Flexible Mesh Current Collectors for Solid Oxide Fuel Cells
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Solution Overview
Problem
Current current collectors for solid oxide fuel cells are not robust enough to withstand the harsh operating conditions, including oxidative and reductive stresses, and thermal cycling, which affects their reliability and efficiency in energy recovery.
Innovation Solution
A lightweight solid oxide fuel cell design featuring anode and cathode current collectors made from flexible, high-temperature-resistant materials such as silver wires and ribbons, with an electrically conductive sealant to ensure reliable electrical connections and reduce ohmic loss, and the use of silver paint for enhanced cathode contact and wire securing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional current collectors (ceramic strips or spiral silver wires) are used, then electrical conductance is improved, but reliability under thermal cycling and physical stress deteriorates
Solution Approach 1:
The patent employs a mesh current collector structure that is mechanically flexible and can dynamically adapt to thermal expansion and contraction during cycling. The mesh configuration allows the current collector to flex and deform without breaking, maintaining electrical contact reliability under thermal and mechanical stress while preserving electrical conductance through its continuous conductive network.
Solution Approach 2:
The patent uses a mesh structure composed of high-temperature resistant conductive materials that combine electrical conductivity with mechanical flexibility and thermal stability. This composite approach creates a current collector that simultaneously achieves good electrical conductance and reliability under harsh operating conditions including thermal cycling and physical stress.
2Stability of the object's composition
If rigid current collectors are used to maintain electrical contact, then electrical connection stability is improved, but adaptability to thermal expansion and physical deformation deteriorates
Solution Approach 1:
The mesh current collector is designed with inherent flexibility that allows it to dynamically adjust its shape and position in response to thermal expansion, contraction, and physical deformation. This dynamic adaptability maintains stable electrical connections without requiring rigid structural support, as the mesh can flex and conform to changing geometries while preserving continuous electrical contact.
3Weight of moving object
If lightweight materials are used for current collectors, then portability is improved, but strength and robustness deteriorate
Solution Approach 1:
The patent employs mesh current collectors made from high-temperature resistant conductive materials that provide both lightweight properties and mechanical strength. The mesh structure itself contributes to strength through its geometric configuration, distributing mechanical loads across the entire structure while maintaining low weight, thus achieving both portability and robustness simultaneously.
Solution Approach 2:
The mesh current collector utilizes a thin-film or fine-wire mesh structure that provides significant strength-to-weight ratio. This flexible mesh configuration achieves robustness through its distributed structural design rather than relying on thick, heavy materials, enabling lightweight construction that maintains strength and resistance to thermal and mechanical stress.
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 design provides a robust and efficient current collection system capable of withstanding physical stresses and thermal cycling, improving energy recovery and reducing ohmic loss and cathode overpotential, while maintaining a lightweight and portable fuel cell structure.
Implementation Method 1
an electrically conductive sealant to ensure reliable electrical connections and reduce ohmic loss
Implementation Method 2
A solid oxide fuel cell (SOFCs) is a type of fuel cell which reacts a fuel gas with an oxidant to generate DC electric current
Implementation Method 3
a catalytic substrate processes a hydrocarbon fuel such as butane (C4H10), propane (C3H8) or diesel fuel (JP-8 or JET-A) to a suitable fuel gas such containing carbon monoxide (CO) and hydrogen (H2)
Implementation Method 4
CO and Hydrogen gas are then oxidized at an active area of a SOFC to carbon dioxide and water, with DC current generated
Data Source
AI summary
A solid oxide fuel cell comprises a plurality of tubes, each having an anode, electrolyte and cathode. Anode and cathode current collectors are mounted on the tubes. The anode current collector electrically connects to the anode and can have a contact with the anode. The cathode current collector electrically connects to the cathode and can have a contact with the cathode. An electrically conductive sealant may be positioned between the anode of one tube and the cathode current collector of another tube.