High-temperature Fuel Cell Stack, and Production Thereof

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This invention relates to a specialized cassette design for high-temperature fuel cell stacks, specifically for solid oxide fuel cells (SOFCs). The core idea is to use a metal frame with two sections (an inner thin, flexible compensating frame and an outer thick, rigid frame) around the fuel cell. The inner frame forms a special bead or relief feature during the manufacturing process, which helps compensate for thermal expansion differences between the ceramic cell and the metal frame as the stack is heated and cooled. This structure significantly reduces the risk of cracks or failure in the delicate ceramic cell and improves overall reliability and durability of high-temperature fuel cell stacks.

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• Solid oxide fuel cell (SOFC) stacks for stationary power generation (e.g., for homes, commercial buildings, or utility-scale electricity supply).
• SOFC-based backup power systems for critical infrastructure like hospitals or data centers.
• High-temperature fuel cell modules for transportation applications, such as fuel cell-powered vehicles or trains.
• Portable or remote power generation equipment using SOFC technology, particularly where high thermal cycles are common.
• SOFC stacks in combined heat and power (CHP) systems for efficient local energy generation.

BenefitsContent extracted from patent full text and abstract with AI.

• Enhanced reliability and longevity of SOFC stacks, reducing the likelihood of cell breakage due to thermal stress.
• Improved efficiency in assembling and manufacturing high-temperature fuel cells, thanks to stress-relieving features tailored to each individual cell.
• Lower maintenance and replacement costs owing to reduced failure rates in ceramic cells and seals.
• Better adaptation to temperature fluctuations, making the technology more feasible in real-world operational scenarios.
• Potential cost reduction for SOFC-based systems, as improved manufacturing and durability lower overall system costs.

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Patent Abstract

A cassette for a high-temperature fuel cell stack, comprising at least one fuel cell including an anode, a cathode, and an electrolyte, and a metal cell frame which surrounds the fuel cell peripherally, wherein the metal cell frame has two sections, these being an inner thin compensating frame that contacts the fuel cell and a thicker, rigid outer frame which is provided for contacting the interconnector. The inner compensating frame comprises a peripheral bead at room temperature, which entirely disappears at temperatures between 980° C. and 1100° C., as a result of the prevailing stresses. The bead has special relief functions. It is significant that this special function of the formed bead is exclusively achieved by way of the warping in the compensating metal sheet or the compensating film, and is formed solely by way of the joining sequence applied, which is to say only in combination with the joining process employed. In contrast, a component that already has a bead prior to the joining process would also be able to compensate for stresses, but not to the same extent as a bead produced using this joining process.