Series-Connected SOFC Network With Insulated Metallic Support
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Solution Overview
Problem
Solid oxide fuel cells (SOFCs) used in aviation suffer from low gravimetric power density and high current collection losses due to limited in-plane conductivity and the risk of explosive mixtures from fuel leaks.
Innovation Solution
A solid oxide fuel cell device with a metallic support structure that is partially or completely non-conductive, supporting SOFC elements in series, and featuring optimized current transport pathways to minimize ohmic losses and prevent short circuits, while using amorph metals and 3-D printing for reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional planar SOFC stacks with interconnector plates are used, then electrical series connection is achieved, but gravimetric power density is low
Solution Approach 1:
The device segments the fuel cell stack into multiple individual SOFC elements arranged in series along a common metallic support structure. Each element is electrically isolated and connected through the support, eliminating the need for complex interconnector plates while maintaining series connection capability. This segmentation approach reduces overall device complexity and weight.
Solution Approach 2:
The metallic support structure serves multiple functions simultaneously: it provides mechanical support for all SOFC elements, acts as an electrical conductor for series connection, and functions as a thermal management component. This multi-functionality eliminates the need for separate interconnector plates, thereby increasing gravimetric power density.
2Loss of energy
If current collection is performed in the longitudinal direction along the cell, then electrical connection is achieved, but current collection losses are high due to limited in-plane conductivity
Solution Approach 1:
The invention transitions from in-plane current collection (within the electrode layer) to through-plane current collection (through the electrolyte and support structure). By collecting current perpendicular to the electrode plane through the metallic support, the system bypasses the limited in-plane conductivity issue and reduces ohmic losses significantly.
3Reliability
If tubular cells with circular current collection are used, then electron travel distance is reduced, but ohmic losses remain high and explosive mixtures risk increases
Solution Approach 1:
The metallic support structure acts as an intermediary for current collection, providing a low-resistance electrical pathway that bypasses the electrode layers. This intermediary conductor collects current from multiple SOFC elements simultaneously, reducing ohmic losses while maintaining safe fuel gas containment through the structured support design.
4Strength
If porous ceramic support with integrated fuel channels is used, then structural integration is achieved, but mechanical and thermal shock resistivity is limited
Solution Approach 1:
The invention employs a composite structure combining metallic support material with SOFC elements. The metallic support provides superior mechanical strength and thermal shock resistivity compared to porous ceramic, while still enabling structural integration and fuel channel formation. This composite approach maintains structural complexity benefits while improving mechanical properties.
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 device achieves a high electrical efficiency and gravimetric power density of 2-3 kW/kg, with reduced weight, complexity, and increased durability, making it suitable for mobile applications and aviation.
Implementation Method 1
each SOFC-element comprises an oxide conducting electrolyte layer (16) arranged between a first electrode layer (18) on one side and a second electrode layer (20) on the other side
Implementation Method 2
a gas permeable metallic support structure (22) supporting the arrangement of SOFC-elements (14) and forming a channel (32) for conducting a fuel gas
Implementation Method 3
wherein an electrically non-conductive layer (24) is provided between the metallic support structure (22) and the arrangement of SOFC-elements (14)
Data Source
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AI summary
A Solid Oxide Fuel Cell (SOFC-) device (10; 11) comprises an arrangement (12) of several solid oxide fuel cell (SOFC-) elements (14) which are electrically connected in series to form a fuel cell network (15). Each SOFC-element (14) comprises an oxide conducting electrolyte layer (16) arranged between a first electrode layer (18) on one side and a second electrode layer (20) on the other side. A gas permeable metallic support structure (22) supports the arrangement (12) of SOFC-elements (14) and forms a channel for (32) conducting a fuel gas (F) along the SOFC-elements (14) on the side of the first electrode layer. An electrically non-conductive layer (24) is provided between the metallic support structure and the arrangement of SOFC-elements (14), or at least a partial area of the metallic support structure (22) has a suppressed or no electrical conductivity. The SOFC-device (10; 11) is e.g. formed as a tube or as a plate comprising one or more channels (32).