SOEC/SOFC Interconnector Tab Geometry for Low Pressure Loss
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Solution Overview
Problem
Existing high-temperature solid oxide electrolyzer (SOEC) and fuel cell (SOFC) stacks face challenges in achieving optimal electrical contact, gas distribution, and reduced pressure losses due to the design of interconnectors, leading to inefficiencies and potential damage from hot spots and gas recombination.
Innovation Solution
An interconnector design with optimized geometry, featuring tabs and raised elements with varying dimensions and configurations, enhances electrical conductivity and gas flow while minimizing pressure losses, using a metallic alloy substrate with ceramic or metallic coating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional interconnector design with standard tab geometry is used, then manufacturing is simpler, but pressure losses increase and electrical contact is insufficient
Solution Approach 1:
The patent applies local quality by varying the tab width along their length, with wider sections at contact points for electrical connection and narrower sections in gas flow regions. This non-uniform geometry optimizes both electrical contact quality and gas distribution while reducing pressure losses, without requiring complete redesign of the entire interconnector structure.
Solution Approach 2:
The patent introduces raised elements that can deform under compression to adapt to surface irregularities between the interconnector and electrochemical cells. This dynamic adaptation ensures consistent electrical contact and gas distribution despite manufacturing tolerances or thermal expansion, resolving the contradiction between simplified design and performance optimization.
2Reliability
If tab width is increased to improve electrical contact, then electrical conductivity improves, but gas flow channels are reduced and pressure losses increase
Solution Approach 1:
The patent implements local quality by creating tabs with non-uniform width: wider sections are positioned at electrical contact points to ensure low resistance connection, while narrower sections are located in gas flow channels to maintain adequate flow cross-section. This spatial variation in tab geometry simultaneously optimizes both electrical conductivity and gas flow characteristics, eliminating the need to choose between the two competing requirements.
3Reliability
If raised elements with varying heights are added to ensure good contact, then electrical contact and gas distribution improve, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by varying the height of raised elements at different locations on the interconnector. Taller raised elements are positioned where greater contact pressure or gas distribution is needed, while shorter elements are used where minimal intervention is required. This graduated approach to height variation achieves optimal contact and gas distribution while remaining compatible with standard forming and machining processes.
4Productivity
If standard interconnector design is used, then device complexity is lower, but hot spots and gas recombination occur reducing efficiency
Solution Approach 1:
The patent implements local quality through optimized tab geometry and strategically positioned raised elements that ensure uniform gas distribution and electrical contact across the electrochemical cell surface. This prevents localized overheating (hot spots) and gas recombination by eliminating dead zones and ensuring consistent flow and contact throughout the active area, thereby improving operational efficiency with minimal structural modification.
Solution Approach 2:
The patent converts the potential harm of manufacturing tolerances and surface irregularities into a benefit by designing raised elements that deform under compression to adapt to these variations. This self-adjusting mechanism ensures optimal contact and gas distribution despite imperfections in manufacturing or thermal cycling, transforming what would be harmful variability into a feature that enhances reliability and efficiency.
Data Source
Figure 1~2
Figure 3~4
Figure 5~5B
AI summary
The invention relates mainly to an interconnector for a stack of solid SOEC/SOFC-type oxide cells, intended to be arranged between two adjacent electrochemical cells, the interconnector (5) being formed by the assembly of at least three elongate plates along first and second axes of symmetry, the central plate having openings, each opening having tabs (710) spaced apart from one another so as to form a comb and slots (711) defined between the edge of an opening (71) and a tab (710) or between two consecutive tabs (711), characterised in that the width (le) of each tab (710) of at least one opening (71) is comprised between 0.1 mm and 3 mm.