Integrated Deposition and Heating for Fuel Cell Manufacturing
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Solution Overview
Problem
The manufacturing of fuel cells is complex and expensive, with the deposition and heating/curing/sintering steps often being dissociated, leading to increased complexity and cost in producing efficient fuel cell systems.
Innovation Solution
An integrated deposition and heating process using electromagnetic radiation (EMR) where a composition comprising a first and second material is deposited slice by slice, with the second material having higher radiation absorption, allowing for simultaneous deposition and heating, reducing the need for separate steps and minimizing residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deposition and heating/curing/sintering steps are dissociated, then each step can be optimized independently, but the manufacturing process complexity and cost increase
Solution Approach 1:
The patent combines the deposition step and heating/curing/sintering step into a single integrated process. The coating is applied directly onto the substrate while simultaneously subjected to electromagnetic radiation for heating, eliminating the need for separate deposition and heating equipment and processes. This merging reduces manufacturing complexity while maintaining the quality benefits of both independent steps.
2Manufacturing precision
If deposition and heating/curing/sintering steps are dissociated, then each step can be controlled separately, but the manufacturing time and cost increase
Solution Approach 1:
The integrated process enables continuous operation where deposition and heating occur simultaneously without interruption. The coating material is deposited and immediately heated in the same continuous process flow, eliminating the idle time between separate deposition and heating steps. This continuity maintains precise process control while significantly reducing total manufacturing time.
3Reliability
If traditional separate deposition and heating processes are used, then equipment can be specialized for each step, but the overall manufacturing cost increases
Solution Approach 1:
The integrated system uses a single piece of equipment that performs both deposition and heating functions. The electromagnetic radiation source serves multiple purposes: it provides the energy for heating/curing/sintering while the deposition system applies the coating material. This multi-functionality reduces the need for multiple specialized equipment purchases and maintenance, lowering overall manufacturing costs while maintaining process reliability through a unified system 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
This method simplifies the manufacturing process, reduces costs, and enables rapid, uniform heating, improving the efficiency and performance of fuel cell production by integrating deposition and heating in a single step, thus shortening sintering time and minimizing thermal stress.
Implementation Method 1
the second material has a higher absorption of the radiation than the first material
Implementation Method 2
heating in situ the object using electromagnetic radiation (EMR)
Data Source
AI summary
Herein disclosed is a method of manufacturing comprises depositing a composition on a substrate slice by slice to form an object; heating in situ the object using electromagnetic radiation (EMR); wherein said composition comprises a first material and a second material, wherein the second material has a higher absorption of the radiation than the first material. In an embodiment, the EMR has a wavelength ranging from 10 to 1500 nm and the EMR has a minimum energy density of 0.1 Joule/cm2. In an embodiment, the EMR comprises UV light, near ultraviolet light, near infrared light, infrared light, visible light, laser, electron beam. In an embodiment, said object comprises a catalyst, a catalyst support, a catalyst composite, an anode, a cathode, an electrolyte, an electrode, an interconnect, a seal, a fuel cell, an electrochemical gas producer, an electrolyser, an electrochemical compressor, a reactor, a heat exchanger, a vessel, or combinations thereof.