SPS Interconnect Formation for Dense Solid Oxide Fuel Cell Stacks
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Solution Overview
Problem
The fabrication of metallic interconnects for solid oxide fuel cell stacks is complex and requires multiple steps, leading to density variations and reduced contact area with fuel cells, which affects stack yield and performance due to the use of conventional fuel manifolds and complex geometry.
Innovation Solution
A method using spark plasma sintering (SPS) to form interconnects from chromium and iron powders, eliminating the need for separate sintering and oxidation steps, and optionally incorporating protective coatings like LSM or MCO to enhance performance and simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-step fabrication methods are used, then interconnects can be formed with standard geometry, but the process complexity increases and density variations occur
Solution Approach 1:
The patent combines multiple fabrication steps (forming, sintering, and oxidation) into a single spark plasma sintering process. The interconnect body is formed directly from powder compacts through SPS, eliminating the need for separate sintering and oxidation steps that are required in conventional methods, thereby reducing process complexity and achieving uniform density.
Solution Approach 2:
The patent utilizes controlled atmosphere parameters during spark plasma sintering to achieve both densification and oxidation resistance simultaneously. By adjusting the sintering atmosphere and temperature parameters, the process produces high-density interconnects with reduced porosity while preventing harmful oxide formation, resolving the contradiction between density uniformity and process complexity.
2Reliability
If complex geometry with conventional fuel manifolds is used, then interconnects can provide fuel distribution, but contact area with fuel cells is reduced and yield decreases
Solution Approach 1:
The patent segments the fuel distribution function from the interconnect body by incorporating separate fuel manifold components. This allows the interconnect to maintain maximum contact area with fuel cells for improved electrical connection and thermal contact, while fuel distribution is handled by the integrated manifold structure, thereby increasing stack yield.
Solution Approach 2:
The interconnect design integrates multiple functions into a single component: electrical connection, thermal management, and fuel distribution. By making the interconnect multi-functional through integrated manifolds, the design eliminates the need for separate fuel distribution systems that would reduce contact area, thus improving both reliability and contact area simultaneously.
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 approach results in high-density interconnects with improved thermal and electrical conductivity, reduced porosity, and uniform fuel distribution, enhancing fuel cell stack performance and simplifying the fabrication process while avoiding internal oxide formation.
Implementation Method 1
spark plasma sintering (SPS) the interconnect material to form a body of the interconnect
Implementation Method 2
spark plasma sintering (SPS) the interconnect material
Data Source
AI summary
A method of forming an interconnect for an electrochemical device stack includes loading a die with an interconnect material comprising an interconnect body powder comprising chromium and iron, and spark plasma sintering (SPS) the interconnect material to form a body of the interconnect.