Solid-oxide fuel cell unit cell with vertical flow holes

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Solution Overview

Problem

Conventional solid-oxide fuel cells require additional separation plates and metal connectors, leading to increased manufacturing costs, weight, and complexity due to corrosion and difficulty in forming seals, especially in large-area planar cells.

Innovation Solution

A unit cell design with vertically formed air and fuel flow holes in the anode, eliminating the need for additional separation plates and using a ceramic connector layer to connect unit cells, which reduces manufacturing costs and weight while improving power generation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal connector is used to separate fuel and air flows and connect fuel cells, then the connection and isolation function is achieved, but corrosion occurs at high temperature and Cr volatilization deteriorates fuel cell performance

Engineering Contradiction:

Improvedurability of fuel cell stackVSAvoidcorrosion and Cr volatilization

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the metal connector with a ceramic connector layer that is integrated into the fuel cell structure. This ceramic connector eliminates corrosion and Cr volatilization issues while maintaining the isolation and connection functions, thereby improving durability without sacrificing performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If additional seal material is used to separate fuel and air flows at upper and lower parts of the cell, then flow separation is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveflow separationVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the flow separation function with the connector layer by forming the connector layer directly on the lower surface of the anode. This integration eliminates the need for separate seal materials and reduces manufacturing steps, thereby simplifying the manufacturing process while maintaining effective flow separation.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If a metal connecting plate is used to facilitate layering and current collection, then assembly is simplified, but large-area cell manufacturing becomes difficult

Engineering Contradiction:

Improvelayering and current collectionVSAvoidcell area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The patent makes the connector layer multi-functional by integrating current collection, flow separation, and structural support functions into a single ceramic layer. This eliminates the need for separate metal connecting plates and enables scalable manufacturing of large-area cells while maintaining assembly simplicity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Strength

If conventional cell configuration with metal connector and cell frame is used, then structural support is provided, but weight and volume of the stack increase

Engineering Contradiction:

Improvestructural supportVSAvoidstack weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent extracts the metal connector and cell frame from the fuel cell structure and replaces them with a lightweight ceramic connector layer that provides sufficient structural support. This removal of heavy metal components significantly reduces the weight and volume of the fuel cell stack while maintaining structural integrity.

Inventive Principle:

Principle #2Taking out (Extraction)

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 design simplifies manufacturing, reduces weight and size, and enhances power generation efficiency by eliminating the need for lateral sealing and using corrosion-resistant ceramic connectors, resulting in a more cost-effective and durable fuel cell stack.

Implementation Method 1

an electrolyte layer such as yttria-stabilized zirconia... so as not to allow fuel to be mixed with air

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 2

an anode (fuel electrode) and a cathode (air electrode)... has a porous structure so as to allow fuel and hydrogen to be efficiently diffused

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentUS9806360B2Unit cell for solid-oxide fuel cell and solid-oxide fuel cell using same

Publication Date: 2017.10.31 KOREA INST OF ENERGY RES

AI summary

The present invention relates to a unit cell for a solid-oxide fuel cell and to a solid-oxide fuel cell using same, and, more specifically, relates to: a unit cell for a solid-oxide fuel cell, wherein a fuel charging-and-discharging part and an air charging-and-discharging part are provided perpendicularly to a cathode comprised in the solid-oxide fuel cell; and a solid-oxide fuel cell using same.