Metal-Supported Electrochemical Element Hole-Lining for Durability
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Solution Overview
Problem
The inner surfaces of through-holes in metal substrates of electrochemical elements are exposed, leading to degradation when used as fuel cells or electrolytic cells, and existing manufacturing methods require high-temperature firing, which can damage the metal support and increase costs.
Innovation Solution
A method involving the application of a paste containing an electrode material into the through-holes of a metal support, followed by firing and compression, with controlled atmospheric conditions and low-temperature processes to form an electrode layer that covers and fills the holes, enhancing durability and reducing gas permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high temperature firing is performed to ensure sufficient adhesion strength between layers, then the adhesion strength is improved, but the metal substrate degrades and manufacturing costs increase
Solution Approach 1:
The patent applies parameter changes by reducing the firing temperature from conventional high temperatures (1400°C) to a lower temperature range (900-1100°C). This temperature parameter modification allows sufficient adhesion strength to be achieved while preventing substrate degradation, thus resolving the contradiction between improving adhesion strength and maintaining substrate durability
Solution Approach 2:
The patent employs composite materials by forming an electrode layer that penetrates into the through-holes of the metal substrate, creating a composite structure where the electrode material and metal substrate are interconnected. This composite configuration enhances adhesion strength through mechanical interlocking while allowing lower firing temperatures, thereby protecting the substrate from thermal degradation
2Manufacturing precision
If the paste is compressed to reduce pore size, then the electrode layer density is improved, but the gas permeability of through-holes decreases
Solution Approach 1:
The patent applies local quality by implementing selective compression: the paste on the surface of the metal substrate is compressed to reduce pore size and increase density, while the paste that has penetrated into the through-holes is left uncompressed to maintain large pore sizes and high gas permeability. This localized differentiation of compression levels allows simultaneous achievement of electrode layer density and through-hole gas permeability
Solution Approach 2:
The patent utilizes dimensional differentiation by applying compression in the planar direction (parallel to substrate surface) while preserving the vertical structure (into through-holes). This dimensional selectivity allows density improvement in the electrode layer without compromising the gas transport pathways that extend vertically through the through-holes
3Productivity
If through-holes are formed in metal substrate to improve gas transport, then the gas permeability is improved, but the inner surfaces of holes are exposed leading to degradation
Solution Approach 1:
The patent applies the nested doll principle by having the electrode layer penetrate into and line the through-holes of the metal substrate. The electrode material nests within the hollow cylindrical space of each through-hole, creating a protective lining that covers the exposed metal surfaces while preserving the gas transport function of the through-holes
Solution Approach 2:
The electrode layer functions as a thin film that conforms to and covers the inner surfaces of the through-holes. This thin film structure protects the exposed metal surfaces from degradation while maintaining the open channel structure necessary for gas permeability, thus resolving the contradiction between gas transport and substrate protection
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 improves the durability and performance of electrochemical elements by covering the inner surfaces of through-holes with an electrode layer, reducing gas permeability, and minimizing equipment and material costs while maintaining high-quality electrode formation.
Implementation Method 1
an application step of applying the paste to a surface of the metal support in such a manner that the paste enters the through-holes
Implementation Method 2
a firing step of firing the metal support to which the paste has been applied
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Provided are an electrochemical element, an electrochemical module, a solid oxide fuel cell, a solid oxide electrolytic cell, an electrochemical device, and an energy system, each with improved durability, and a method for manufacturing an electrochemical element with improved durability. A method for manufacturing an electrochemical element E by forming an electrode layer 2 on a metal support 1 having through-holes 1a includes: a preparation step of preparing a paste that contains a material of the electrode layer 2 and a pore-forming material; an application step of applying the paste to a surface of the metal support 1 in such a manner that the electrode layer paste enters the through-holes 1a; a firing step of firing the metal support 1 that has undergone the application step; and a compression step of compressing a layer of the paste that has been applied or the electrode layer 2 that has been fired.