Solid Oxide Fuel Cell Interconnect with Lattice Core and Ceramic Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing interconnects for solid oxide fuel cells are prone to oxidation at high temperatures, leading to reduced electrical conductivity and durability issues due to the formation of oxide films and secondary phases, and thermal expansion mismatches cause delamination and sealing problems with coating layers.
Innovation Solution
A lattice-type interconnect with a conductive core made from high-melting-point materials, wrapped in an oxidation-resistant insulating ceramic layer and coated with a noble metal conductive layer, which is electrically connected to the fuel cell electrodes, and optionally includes a middle layer to match thermal expansion coefficients, preventing oxidation and delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an oxidation-resistant coating layer is formed on the interconnect, then oxidation resistance is improved, but delamination occurs due to thermal expansion mismatch
Solution Approach 1:
The interconnect employs a composite structure consisting of a metal substrate combined with a ceramic coating layer. The metal substrate provides mechanical strength and conductivity, while the ceramic coating provides oxidation resistance. This composite approach allows each material to contribute its advantageous properties while mitigating their individual weaknesses, particularly addressing the thermal expansion mismatch issue by carefully selecting ceramic materials with compatible thermal properties.
Solution Approach 2:
The invention modifies the chemical composition and physical parameters of both the metal substrate and ceramic coating to achieve better thermal compatibility. By adjusting alloying elements in the metal and selecting specific ceramic compositions, the thermal expansion coefficients are optimized to reduce the mismatch between layers, thereby preventing delamination while maintaining oxidation resistance.
2Reliability
If a metal interconnect is used, then electrical conductivity is improved, but oxidation occurs at high temperatures forming oxide films
Solution Approach 1:
The interconnect applies different material properties to different regions: the bulk metal substrate maintains high electrical conductivity for current collection, while the surface ceramic coating provides oxidation protection. This local differentiation of material qualities allows the interconnect to simultaneously achieve excellent electrical performance and oxidation resistance by assigning specific functions to specific regions of the structure.
Solution Approach 2:
The combination of metal and ceramic materials creates a composite interconnect where the metal phase provides electrical conductivity and the ceramic phase provides oxidation resistance. This composite material approach resolves the contradiction by integrating two materials with complementary properties into a single functional component.
3Reliability
If chrome component is added to improve oxidation resistance, then oxidation protection is improved, but secondary phases form deteriorating electrode and electrolyte performance
Solution Approach 1:
The invention extracts and eliminates the problematic chrome component from the interconnect composition while retaining oxidation protection through alternative ceramic coating materials. By removing the chrome element that causes secondary phase formation and deterioration of adjacent components, the design achieves oxidation resistance without the harmful side effects, directly applying the extraction principle to eliminate the disturbing substance.
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
The interconnect maintains durability and electrical efficiency over long periods, prevents voltage loss due to oxidation, and eliminates sealing and delamination issues, while being cost-effective and having a simple structure.
Implementation Method 1
an oxidation-resistant insulating part receiving and wrapping the conductive core therein, to thereby prevent oxidation of the conductive core
Implementation Method 2
an oxidation-resistant conductive material layer coated on an exposed surface of the conductive core
Implementation Method 3
optionally includes a middle layer to match thermal expansion coefficients, preventing oxidation and delamination
Data Source
AI summary
Disclosed herein are an interconnect for a solid oxide fuel cell and a method for manufacturing the same, the interconnect including: a conductive core; an oxidation-resistant insulating part receiving therein; and an oxidation-resistant conductive material layer coated on an exposed surface of the conductive core, which is exposed to an external environment by removing a portion of the oxidation-resistant insulating part, so that the interconnect can maintain durability against high-temperature heat generated from a flat type solid oxide fuel cell for a long time and thus have a very small voltage loss due to oxidation even with the use over a long-time period; have no sealing problem and no delaminating problem of a coating film due to a difference in coefficient of thermal expansion; be inexpensive; and have a simple structure.