Inkjet Ceramic Coating for SOFC Metal Interconnectors
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Solution Overview
Problem
Conventional deposition technologies struggle to apply protective ceramic coatings on metallic interconnectors with complex geometries in solid oxide fuel cell stacks, leading to material waste, poor resolution, and the need to mask areas not to be coated, while also failing to maintain electrical conductivity and prevent high-temperature oxidation.
Innovation Solution
The method employs inkjet printing to selectively deposit ceramic materials with high resolution on complex surfaces, allowing for the simultaneous application of multiple materials without masking, reducing material waste, and enabling the creation of composition gradients within the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional deposition technologies (screen printing, dip coating, thermal spray) are used to apply protective ceramic coatings on metallic interconnectors, then the coating process is simple and can be applied to large surfaces, but the resolution is poor, material waste exceeds 70%, and complex three-dimensional surfaces cannot be adequately coated
Solution Approach 1:
The patent replaces conventional mechanical deposition systems (screen printing, dip coating, thermal spray) with inkjet printing technology. This substitution enables precise digital control of material deposition, achieving high-resolution coatings on complex geometries while reducing material waste from over 70% to minimal amounts through selective droplet placement.
Solution Approach 2:
The patent changes the deposition method from bulk material application to controlled droplet deposition with precise spatial and temporal parameters. Inkjet printing allows independent control of deposition location, quantity, and timing, enabling high-resolution coating patterns and selective application on complex three-dimensional surfaces without masking.
2Adaptability or versatility
If conventional deposition technologies are used on complex three-dimensional surfaces, then the process can be applied to large surfaces, but areas with complex geometry are hard to access and require masking
Solution Approach 1:
The patent replaces mechanical masking systems with digital patterning control in inkjet printing. The digital image data directly controls droplet placement, eliminating the need for physical masks and enabling easy adaptation to complex three-dimensional geometries through software configuration rather than physical modifications.
Solution Approach 2:
The inkjet printing system provides universal applicability across diverse interconnector geometries without requiring dedicated masking setups for each design. The same printing system can accommodate varying complex geometries by simply changing the digital pattern data, making the process highly versatile and adaptable.
3Reliability
If protective ceramic coatings are applied to prevent high-temperature oxidation, then the metal is protected from oxidation and volatile element release, but electrical conductivity at the interface is reduced
Solution Approach 1:
The patent applies different coating materials or compositions to different local areas of the interconnector based on functional requirements. Electrically conductive ceramic materials are applied specifically at interfaces requiring electrical connection, while protective ceramic coatings are applied in oxidation-prone areas, optimizing both protection and conductivity locally rather than uniformly across the entire surface.
Solution Approach 2:
The patent uses composite coating systems combining ceramic materials with different properties. By integrating conductive and protective ceramic materials in a single coating system, the patent achieves both oxidation protection and maintained electrical conductivity through the synergistic properties of the composite material structure.
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 effectively reduces material waste, achieves high-resolution coatings on complex geometries, and maintains electrical conductivity while protecting the metal from oxidation, ensuring the longevity of fuel cell stacks.
Implementation Method 1
suspending the ceramic material in an aerosol
Implementation Method 2
The organic solvent of the deposited layer is then evaporated
Data Source
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Figure 6
AI summary
The present invention regards a method for depositing a material layer on a metallic interconnector or support (1) for fuel cells or cells for electrolysis.