Doped Sintered Ceramic Composition for Low-Temperature High Density
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Solution Overview
Problem
Existing magnesia-magnesium aluminate spinel ceramics used in solid oxide fuel cell manifolds often contain impurities that result in undesirable colors and potential contamination, while also requiring high sintering temperatures to achieve adequate density.
Innovation Solution
The use of high purity magnesia-magnesium aluminate ceramics intentionally doped with CaO, TiO2, or combinations thereof, to enhance sintering properties, achieve high density, and control color, while maintaining low levels of impurities that could affect performance or appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If commercial grade materials are used to make magnesia-magnesium aluminate spinel ceramics, then manufacturing cost is reduced, but impurities cause undesired colors and potential contamination
Solution Approach 1:
The patent changes the purity parameter of the starting materials from commercial grade to high purity (99.9% or higher), and introduces controlled dopant parameters (CaO, TiO2, Fe2O3, Cr2O3, CoO, NiO, MnO, ZnO, PbO, B2O3, SiO2, P2O5, Al2O3, ZrO2, HfO2, Ta2O5, Nb2O5, MoO3, WO3, V2O5, GeO2, As2O3, Sb2O3, Bi2O3, SnO2, In2O3, Ga2O3, Tb4O7, Dy2O3, Ho2O3, Er2O3, Tm2O3, Lu2O3, Sm2O3, Eu2O3, Gd2O3, La2O3, CeO2, Pr6O11, Nd2O3, and their combinations) to achieve the desired balance between manufacturing feasibility and product quality
Solution Approach 2:
The patent creates a composite material system combining high purity magnesia-magnesium aluminate spinel base material with controlled amounts of various dopants (CaO, TiO2, Fe2O3, Cr2O3, CoO, NiO, MnO, ZnO, PbO, B2O3, SiO2, P2O5, Al2O3, ZrO2, HfO2, Ta2O5, Nb2O5, MoO3, WO3, V2O5, GeO2, As2O3, Sb2O3, Bi2O3, SnO2, In2O3, Ga2O3, Tb4O7, Dy2O3, Ho2O3, Er2O3, Tm2O3, Lu2O3, Sm2O3, Eu2O3, Gd2O3, La2O3, CeO2, Pr6O11, Nd2O3 and their combinations), where each dopant serves specific functions in controlling color, sintering behavior, and impurity management
2Manufacturing precision
If high sintering temperatures are used to achieve adequate density, then density is improved, but energy consumption increases and impurity-related issues worsen
Solution Approach 1:
The patent changes the sintering temperature parameter from conventional high temperatures to a reduced range (1000°C to 1600°C) by introducing dopants that lower the sintering temperature requirement while maintaining or improving density through enhanced sintering kinetics and grain growth control
Solution Approach 2:
The patent converts the potential harm of impurities into benefit by using controlled dopants (CaO, TiO2, Fe2O3, Cr2O3, CoO, NiO, MnO, ZnO, PbO, B2O3, SiO2, P2O5, Al2O3, ZrO2, HfO2, Ta2O5, Nb2O5, MoO3, WO3, V2O5, GeO2, As2O3, Sb2O3, Bi2O3, SnO2, In2O3, Ga2O3, Tb4O7, Dy2O3, Ho2O3, Er2O3, Tm2O3, Lu2O3, Sm2O3, Eu2O3, Gd2O3, La2O3, CeO2, Pr6O11, Nd2O3 and their combinations) that, when present in controlled amounts, improve sintering behavior, lower processing temperatures, and enhance final product properties
3Manufacturing precision
If high sintering temperatures are used to achieve adequate density, then density is improved, but impurity-related issues worsen
Solution Approach 1:
The patent changes the purity parameter of starting materials to 99.9% or higher and precisely controls dopant concentrations to achieve high density while minimizing impurity-related issues, demonstrating that lower processing temperatures with high purity materials and controlled doping can achieve better results than conventional high-temperature processing of commercial grade materials
Solution Approach 2:
The patent creates a composite material system where high purity magnesia-magnesium aluminate spinel is combined with controlled amounts of specific dopants (CaO, TiO2, Fe2O3, Cr2O3, CoO, NiO, MnO, ZnO, PbO, B2O3, SiO2, P2O5, Al2O3, ZrO2, HfO2, Ta2O5, Nb2O5, MoO3, WO3, V2O5, GeO2, As2O3, Sb2O3, Bi2O3, SnO2, In2O3, Ga2O3, Tb4O7, Dy2O3, Ho2O3, Er2O3, Tm2O3, Lu2O3, Sm2O3, Eu2O3, Gd2O3, La2O3, CeO2, Pr6O11, Nd2O3 and their combinations) to achieve high density while controlling impurity effects through deliberate compositional design
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 doped sintered ceramic components achieve densities of at least 90% of theoretical density at lower sintering temperatures, while maintaining a desired color and minimizing impurity-related issues, thus improving the performance and reliability of solid oxide fuel cell manifolds.
Implementation Method 1
The doped sintered ceramic components achieve densities of at least 90% of theoretical density at lower sintering temperatures
Implementation Method 2
The starting composition can include CaO, TiO2, Fe2O3, Cr2O3, CoO, NiO, MnO, ZnO, PbO, B2O3, SiO2, P2O5, Al2O3, ZrO2, HfO2, Ta2O5, Nb2O5, MoO3, WO3, V2O5, GeO2, As2O3, Sb2O3, Bi2O3, SnO2, In2O3, Ga2O3, Tb4O7, Dy2O3, Ho2O3, Er2O3, Tm2O3, Lu2O3, Sm2O3, Eu2O3, Gd2O3, La2O3, CeO2, Pr6O11, Nd2O3, and their combinations, in various amounts
Data Source
Figure 1~2
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Figure 5~6
AI summary
A sintered ceramic component can have a final composition including at least 50 wt.% MgO and at least one desired dopant, wherein each dopant of the at least one desired dopant has a desired dopant content of at least 0.1 wt.%. All impurities (not including the desired dopant(s)) are present at a combined impurity content of less than 0.7 wt.%. A remainder can include A12O3. The selection of dopants can allow for better control over the visual appearance of the sintered ceramic component, reduces the presence of undesired impurities that may adversely affect another part of an apparatus, or both. The addition of the dopant(s) can help to improve the sintering characteristics and density as compared to a sintered ceramic component that includes the material with no dopant and a relatively low impurity content.