Solid Oxide Fuel Cell Co-Sintering and Dense Interconnectors
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Solution Overview
Problem
The manufacturing of solid oxide fuel cell (SOFC) modules of the multi-segment type faces challenges such as poor sinterability of fuel electrodes, electrolytes, and interconnectors, leading to low mechanical strength, poor gas-sealing performance, and high electrical resistivity, which hinder productivity and increase costs.
Innovation Solution
A method involving co-sintering of fuel electrodes and electrolytes, followed by the formation of dense interconnectors using a dense interconnector material, which is then electrically connected to the air electrode, enhances the sinterability and gas-sealing performance while reducing electrical resistivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sintering methods are used for fuel electrodes, electrolytes, and interconnectors, then the manufacturing process is simple, but the mechanical strength is poor and gas-sealing performance deteriorates
Solution Approach 1:
The patent combines the sintering of fuel electrodes, electrolytes, and interconnectors into a single co-sintering process. This merging of previously separate sintering steps into one unified process enables simultaneous densification of all components, achieving high mechanical strength and gas-sealing performance without requiring multiple processing steps, thereby resolving the contradiction between improved strength and manufacturing complexity.
2Reliability
If conventional sintering is applied to interconnectors, then the manufacturing process is straightforward, but electrical resistivity increases and gas-sealing performance poor
Solution Approach 1:
The interconnector sintering is merged with fuel electrode and electrolyte sintering in a single co-sintering step. This unified process achieves dense, gas-tight interconnectors with low electrical resistivity while maintaining manufacturing simplicity, eliminating the need for separate sintering operations and achieving superior sealing performance without increasing process complexity.
3Productivity
If separate sintering processes are used for each component, then each component can be optimized individually, but productivity decreases and production costs increase
Solution Approach 1:
The patent merges separate sintering processes for fuel electrodes, electrolytes, and interconnectors into a single co-sintering operation. This consolidation dramatically improves productivity by reducing the number of processing steps and cycle time, while the carefully controlled co-sintering parameters ensure that each component achieves optimal densification and bonding, thereby maintaining manufacturing precision despite the process simplification.
4Reliability
If dense interconnector material is used, then gas-sealing performance improves, but manufacturing complexity increases
Solution Approach 1:
The use of dense interconnector material is integrated into the co-sintering process with fuel electrodes and electrolytes. This merging eliminates the need for separate densification steps or complex post-processing operations, achieving high gas-sealing performance through the unified sintering process while keeping manufacturing complexity low.
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 improves the mechanical strength and gas-sealing performance of SOFC modules, increases productivity, and reduces production costs by ensuring effective electrical contact and sealing.
Implementation Method 1
co-sintering of fuel electrodes and electrolytes
Implementation Method 2
reducing electrical resistivity
Data Source
AI summary
A method of manufacturing a solid oxide fuel cell module involves the steps of co-sintering the respective fuel electrodes, and the respective electrolytes, subsequently forming a dense interconnector out of a dense interconnector material, or an interconnector material which turns dense by sintering in at least parts of the solid oxide fuel cell module, in contact with the respective fuel electrodes, and the respective electrolyte, and forming an air electrode on the respective electrolytes before electrically connecting the respective electrodes with the respective first parts of the interconnectors electrically connecting the respective electrodes with the respective first parts of the respective interconnectors via respective second parts of the interconnectors which have a density less than the respective first parts.