Conductive Electrolyte Layer Sputtering for Low-Temperature PCFCs
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Solution Overview
Problem
Conventional high-temperature wet processes for manufacturing protonic ceramic fuel cells (PCFCs) lead to degradation and formation of secondary phases, limiting their performance and durability due to high sintering temperatures and low sinterability of materials.
Innovation Solution
A low-temperature dry process using a sputtering method to form a conductive electrolyte layer with a BZY composite, involving co-sputtering of BaCO3, ZrO2, and Y2O3 targets, and optimizing power and gas composition to achieve a thin, dense electrolyte layer with improved ion conductivity, operated at 500°C or lower.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a high-temperature thermal process (1400°C or higher) is used to manufacture PCFC through wet ceramics process, then the material sinterability is improved, but the fuel cell structure degrades and secondary phases form
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature (1400°C or higher) to low-temperature (900°C or lower) processing. This parameter change enables the formation of dense electrolyte layers without causing structural degradation or secondary phase formation, thus resolving the contradiction between sinterability and structural integrity
Solution Approach 2:
The patent replaces the conventional wet ceramics process with a dry thin film deposition process. This substitution eliminates the need for high-temperature thermal processing while achieving dense electrolyte layers through controlled deposition, thereby preventing structural degradation
2Reliability
If a low-temperature dry process (900°C or lower) is used to manufacture PCFC, then the fuel cell structure integrity is preserved, but the material sinterability deteriorates
Solution Approach 1:
The patent replaces the wet ceramics process with a dry thin film deposition process that uses physical vapor deposition techniques. This substitution enables dense electrolyte layer formation at low temperatures (900°C or lower) without requiring high-temperature sintering, thus maintaining structural integrity while achieving good manufacturability
Solution Approach 2:
The patent changes the processing temperature parameter to low-temperature (900°C or lower) regime and adjusts deposition parameters (gas composition, pressure, power) to achieve dense electrolyte layers. This parameter optimization enables low-temperature processing with good sinterability, resolving the contradiction between structural integrity and manufacturability
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 metal-supported PCFCs with enhanced durability, stability, and performance by avoiding high-temperature-induced degradation and secondary phase formation, while reducing manufacturing costs and enabling large-area cell production.
Implementation Method 1
A low-temperature dry process using a sputtering method to form a conductive electrolyte layer with a BZY composite, involving co-sputtering of BaCO3, ZrO2, and Y2O3 targets
Implementation Method 2
a deposition apparatus for forming a conductive electrolyte layer, and the deposition apparatus may control a gas atmosphere, a pressure, a temperature, and the like in a chamber
Data Source
AI summary
A method of forming a conductive electrolyte layer according to various embodiments of the present disclosure for achieving the objects is disclosed. The method includes loading a substrate into a sputtering chamber, connecting multiple targets to the chamber, injecting a mixed gas into the chamber, supplying power to each of the multiple targets and forming the conductive electrolyte layer on one surface of the substrate, and sintering the conductive electrolyte layer at a set sintering temperature.