Metallic Self-Supporting Substrate for Electrochemical Cell Contacting
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Solution Overview
Problem
Rechargeable solid electrolyte metal-air batteries and fuel cells with oxide ceramic membrane electrode assemblies face challenges in electrical contacting due to low conductivity and brittleness, making it difficult to test electrical properties before assembly and leading to excessive internal stresses during stacking.
Innovation Solution
The use of a porous, metallic self-supporting substrate as part of the membrane electrode assembly, which is electrically conductive and allows for integrated contacting, enabling testing of electrical properties before assembly and reducing brittleness by using a more ductile material compared to ceramic substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oxide ceramic MEA structures are used, then electrochemical conversion is enabled, but electrical conductivity and current carrying capacity are low
Solution Approach 1:
A metallic interconnector plate is introduced as an intermediary component between multiple MEAs. This plate serves as a common electrical contact surface that collects current from multiple ceramic MEAs and conducts it to external terminals, overcoming the low conductivity of individual ceramic electrolytes without modifying the MEA structure itself
Solution Approach 2:
The electrical contact function is replicated from individual MEA-to-MEA contacts to a centralized plate contact system. Instead of each MEA requiring direct contact with neighboring MEAs, the plate copies and consolidates this contact function across multiple MEAs simultaneously, simplifying the overall contacting architecture
2Reliability
If oxide ceramic MEA structures are used, then electrochemical conversion is enabled, but brittleness increases and excessive internal stresses occur during stacking
Solution Approach 1:
The rigid ceramic MEA structure is combined with a flexible metallic plate that can accommodate dimensional variations and thermal expansion differences. The plate acts as a compliant mounting surface that distributes mechanical stresses uniformly across multiple MEAs, preventing stress concentration and reducing the risk of fracture during assembly and operation
Solution Approach 2:
The mechanical properties of the supporting structure are changed from brittle ceramic to ductile metal. This parameter change in material properties allows the structure to deform plastically under stress rather than fracturing, accommodating manufacturing tolerances and thermal cycles without failure
3Reliability
If conventional MEA structures are used, then electrochemical conversion is enabled, but electrical properties can only be tested in assembled state
Solution Approach 1:
The electrical contact system is segmented into modular components: individual MEAs with their own contact surfaces and a separate metallic plate with multiple contact points. This segmentation allows MEAs to be tested individually for electrical properties before assembly, and the plate to be tested separately, simplifying the overall testing process while maintaining system reliability
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 solution allows for no-load assembly and reduced mechanical stress, improving the mechanical stability and reducing manufacturing costs by enabling pre-assembly testing of electrical properties and integrating contacting within the energy conversion unit, thus enhancing the overall performance and efficiency of the energy conversion cell.
Implementation Method 1
The electrons are discharged laterally through the porous metallic self-supporting substrate and laterally introduced into a circuit by integration of the current drain within a membrane-electrode assembly
Implementation Method 2
enables the conversion of electrical energy into chemical energy and vice-versa
Implementation Method 3
A redox pair of metal and metal oxide, such as, for example, iron and iron oxide in various stages of oxidation or nickel and nickel oxide, is used for storing the energy
Implementation Method 4
The combination of oxide ceramic electrodes and solid state electrolytes... the oxygen is brought from the negative electrode to the surface of the storage medium
Data Source
AI summary
An energy conversion cell includes an electrochemical conversion unit. The energy conversion cell has an electrically positive side with a process gas supply and an electrically negative side. The electrochemical conversion unit, which has a self-supporting substrate and a number of functional layers, is disposed between the two sides. The electrochemical conversion unit has a positive electrode and a negative electrode. The negative electrode includes a porous metallic, self-supporting substrate.