Solid oxide fuel cell interconnect
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Solution Overview
Problem
Existing solid oxide fuel cells face challenges with heavy interconnects made of metals like stainless steel, necessitating the development of lighter weight materials that maintain structural integrity and electrical conductivity at high temperatures.
Innovation Solution
The use of a carbon matrix composite interconnect with a porosity gradient and a density less than or equal to 3.4 grams per cubic centimeter, incorporating carbon fibers, metal fibers, or ceramic fibers, which is thermo-mechanically stable at temperatures greater than 400°C and has low electrical resistivity, along with a coating to ensure impermeability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal interconnects (stainless steel) are used, then structural integrity and electrical conductivity are maintained, but weight increases
Solution Approach 1:
The patent employs a composite interconnect structure consisting of a porous substrate (ceramic or metal foam) infiltrated with conductive material (metal powder, ceramic powder, or carbon-based material). This composite approach achieves both weight reduction and maintenance of electrical conductivity, as the porous substrate provides lightweight structural support while the infiltrated conductive material ensures electrical performance.
Solution Approach 2:
The patent applies different materials or structures to different regions of the interconnect. The surface regions are designed with specific porosity and conductivity characteristics for electrical function, while internal regions provide structural support. This local differentiation allows optimization of both weight and reliability in different functional zones.
2Weight of moving object
If lighter weight materials are used for interconnects, then weight is reduced, but maintaining structural integrity and electrical conductivity at high temperatures becomes challenging
Solution Approach 1:
The patent uses composite structures combining lightweight porous substrates (such as ceramic foams or metal foams with controlled porosity) with thermally stable conductive infiltrates. The porous substrate provides weight reduction while the infiltrated materials maintain thermal and electrical stability at high temperatures, achieving both goals simultaneously.
Solution Approach 2:
The patent optimizes parameters such as porosity (20-80%), particle size distribution, and infiltrate concentration to achieve the desired balance between weight reduction and high-temperature stability. By carefully controlling these parameters, the interconnect maintains structural integrity and electrical conductivity even at elevated operating temperatures.
3Weight of moving object
If porous materials are used to reduce weight, then weight decreases, but gas or fluid impermeability may be compromised
Solution Approach 1:
The patent implements spatially varying porosity within the interconnect structure. Regions requiring gas or fluid impermeability (such as sealing surfaces or specific functional zones) are designed with lower porosity or denser material distribution, while other regions maintain higher porosity for weight reduction. This local differentiation resolves the contradiction between weight and impermeability.
Solution Approach 2:
The composite structure combines a porous lightweight substrate with infiltrated materials that provide both structural reinforcement and controlled permeability. The infiltrate material can be selected and distributed to achieve the desired gas/fluid barrier properties in specific regions while maintaining overall weight reduction through the porous architecture.
Data Source
AI summary
Disclosed is a solid oxide fuel cell including an electrode-electrolyte assembly (12) and an interconnect (14) in communication with the electrode-electrolyte assembly (12), wherein the interconnect (14) has a porosity gradient.