SOFC Interconnector Laser Grooving and Coating
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Solution Overview
Problem
Current interconnectors for solid oxide fuel cells (SOFC) and high-temperature electrolysis (EHT) face challenges such as high material costs, complex production techniques, and inadequate electrical contact, along with issues related to corrosion and thermomechanical compatibility, which affect their durability and efficiency.
Innovation Solution
A chromino-former metal alloy interconnector with a thick, grooved ceramic or metal layer on its surface, allowing for flexible adaptation to thermomechanical stresses and improved electrical contact, is used, featuring a substrate of iron or nickel with ceramic or metal layers that are not dense, enabling compressive force application for sealing and channel formation through laser ablation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining techniques are used to create channels in interconnectors, then channel definition precision is achieved, but material waste and production complexity increase significantly
Solution Approach 1:
The patent replaces traditional mechanical machining processes with laser ablation technology to create channels in the interconnector. This substitution eliminates complex mechanical tooling, reduces material waste, and simplifies the manufacturing process while maintaining precise channel definition. The laser ablation process directly creates the required channel geometry through controlled material removal without mechanical contact.
Solution Approach 2:
The patent changes the manufacturing approach from mechanical removal to thermal processing parameters. By controlling laser power, scanning speed, and pass number, precise channel geometries are achieved with minimal material waste. The process parameters are optimized to balance channel definition precision with manufacturing efficiency, eliminating the need for complex mechanical tooling and multiple machining steps.
2Reliability
If thick ceramic or metal layers are applied to the interconnector surface, then thermomechanical accommodation and electrical contact are improved, but material costs and processing complexity increase
Solution Approach 1:
The patent employs a composite structure consisting of a metal alloy substrate (chromium-forming ferritic stainless steel) combined with thick ceramic or metal layers. This composite construction provides both thermomechanical compatibility through the metal substrate and improved electrical contact through the conductive ceramic or metal coating. The chromium oxide layer formed on the metal substrate provides corrosion resistance while the thick coating ensures good electrical contact with the electrolyte.
Solution Approach 2:
The patent applies different materials and thicknesses at different locations on the interconnector surface. The thick ceramic or metal layers are strategically positioned at contact areas with the electrolyte to ensure optimal electrical contact, while the chromium-forming metal substrate provides overall structural integrity and corrosion resistance. This localized application optimizes performance without unnecessarily increasing overall complexity.
3Reliability
If chromium-containing metal alloys are used for interconnectors, then corrosion resistance in oxidizing atmospheres is improved, but chromium evaporation and electrode poisoning occur at high temperatures
Solution Approach 1:
The patent controls the chromium content and oxidation conditions to optimize the protective oxide layer formation. By maintaining appropriate oxygen partial pressures and temperature ranges, a stable chromium oxide protective layer is formed that prevents further corrosion while minimizing chromium evaporation. The thick ceramic or metal coating also acts as a physical barrier that reduces chromium evaporation to the electrolyte.
Solution Approach 2:
The patent uses a composite structure where the chromium-containing metal alloy substrate provides corrosion resistance through chromium oxide formation, while the additional thick ceramic or metal layer serves as a protective barrier that reduces chromium evaporation. This composite approach maintains the beneficial corrosion resistance of chromium-containing alloys while mitigating the harmful evaporation effect.
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 solution reduces material costs, simplifies production, enhances the fineness of channel definition, and achieves low electrical resistance, improving thermomechanical accommodation and electrical contact quality, comparable to gold grids, while maintaining mechanical integrity under high temperatures.
Implementation Method 1
said thick layer ceramic being grooved by delimiting channels adapted for the distribution and/or the collection of gases
Data Source
Figure 1~1B
Figure 2~4
Figure 5~6
AI summary
The invention relates to a component (8) comprising a substrate made of chromia-former metal alloy (82), the basic element of which is iron (Fe) or nickel (Ni), wherein the substrate has two main planar faces. According to the invention: - one of the main planar faces is coated with a coating comprising a thick layer of ceramic (80), grooved to delimit channels (800) suitable for the distribution and/or collection of gases, such as H2O water vapour, H2 or air, and/or - one of the main planar faces is coated with a thick metal layer (81), grooved to delimit channels (810) suitable for the distribution and/or collection of gases, such as H2O water vapour, H2, O2 or draining gas. The invention also relates to the associated production processes.