Compact SOFC Stack Base Plate Sealing for Thermal Stress Relief
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Solution Overview
Problem
Current solid oxide fuel cell (SOFC) technologies face challenges in achieving marketable price, reasonable performance, and useful lifetime, particularly in compact high power density designs suitable for mobile applications.
Innovation Solution
The development of electrochemical cell stacks with corrugated interconnects that form fuel and oxidant channels, sealed via sealing members to provide compliance and prevent gas mixing, while reducing material content and thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional SOFC stack designs are used, then structural integrity and sealing are maintained, but weight and volume are excessive for mobile applications
Solution Approach 1:
The stack is divided into repeating units, each comprising a single electrochemical cell with integrated interconnects. This segmentation eliminates the need for heavy external manifolds and sealing systems, reducing overall weight while maintaining structural integrity through modular assembly
Solution Approach 2:
The interconnects are designed with integrated flow channels that are nested within the interconnect structure itself, rather than requiring separate external manifolds. This nesting of flow paths within the structural components eliminates redundant materials and reduces stack weight and volume
2Power
If compact high power density designs are implemented, then power density increases, but thermal stress and manufacturing complexity increase
Solution Approach 1:
Multiple functions are merged into the interconnects: they provide structural support, electrical connection, and integrated flow channeling for both fuel and oxidant. This consolidation reduces the number of discrete components and simplifies manufacturing while enabling compact high power density configurations
Solution Approach 2:
The interconnects serve multiple purposes simultaneously: mechanical support, electrical conduction, and fluid distribution. This multi-functionality reduces component count and manufacturing complexity while achieving compact design for high power density
3Loss of substance
If corrugated interconnects with integrated channels are used, then material content is reduced, but sealing complexity increases
Solution Approach 1:
The sealing function is extracted from the interconnect structure itself and assigned to dedicated sealing members positioned at the cell-perimeter interfaces. This separation allows the interconnects to be simplified and lighter while the sealing complexity is localized to specific interfaces, reducing overall material content
4Loss of time
If rapid transient response is achieved through compact design, then response time improves, but thermal management challenges increase
Solution Approach 1:
The compact modular unit design with integrated flow channels enables segmented thermal management, where each unit can be independently controlled and cooled. This segmentation allows rapid transient response while managing thermal loads through distributed heat dissipation paths
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 approach results in higher power density, reduced weight and volume, lower costs, rapid transient response, and improved thermal management, enabling efficient operation in both mobile and stationary applications.
Implementation Method 1
the interconnects configured to provide compliance to the electrochemical cell stack
Implementation Method 2
fluidly isolated via sealing members
Implementation Method 3
Solid oxide fuel cells comprise an electrolyte sandwiched between a cathode and an anode. Oxygen reacts with electrons at the cathode to form oxygen ions, which are conducted through the ion-conducting ceramic electrolyte to the anode. At the anode, oxygen ions combine with available fuel to form products thereby liberating electrons to produce electrical power
Implementation Method 4
oxygen ions, which are conducted through the ion-conducting ceramic electrolyte to the anode
Data Source
AI summary
A base plate assembly for an electrochemical cell stack includes a bottom end plate defining a fuel inlet port, a fuel outlet port, and an oxidant port. The base plate assembly further includes a high strength sealing plate including openings that align with the fuel inlet port, the fuel outlet port, and the oxidant port, and a plurality of tubes located between the bottom end plate and the high strength sealing plate. The tubes are configured to yield to reduce transfer of mechanical stress from the high strength sealing plate to the bottom end plate.