Metal-Substrate Electrochemical Element for Thin SOFC Support
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Solution Overview
Problem
Conventional solid oxide fuel cells using ceramic support substrates face issues with high material and processing costs due to the need for thick, expensive, and brittle substrates, which also complicate the arrangement of multiple power generating bodies and increase size and weight.
Innovation Solution
A metal substrate with gas flow allowing regions is used, featuring an electrode layer, electrolyte layer, and counter electrode layer, where the electrolyte layer is positioned between the electrode and counter electrode, and a metal oxide film is applied to prevent component dispersion and vaporization, enhancing strength, reliability, and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ceramic support substrate is used to provide strength, then the strength is improved, but the material cost and processing cost increase, and the size and weight increase
Solution Approach 1:
The invention changes the material parameter from ceramic to metal, fundamentally altering the substrate's properties. This enables thinning the substrate while maintaining strength, reduces material cost, and simplifies processing. The metal substrate with thickness of 0.03 to 0.5 mm provides sufficient strength without the cost and weight penalties of ceramic substrates requiring several millimeters thickness.
Solution Approach 2:
The invention creates a composite structure by forming a metal oxide film on the metal substrate surface. This composite approach combines the high strength and formability of metal with the oxidation resistance and stability of metal oxide, achieving both mechanical performance and chemical stability without using expensive ceramic materials.
2Strength
If a ceramic support substrate is used, then the strength is improved, but the device size and weight increase
Solution Approach 1:
Changing from ceramic to metal substrate material enables significant weight reduction. The metal substrate can be made much thinner (0.03 to 0.5 mm) while maintaining adequate strength, compared to ceramic substrates that require several millimeters thickness. This parameter change directly reduces both substrate weight and overall device weight.
3Strength
If a ceramic support substrate is used, then the strength is improved, but the manufacturing precision and ease of arranging multiple power generating bodies deteriorate
Solution Approach 1:
The invention changes the substrate material from brittle ceramic to ductile metal, fundamentally improving manufacturability. The metal substrate can be precisely formed using conventional metal forming techniques, enabling accurate positioning of multiple power generating bodies. This material parameter change allows for fine processing and high manufacturing precision that is difficult to achieve with ceramic substrates.
4Weight of stationary object
If the metal substrate is made thin to reduce size and weight, then the size and weight are reduced, but the strength deteriorates
Solution Approach 1:
The invention applies a metal oxide film on the metal substrate surface, creating a composite structure. This composite approach maintains the lightweight advantage of thin metal substrate while the metal oxide film provides oxidation resistance and enhances surface stability. The combination allows thin substrate design without compromising overall structural integrity and chemical stability.
5Productivity
If multiple power generating bodies are arranged side-by-side on a single support substrate, then the performance is improved, but the processing cost and complexity increase when using ceramic substrates
Solution Approach 1:
The invention changes the substrate material from ceramic to metal, which can be precisely formed using conventional metal forming techniques. This enables cost-effective mass production of substrates with multiple power generating bodies arranged side-by-side. The metal substrate's formability allows for integrated manufacturing of complex multi-body configurations without the high processing costs associated with ceramic fabrication.
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 solution results in a compact, high-performance electrochemical element with reduced material and processing costs, improved strength, and effective gas sealing, while preventing performance reductions due to component dispersion or vaporization.
Implementation Method 1
a metal oxide film is applied to prevent component dispersion and vaporization
Implementation Method 2
the electrolyte layer is arranged at least between the electrode layer and the counter electrode layer
Data Source
AI summary
An electrochemical element (Q) has a metal substrate (1) and multiple electrochemical reaction portions. The metal substrate (1) has gas flow allowing regions that allow the flowing of a gas between the upper side (4) and the lower side (5) of the metal substrate (1). The electrochemical reaction portions each have at least an electrode layer (A), an electrolyte layer (B), and a counter electrode layer (C), and are arranged on the upper side (4) of the metal substrate (1). The electrolyte layer (B) is arranged between the electrode layer (A) and the counter electrode layer (C), and the gas flowing through the gas flow allowing regions is supplied to the electrode layer (A).