Metal-Supported Cell Adhesion via Low-Temperature Sintering
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Solution Overview
Problem
Metal-supported cells face challenges in achieving high ion-conductivity and adhesion between the solid electrolyte layer and metal support to prevent interfacial peeling, while maintaining stable cell characteristics, especially during sintering at lower temperatures.
Innovation Solution
A metal-supported cell design featuring a laminate structure with a metal support having a continuous pore from the front to the back surface, a fuel electrode layer with a high NiO content, and a solid electrolyte layer containing scandia-stabilized zirconia with bismuth, where the solid electrolyte layer covers the fuel electrode layer and has a porosity of 5.0% or less, ensuring strong adhesion and preventing peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid electrolyte layers and metal supports are sintered together at high temperature, then strong adhesion between layers is achieved, but metal support deterioration and interfacial peeling occur
Solution Approach 1:
The invention changes the sintering temperature parameter from conventional high temperature (1300-1500°C) to a lower temperature range (900-1200°C). This parameter change is achieved by modifying the solid electrolyte composition to include specific amounts of Bi2O3 (0.1-10 wt%) and CeO2 (0.1-10 wt%), which act as sintering aids enabling densification at lower temperatures. The metal support composition is also optimized with Fe-Cr-Ni alloy ratios and controlled porosity (30-60%) to ensure compatibility with low-temperature sintering while maintaining mechanical strength and adhesion.
Solution Approach 2:
The invention creates a composite system consisting of three main components: (1) metal support made of Fe-Cr-Ni alloy with controlled porosity, (2) solid electrolyte layer composed of Sc-Zr-O system doped with Bi2O3 and CeO2, and (3) fuel electrode layer containing Ni and GDC. The composite material design ensures that each component is optimized for its specific function while maintaining interfacial compatibility. The solid electrolyte composition (8-12 mol% Sc2O3, 0.5-5 wt% Bi2O3, 0.5-5 wt% CeO2) creates a composite structure that facilitates low-temperature sintering and strong adhesion to the metal support without causing deterioration or peeling.
2Reliability
If sintering temperature is reduced to prevent metal support deterioration, then adhesion between solid electrolyte layer and metal support decreases, but interfacial peeling occurs
Solution Approach 1:
The invention simultaneously optimizes multiple parameters: sintering temperature (900-1200°C), solid electrolyte composition (Sc2O3 content 8-12 mol%, Bi2O3 content 0.5-5 wt%, CeO2 content 0.5-5 wt%), metal support porosity (30-60%), and metal support composition (Fe-20-40 wt%, Cr-10-30 wt%, Ni-10-30 wt%). The specific composition ratios and their interactions enable strong adhesion at lower sintering temperatures by promoting intimate contact and chemical bonding between the solid electrolyte and metal support interfaces, while preventing the deterioration and peeling issues associated with high-temperature processing.
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 achieves high ion-conductivity and stable cell characteristics by enhancing adhesion between the solid electrolyte layer and the metal support, thereby preventing interfacial peeling and ensuring reliable cell performance.
Implementation Method 1
Bi2O3 has been known as a sintering agent in forming of the solid electrolytes containing the stabilized zirconia by the addition of rare earth atoms or the like
Implementation Method 2
The solid electrolyte layer mainly contains a scandia-stabilized zirconia... The fuel electrode layer and the solid electrolyte layer are arranged in this order on the front surface of the metal support
Data Source
AI summary
A metal-supported cell comprises a laminate wherein a fuel electrode layer and a solid electrolyte layer are sequentially arranged in this order on a front surface of a metal support provided with a pore continuing from the front surface to the back surface. The solid electrolyte layer covers all parts of the surface of the fuel electrode layer, the parts being not in contact with the metal support. The peripheral part of the solid electrolyte layer is in contact with the front surface of the metal support. The metal support has a metal oxide layer. The fuel electrode layer contains NiO and Ni with molar ratio NiO/(Ni+NiO) of 45% or more, while containing gadolinium-doped ceria. The solid electrolyte layer mainly contains scandia-stabilized zirconia, while containing 0.1-10.0 mol of Bi atoms per 100 mol of Zr atoms having cross-sectional void fraction of 5.0% or less.