Enhanced electrical and mechanical performance by a novel interconnector design for solid oxide fuel cell stacks

The design of interconnectors plays a pivotal role in balancing the electrical efficiency and mechanical integrity of solid oxide fuel cells (SOFCs) stacks, yet prior studies have predominantly prioritized electrical optimization over mechanical reliability. This work presents an innovative interconnector design for planar SOFCs, incorporating discretely distributed ribs that replace conventional continuous ribs to enhance gas distribution and reduce electrochemical polarization. Using a developed 3D Multiphysics model coupling electrochemical, thermal, and mechanical phenomena, we systematically evaluate the influence of geometry and compressive loading on stack performance. The optimized design achieves a 50 % increase in current density (from 0.52 to 0.78 A cm−2 at 0.5 V) and improves mechanical reliability. Under 1.0 MPa compression, anode tensile stress decreases from 21.26 MPa to 12.43 MPa while cathode equivalent strain is reduced by 37.5 %. These results demonstrate that strategic interconnector redesign synergistically enhances both electrical output and mechanical durability, providing a transformative approach for high-performance SOFCs systems.