Low-Warp Metal Support for Uniform SOFC Electrode Printing
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Solution Overview
Problem
The existing metal supports for electrochemical elements, such as those in metal-supported SOFCs, face challenges in forming uniform electrode layers due to distortion caused by printing pressure, leading to surface defects like breakage and separation.
Innovation Solution
A metal support with a plate shape and penetration spaces that have a warping degree of 1.5×10−2 or less, calculated using a least squares method, to ensure uniform electrode layer formation and reduced surface defects, is developed. This support is made of a Fe—Cr based alloy with specific thickness and structural features to enhance strength and adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a thin metal foil is used to reduce weight and improve flexibility, then the metal support becomes more adaptable, but the metal foil distorts under printing pressure causing surface defects
Solution Approach 1:
The patent employs a composite structure combining a metal mesh substrate with a metal foil layer. The metal mesh provides structural support and rigidity to prevent distortion during printing, while the metal foil layer maintains flexibility and enables adaptability. This composite configuration resolves the contradiction by allowing the thin metal support to remain flexible without sacrificing surface flatness under printing pressure.
2Ease of manufacture
If printing pressure is applied to form electrode layers, then the electrode layer is deposited onto the metal support, but the metal foil distorts causing non-uniform thickness and surface defects
Solution Approach 1:
The metal mesh underlying structure provides rigid support that prevents foil distortion during the printing process, enabling uniform electrode layer formation with consistent thickness while maintaining ease of manufacture through standard printing techniques.
Solution Approach 2:
The metal foil is pre-mounted onto the metal mesh before the printing process. This preliminary action of securing the foil to the rigid mesh substrate ensures that the foil remains stable and flat during subsequent printing operations, preventing distortion and ensuring uniform electrode layer deposition.
3Strength
If a metal mesh structure is used to provide support, then structural strength is improved, but the metal foil mounted on it distorts due to low strength
Solution Approach 1:
The combination of metal mesh and metal foil creates a composite structure where the metal mesh provides the rigid structural support framework, while the metal foil layer maintains stability through its attachment to the mesh. The mesh structure prevents foil distortion by providing a stable underlying geometry that resists deformation under printing pressure.
Data Source
AI summary
A metal support for an electrochemical element where the metal support includes a plate face, has a plate shape as a whole, and has a warping degree of 1.5×10−2 or less determined by calculating a least square value through the least squares method using at least three points in the plate face of the metal support, calculating a first difference between the least square value and a positive-side maximum displacement value on a positive side with respect to the least square value and a second difference between the least square value and a negative-side maximum displacement value on a negative side that is opposite to the positive side with respect to the least square value, and dividing the sum of the first difference and the second difference by a maximum length of the plate face of the metal support that passes through a center of gravity.