support layer positioned at the anode opposite the electrolyte, and a separator plate located at the support layer opposite the anode. The separator plate is configured to contact the cathode of an adjacent fuel cell layer of the plurality of fuel cell layers. The separator plate defines a plurality of anode flow channels configured to deliver a fuel therethrough and a plurality of cathode flow channels configured to deliver an air flow therethrough. The separator plate is formed from a bulk metallic glass material.