Anode-Supported Cell Co-Sintering With C-Axis Apatite Electrolyte
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Solution Overview
Problem
Existing methods struggle to co-sinter materials for solid electrolyte layers and anode materials in anode-supported cells, leading to difficulties in producing thin solid electrolyte layers that can withstand the process and maintain high oxide ion conductivity.
Innovation Solution
A production method involving the stacking and heating of layers containing specific oxides, such as La2Si2O7 and cerium oxide, with nickel oxide, and optionally an auxiliary support layer, at temperatures of 1000°C or more, to create a c-axis oriented apatite structure solid electrolyte, and incorporating cerium oxide doped with rare earth elements in intermediate layers to enhance oxide ion conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If element diffusion heating is used to produce solid electrolyte layer, then oxide ion conductivity is improved, but manufacturing complexity increases due to additional polishing and removal of unreacted layer
Solution Approach 1:
The invention combines the solid electrolyte layer formation and anode material co-sintering into a single heating process. The stacked body includes the oxide layer, cerium oxide layer, and nickel oxide layer that are co-sintered simultaneously to form the solid electrolyte layer with apatite structure and the anode material, eliminating the need for separate polishing and removal steps required in conventional element diffusion methods
Solution Approach 2:
The invention performs preliminary preparation of the stacked body structure with specific layer arrangements (oxide layer, cerium oxide layer, nickel oxide layer) before heating. This preliminary configuration enables the subsequent single heating step to achieve both solid electrolyte formation and anode material formation without requiring post-processing steps
2Productivity
If thin solid electrolyte layer is used in anode-supported cell, then power generation efficiency is improved, but mechanical strength deteriorates making the layer unable to withstand co-sintering process
Solution Approach 1:
The invention uses composite material structure in the stacked body where the oxide layer (containing La2Si2O7), cerium oxide layer, and nickel oxide layer are combined. This composite structure enables the formation of a thin solid electrolyte layer with sufficient mechanical strength to withstand co-sintering, while maintaining high oxide ion conductivity for improved power generation efficiency
Solution Approach 2:
The invention changes the chemical composition parameters of the layered structure by using specific oxides (La2Si2O7, cerium oxide, nickel oxide) in the stacked body. This parameter change enables the solid electrolyte layer to achieve both thinness for efficiency and adequate strength for co-sintering process
3Reliability
If multiple heating processes are used to produce cell with intermediate layers and electrodes, then structural integrity is improved, but production time increases
Solution Approach 1:
The invention merges multiple heating processes into a single co-sintering operation. The stacked body (oxide layer, cerium oxide layer, nickel oxide layer) is heated once to simultaneously form the solid electrolyte layer, intermediate layers, and anode material, reducing production time while maintaining structural integrity through proper initial layer configuration
Solution Approach 2:
The stacked body structure serves multiple functions: the oxide layer provides solid electrolyte material, the cerium oxide layer provides intermediate layer material, and the nickel oxide layer provides anode material. This multi-functional design allows a single heating process to produce all necessary cell components, eliminating the need for separate heating steps for each layer
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
The method enables the production of anode-supported cells with improved mechanical strength and oxide ion conductivity, resulting in enhanced power generation characteristics and reduced electric resistance.
Implementation Method 1
a step of heating a first stacked body, in which a layer, a first layer and a nickel oxide-containing layer are stacked, at 1000° C. or more, wherein the layer contains an oxide represented by a composition formula: La2Si2O7, and thereby generating, from the oxide represented by the composition formula, a solid electrolyte that has an apatite structure and is c-axis oriented
Implementation Method 2
a step of heating a first stacked body, in which a layer, a first layer and a nickel oxide-containing layer are stacked, at 1000° C. or more
Data Source
AI summary
A production method includes: heating a first stacked body at 1000° C. or more, the first stacked body having: a layer containing an oxide represented by the composition formula: La2Si2O7; a first layer provided on one side of the oxide-containing layer and containing cerium oxide doped with a lanthanum element; and a layer provided on the first layer opposite to the oxide-containing layer and containing nickel oxide, and thereby generating, from the oxide represented by the composition formula, a solid electrolyte that has an apatite structure and is c-axis oriented; placing a second layer containing cerium oxide doped or not doped with an Ln element (a rare earth element other than cerium), on the solid electrolyte-containing layer opposite to the cerium oxide-containing layer, and thereby obtaining a second stacked body; and heating the second stacked body at 1000° C. or more.