Compliant, strain tolerant interconnects for solid oxide fuel cell stack

Abstract

An interconnect for a solid oxide fuel cell includes a compliant superstructure having a first portion defining a separator plate contact zone and a second portion defining an electrode contact zone, wherein the super structure is porous. In one embodiment, the superstructure is defined by a plurality of compliant substructures provided in a first direction and a plurality of compliant substructures provided in second direction to define a woven structure.

What is claimed is:  
     
         1 . An interconnect assembly for a solid oxide fuel cell, comprising: 
 a separator plate having two opposed surfaces; and    at least one electron conducting compliant interconnect in electrical communication with the separator plate, the compliant interconnect comprising a compliant superstructure having a first portion defining a separator plate contact zone and a second portion defining an electrode contact zone, wherein the superstructure is porous to operating fuel cell gaseous materials.    
     
     
         2 . The assembly of  claim 1 , wherein said compliant superstructure is compliant in at least three orthogonal axes.  
     
     
         3 . The assembly of  claim 1 , wherein said compliant superstructure is compliant with respect to a load applied from any direction.  
     
     
         4 . The assembly of  claim 1 , wherein said compliant superstructure comprises a first plurality of compliant substructures disposed in a first direction and a second plurality of compliant substructures disposed in a second direction different from said first direction so as to define a woven structure.  
     
     
         5 . The assembly of  claim 4  wherein at least one compliant substructure is pre-buckled.  
     
     
         6 . The assembly of  claim 4  wherein said compliant substructures comprise wires, and wherein said woven structure is a wire weave.  
     
     
         7 . The assembly of  claim 4  wherein said compliant substructures comprise pre-buckled wires, and wherein said woven structure is a wire weave.  
     
     
         8 . The assembly of  claim 4  wherein said compliant superstructure is dimpled, and wherein further a first plurality of dimples define said separator plate contact zone and a second plurality of dimples define said electrode contact zone.  
     
     
         9 . The assembly of  claim 8  wherein said first plurality of dimples extend substantially opposite to said second plurality of dimples.  
     
     
         10 . The assembly of  claim 1  wherein said interconnect is a cathode-side interconnect.  
     
     
         11 . The assembly of  claim 1  wherein said interconnect is an anode-side interconnect.  
     
     
         12 . The assembly of  claim 1 , wherein said superstructure has a compliance of at least about 5×10 −6  mm 2 /N.  
     
     
         13 . The assembly of  claim 1 , wherein said superstructure has a compliance of at least about 5×10 −5  mm 2 /N.  
     
     
         14 . The assembly of  claim 1 , wherein said superstructure has a compliance of at least about 5×10 −4  mm 2 /N.  
     
     
         15 . The assembly of  claim 1 , wherein said compliant superstructure is shaped to include at least one substantially orthogonal channel.  
     
     
         16 . The assembly of  claim 1 , wherein said compliant superstructure is shaped to include at least one substantially slanted channel.  
     
     
         17 . The assembly of  claim 1 , wherein said compliant superstructure is shaped to include at least one substantially square channel.  
     
     
         18 . The assembly of  claim 1 , wherein said compliant superstructure is shaped to include at least one substantially rectangular channel.  
     
     
         19  The assembly of  claim 1 , wherein said compliant superstructure is shaped to include at least one substantially sinusoidal channel.  
     
     
         20 . The assembly of  claim 1 , wherein said compliant superstructure is shaped to include at least one substantially hour-glass shaped channel.  
     
     
         21 . The assembly of  claim 1 , wherein said compliant superstructure is comprised of a stainless steel, stainless steel alloy, or stainless steel super-alloy.  
     
     
         22 . The assembly of  claim 1 , wherein said compliant superstructure is comprised of a chromium-based alloy.  
     
     
         23 . The assembly of  claim 1 , wherein said compliant superstructure is comprised of a noble metal-based alloy.  
     
     
         24 . The assembly of  claim 1 , wherein said compliant superstructure is comprised of a composite of at least two materials.  
     
     
         25 . An interconnect for a solid oxide fuel cell, comprising: a compliant superstructure having a first portion defining a separator plate contact zone and a second portion defining an electrode contact zone, wherein the superstructure is porous to operating fuel cell gaseous materials.  
     
     
         26 . The apparatus of  claim 25 , wherein said compliant superstructure is compliant in at least three orthogonal axes.  
     
     
         27 . The apparatus of  claim 25 , wherein said compliant superstructure is compliant with respect to a load applied from any direction.  
     
     
         28 . The apparatus of  claim 25 , wherein said compliant superstructure comprises a first plurality of compliant substructures disposed in a first direction and a second plurality of compliant substructures disposed in a second direction different from said first direction so as to define a woven structure.  
     
     
         29 . The apparatus of  claim 28  wherein at least one compliant substructure is pre-buckled.  
     
     
         30 . The apparatus of  claim 28  wherein said compliant substructures comprise wires, and wherein said woven structure is a wire weave.  
     
     
         31 . The apparatus of  claim 28  wherein said compliant substructures comprise pre-buckled wires, and wherein said woven structure is a wire weave.  
     
     
         32 . The apparatus of  claim 28  wherein said compliant superstructure is dimpled, and wherein further a first plurality of dimples define said separator plate contact zone and a second plurality of dimples define said electrode contact zone.  
     
     
         33 . The apparatus of  claim 32  wherein said first plurality of dimples extend substantially opposite to said second plurality of dimples.  
     
     
         34 . The apparatus of  claim 25  wherein said interconnect is a cathode-side interconnect.  
     
     
         35 . The apparatus of  claim 25  wherein said interconnect is an anode-side interconnect.  
     
     
         36 . The apparatus of  claim 25 , wherein said superstructure has a compliance of at least about 5×10 −6  mm 2 /N.  
     
     
         37 . The apparatus of  claim 25 , wherein said superstructure has a compliance of at least about 5×10 −5  mm 2 /N.  
     
     
         38 . The apparatus of  claim 25 , wherein said superstructure has a compliance of at least about 5×10 −4  mm 2 /N.  
     
     
         39 . The apparatus of  claim 25 , wherein said compliant superstructure is shaped to include at least one substantially orthogonal channel.  
     
     
         40 . The apparatus of  claim 25 , wherein said compliant superstructure is shaped to include at least one substantially slanted channel.  
     
     
         41 . The apparatus of  claim 25 , wherein said compliant superstructure is shaped to include at least one substantially square channel.  
     
     
         42 . The apparatus of  claim 25 , wherein said compliant superstructure is shaped to include at least one substantially rectangular channel.  
     
     
         43 . The apparatus of  claim 25 , wherein said compliant superstructure is shaped to include at least one substantially sinusoidal channel.  
     
     
         44 . The apparatus of  claim 25 , wherein said compliant superstructure is shaped to include at least one substantially hour-glass shaped channel.  
     
     
         45 . The apparatus of  claim 25 , wherein said compliant superstructure is comprised of a stainless steel, stainless steel alloy, or stainless steel super-alloy.  
     
     
         46 . The apparatus of  claim 25 , wherein said compliant superstructure is comprised of a chromium-based alloy.  
     
     
         47 . The apparatus of  claim 25 , wherein said compliant superstructure is comprised of a noble metal-based alloy.  
     
     
         48 . The apparatus of  claim 25 , wherein said compliant superstructure is comprised of a composite of at least two materials.  
     
     
         49 . A solid oxide fuel cell stack comprising: 
 at least three fuel cell assemblies in electrical contact, wherein at least one fuel cell assembly comprises an electrode, a separator plate, and a compliant interconnect positioned between the electrode and the separator plate, the compliant interconnect comprising a compliant superstructure having a first portion defining a separator plate contact zone and a second portion defining an electrode contact zone, wherein the superstructure is porous to operating fuel cell gaseous materials.    
     
     
         50 . The apparatus of  claim 49 , wherein said compliant superstructure is compliant in at least three orthogonal axes.  
     
     
         51 . The apparatus of  claim 49 , wherein said compliant superstructure is compliant with respect to a load applied from any direction.  
     
     
         52 . The apparatus of  claim 49 , wherein said compliant superstructure comprises a first plurality of compliant substructures disposed in a first direction and a second plurality of compliant substructures disposed in a second direction different from said first direction so as to define a woven structure.