Copper Electrode Sintering via Electromagnetic Radiation

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Solution Overview

Problem

The development of copper-containing anodes for solid oxide fuel cells is hindered by expensive and labor-intensive methods, and existing copper electrodes in electrochemical reactors lack inter-dispersed copper and ceramic phases, which affects their performance and efficiency.

Innovation Solution

The creation of copper or copper oxide electrodes with inter-dispersed ceramic phases, such as CGO or SDC, using a method involving the formation of a dispersion, deposition onto a substrate, and sintering with electromagnetic radiation, allowing for percolation and improved conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional methods are used to create copper-containing anodes, then the manufacturing process is well-established, but the process becomes expensive and labor-intensive

Engineering Contradiction:

Improvemanufacturing cost and labor intensityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical mixing and deposition methods with electromagnetic radiation (microwave or radio frequency) to heat and sinter the ceramic-particle-containing composition. This substitution eliminates labor-intensive manual operations and reduces manufacturing costs while maintaining production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes electromagnetic radiation parameters (frequency, power, duration) to control the heating and sintering process. By adjusting these parameters, the method achieves efficient manufacturing without requiring expensive traditional high-temperature furnaces or complex mechanical processing equipment.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If copper and ceramic phases are not inter-dispersed, then the manufacturing process is simpler, but the electrode performance and efficiency are reduced

Engineering Contradiction:

Improveelectrode performanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent incorporates ceramic particles into the copper composition before deposition and sintering, ensuring inter-dispersion is achieved during the formation process rather than requiring post-manufacturing processing. This preliminary incorporation maintains structural simplicity while achieving the desired inter-dispersed morphology for optimal performance.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a composite material consisting of copper matrix with dispersed ceramic particles (such as CGO or SDC). This composite structure enhances electrode performance by combining the electrical conductivity of copper with the functional properties of ceramic phases, achieving both reliability and controlled complexity.

Inventive Principle:

Principle #40Composite materials

3Productivity

If electromagnetic radiation is used for sintering, then the sintering process becomes faster and more efficient, but the equipment complexity increases

Engineering Contradiction:

Improvesintering speedVSAvoidequipment complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces traditional thermal conduction-based sintering (requiring lengthy furnace heating cycles) with electromagnetic radiation heating. This substitution dramatically reduces sintering time and increases productivity, while the equipment complexity is offset by the elimination of expensive furnace systems and the use of more accessible microwave or RF generators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the production of copper electrodes with enhanced conductivity and reduced manufacturing costs, improving the performance and efficiency of electrochemical reactors, including solid oxide fuel cells and gas producers.

Implementation Method 1

sintering with electromagnetic radiation

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Dielectric Heating

Implementation Method 2

allowing for percolation and improved conductivity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11539053B2Method of making copper electrode

Publication Date: 2022.12.27 UTILITY GLOBAL INC

AI summary

Herein discussed is an electrode comprising a copper or copper oxide phase and a ceramic phase, wherein the copper or copper oxide phase and the ceramic phase are sintered and are inter-dispersed with one another. Further discussed herein is a method of making a copper-containing electrode comprising: (a) forming a dispersion comprising ceramic particles and copper or copper oxide particles; (b) depositing the dispersion onto a substrate to form a slice; and (c) sintering the slice using electromagnetic radiation.