Solid Oxide Fuel Cell Inter-Connector Curved Projections
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Solution Overview
Problem
Existing solid oxide fuel cell technologies face challenges with maintaining reliable electrical conduction due to metal plate elasticity loss and deformation, leading to increased production costs, contact resistance, and potential fuel cell cracking, especially when using convex portions formed by etching or press working.
Innovation Solution
A solid oxide fuel cell design featuring an inter-connector with projecting portions having specific curvature profiles to prevent cracking and ensure electrical connection, formed from metallic materials like stainless steel or nickel-based alloys, which can be manufactured through press working to maintain contact area and reduce stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If convex portions are formed on a metal plate by etching, then electrical conduction is established, but production cost increases due to etching time
Solution Approach 1:
The patent replaces the chemical etching process with a mechanical press working process to form convex portions on the metal plate. This substitution eliminates the time-consuming etching step while achieving the same functional result of creating contact protrusions for electrical conduction, thereby reducing production cost and improving manufacturing efficiency.
2Productivity
If convex portions are formed on a metal plate by press working, then production cost is reduced, but the flatness of convex portions deteriorates due to spring back
Solution Approach 1:
The patent specifies that the convex portions formed by press working should have a curved surface with a controlled radius of curvature between 0.5mm and 2mm. This curvature requirement compensates for the spring back effect by pre-designing the shape to account for elastic recovery, ensuring that the final convex portions maintain adequate contact area and flatness despite the inherent limitations of press working.
3Productivity
If convex portions are formed by press working, then production cost is reduced, but contact resistance increases due to local contact
Solution Approach 1:
The patent optimizes multiple parameters of the convex portions including the radius of curvature (0.5mm-2mm), height (0.2mm-0.5mm), and the spacing between adjacent convex portions. By carefully controlling these geometric parameters, the design ensures sufficient contact area between the inter-connector and fuel cell body, thereby maintaining low contact resistance while still using the cost-effective press working process.
4Productivity
If convex portions are formed by press working, then production cost is reduced, but stresses concentrate on local area of fuel cell body, causing cracks
Solution Approach 1:
The patent specifies that the convex portions should have a curved surface rather than sharp edges, with a radius of curvature between 0.5mm and 2mm. This rounded geometry distributes the contact stress over a larger area of the fuel cell body, preventing stress concentration that would lead to cracking, while still maintaining effective electrical contact.
5Reliability
If the metal plate loses elasticity due to heat cycles, then electrical conduction reliability is impaired, but maintaining elasticity increases device complexity
Solution Approach 1:
The patent selects specific metal materials with appropriate physical properties including elasticity modulus, thermal expansion coefficient, and electrical conductivity. By choosing materials that inherently maintain their elastic properties across the operating temperature range, the design ensures continuous electrical contact without requiring additional complexity-based elasticity maintenance mechanisms.
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 solution enables large-scale production of solid oxide fuel cells with improved electrical conduction and reduced risk of cracking, maintaining low contact resistance and efficient gas flow even under thermal cycles and deformation, thus enhancing the durability and performance of the fuel cell.
Implementation Method 1
a solid electrolyte layer formed of an oxide and having ion conductivity
Implementation Method 2
When a fuel gas is supplied to the anode and air is supplied to the cathode, the fuel chemically reacts with oxygen contained in the air through the solid electrolyte body
Data Source
AI summary
A solid oxide fuel cell includes a fuel cell body and an inter-connector. The inter-connector has a base portion and a plurality of projecting portions projecting from the base portion toward the fuel cell body and electrically connected to the fuel cell body, and is integrally formed from a metallic material. Each of the projecting portions has a contour composed of a pair of linear portions which are disposed parallel to each other and each of which includes a straight line, and a pair of curved portions which connect opposite ends of the linear portions.