Gas-Tight Ion-Conducting Ceramic Layer With Low-Temperature Sintering

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Solution Overview

Problem

Existing methods for producing gas-tight, ion-conducting ceramic functional layers in fuel cells and electrolysis cells require high processing temperatures and inorganic sintering additives, leading to unsatisfactory electrochemical properties and mechanical stresses due to thermal shrinkage and interdiffusion.

Innovation Solution

A method involving pressing ceramic powder with a sintering additive at high pressure, followed by low-temperature sintering, to achieve high density and gas-tightness without inorganic additives, using liquid or functional-group-containing sintering agents to minimize thermal shrinkage and interfacial reactions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high processing temperatures and inorganic sintering additives are used to achieve gas-tightness, then gas-tightness is improved, but electrochemical properties deteriorate and thermal stresses increase

Engineering Contradiction:

Improvegas-tightnessVSAvoidelectrochemical property degradation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the sintering temperature parameter from conventional high temperatures (>1350°C) to low temperatures (900-1100°C), and changes the sintering additive from inorganic solids to organic compounds with low decomposition temperatures. This parameter transformation enables achievement of gas-tightness without the harmful effects of high temperature processing and inorganic additives on electrochemical properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses organic sintering additives (wax, alcohol, carboxylic acids) that decompose completely at low temperatures, leaving no residual harmful substances. These temporary additives serve their purpose during sintering and then disappear, unlike persistent inorganic additives that remain as contaminants and degrade electrochemical performance

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If high processing temperatures are used to achieve sufficient gas-tightness, then gas-tightness is improved, but mechanical stability deteriorates due to thermal shrinkage and interlayer stresses

Engineering Contradiction:

Improvegas-tightnessVSAvoidmechanical stability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent transforms the sintering temperature parameter from high (>1350°C) to low (900-1100°C), which eliminates excessive thermal shrinkage and interlayer stresses while still achieving adequate gas-tightness through the organic additive-assisted sintering process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The organic sintering additives create a controlled sintering environment that cushions against thermal shocks and stress concentrations during the low-temperature process, preventing mechanical failures before they occur

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If inorganic sintering additives are used to achieve gas-tightness, then gas-tightness is improved, but electrochemical properties deteriorate due to secondary phase formation

Engineering Contradiction:

Improvegas-tightnessVSAvoidsecondary phase formation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent employs organic sintering additives (waxes, alcohols, carboxylic acids) that decompose completely at low temperatures, serving as temporary aids during sintering and then disappearing without leaving residual contaminants. This eliminates secondary phase formation that plagues inorganic additive systems

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent extracts and removes inorganic sintering additives from the process entirely, replacing them with organic alternatives that do not form harmful secondary phases, thereby purifying the final ceramic product

Inventive Principle:

Principle #2Taking out (Extraction)

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 allows for the production of components with improved electrochemical properties and mechanical stability at lower sintering temperatures, reducing thermal stresses and secondary phase formation, while maintaining high ion conductivity and gas-tightness.

Implementation Method 1

pressing ceramic powder material together with a sintering additive by a pressing tool with a pressing pressure of at least 50 MPa

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The pressed powder material and the sintering additive pressed with it are sintered

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS20260018624A1Production of a component with a gas-tight ion-conducting functional layer, and component

Publication Date: 2026.01.15 FORSCHUNGSZENTRUM JULICH GMBH

AI summary

The invention relates to a method for producing a component (11) having a gas-tight, ion-conducting ceramic functional layer (9), comprising the steps of:ceramic powder material is pressed with a sintering additive by a pressing tool (1) at a pressure of at least 50 MPa,the pressed ceramic powder material and the sintering additive are sintered.The invention also relates to a component producible with the method.