Metal Porous Current Collector Structure for Low SOFC Contact Resistance
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Solution Overview
Problem
Sponge-shaped metals used as current collectors in solid oxide fuel cells experience increased resistance due to point-contact with ceramic electrodes, particularly in solid oxide fuel cells (SOFCs), which affects the fuel cell's performance.
Innovation Solution
A metal porous body with a three-dimensional network structure and controlled porosity and density is developed, featuring openings between 3 µm to 55 µm in diameter and a sheet-like shape, allowing for low resistance and excellent fluid permeability, suitable for use as a current collector in fuel cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sponge-shaped metal is used as current collector, then electrical conductivity is improved, but contact resistance increases due to point-contact with ceramic electrodes
Solution Approach 1:
The patent applies porous materials by using a metal porous body with controlled porosity (30-70%) and specific pore size (3-55 µm). The porous structure provides multiple contact points between the current collector and ceramic electrode, transforming the point-contact problem into面-contact, thereby reducing contact resistance while maintaining electrical conductivity.
Solution Approach 2:
The patent changes physical parameters including pore size (3-55 µm), porosity (30-70%), and metal fiber diameter (1-10 µm) to optimize both electrical conductivity and contact characteristics. By controlling these parameters, the invention achieves low contact resistance while preserving the electrical conductivity benefits of sponge-shaped metal.
2Productivity
If metal porous body with small pore size is used, then fluid permeability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs porous materials with specifically controlled pore structures (3-55 µm) that balance fluid permeability and manufacturability. The porous metal body achieves excellent fluid permeability while maintaining a structure that can be manufactured through established techniques such as sintering or electrospinning.
Solution Approach 2:
The patent optimizes physical parameters including pore size (3-55 µm), porosity (30-70%), and metal fiber diameter (1-10 µm) to achieve the desired balance between fluid permeability and manufacturing feasibility. These parameter ranges are specifically selected to ensure both performance and manufacturability.
Data Source
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AI summary
A metal porous body having a frame of a three-dimensional network structure, the frame being formed of a plurality of bone members connected to each other, the plurality of bone members defining openings in a surface of the metal porous body, the plurality of bone members defining voids inside the metal porous body, the openings and the voids communicating with each other, a porosity being from 1 volume% to 55 volume%, a density being from 3 g/cm3 to 10 g/cm3.