SOFC Metal Plate Structure Balancing Strength and Gas Permeability

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Solution Overview

Problem

Conventional metal-supported SOFCs face challenges with the strength and workability of thin metal foils, making them unsuitable for mass production and efficient gas flow, while optimizing hole shape for cost-effective production remains unaddressed.

Innovation Solution

A metal plate configuration with thick and thin portions, where the thin portions have penetration spaces, enhancing strength and gas permeability, made from Fe—Cr based alloys with a metal oxide film to prevent component diffusion, allowing for efficient electrochemical element formation and reduced material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a thin metal foil is used to ensure gas permeability, then the permeability to fluid is improved, but the strength of the metal plate deteriorates

Engineering Contradiction:

Improvegas permeabilityVSAvoidmetal plate strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The metal plate is designed with non-uniform thickness, featuring thick portions and thin portions. The thin portions provide high gas permeability while the thick portions maintain structural strength. This local variation in thickness allows each region to fulfill its specific function optimally.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The metal plate is segmented into multiple functional regions: thick portions for structural support and thin portions with penetration spaces for gas flow. This segmentation allows the plate to simultaneously achieve both strength and permeability requirements.

Inventive Principle:

Principle #1Segmentation

2Weight of moving object

If the metal plate thickness is reduced to reduce weight and cost, then the weight and manufacturing cost are reduced, but the strength and workability deteriorate

Engineering Contradiction:

Improvemetal plate weightVSAvoidmetal plate strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

Instead of uniformly reducing thickness, the plate employs local thickness variation with thin portions (0.01-0.5mm) for weight reduction and thick portions maintaining adequate strength. This allows weight reduction while preserving necessary mechanical properties.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The plate is divided into thick and thin portions, where only the thin portions contribute significantly to weight reduction while the thick portions ensure structural integrity and workability during handling.

Inventive Principle:

Principle #1Segmentation

3Quantity of substance

If many holes are provided in the metal plate to improve gas flow, then the gas permeability is improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvegas flow efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The penetration spaces are concentrated in the thin portions of the metal plate, where the reduced thickness facilitates easier formation of holes or channels. This local concentration of permeability features simplifies manufacturing compared to distributing holes throughout the entire plate.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of creating holes through the entire thickness of a uniform plate (which is difficult and expensive), the invention inverts the approach by first creating thin portions and then forming penetration spaces only in these thin regions, significantly easing manufacturing.

Inventive Principle:

Principle #13The other way round (Inversion)

4Strength

If the penetration spaces are made small to increase strength, then the strength is improved, but the gas permeability deteriorates

Engineering Contradiction:

Improvemetal plate strengthVSAvoidgas permeability

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The penetration spaces are located exclusively in the thin portions where their small size does not compromise overall plate strength, as the thick portions provide the primary structural support. The thin portions with small penetration spaces contribute to gas flow without being the main load-bearing elements.

Inventive Principle:

Principle #3Local quality

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 configuration improves the strength and permeability of the metal plate, facilitating cost-effective mass production of electrochemical elements with enhanced durability and performance, suitable for solid oxide fuel cells operating at high temperatures.

Implementation Method 1

made from Fe—Cr based alloys with a metal oxide film to prevent component diffusion

Methodology Applied

Scientific EffectDiffusion barrier: Diffusion Barrier

Data Source

PatentUS11749824B2Metal plate, electrochemical element, electrochemical module, electrochemical device, energy system, solid oxide fuel cell, and method for manufacturing metal plate

Publication Date: 2023.09.05 OSAKA GAS CO LTD

AI summary

Provided are a metal plate configured such that sufficient strength and performance are ensured and the workability and cost of mass production are improved, and an electrochemical element and the like including the metal plate. A metal plate 1 includes a thick portion 110, and a thin portion 120 that is thinner than the thick portion 110. The thin portion 120 is provided with a penetration space 1c passing through the thin portion 120 in the thickness direction.