Monolithic SOC Stack 3D Printing With Integrated Fluidic Channels
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Solution Overview
Problem
Conventional fabrication of solid oxide cell (SOC) stacks is expensive, time-consuming, and limited by multi-step processes, which restricts design flexibility and durability, and results in significant material waste.
Innovation Solution
An integrated single-step 3D printing process using stereolithography and direct ink-writing techniques to layer-by-layer stack active materials, incorporating sacrificial materials to create channels and tracks, allowing for customizable, joint-free, and self-supported SOC stacks with integrated fluidics and structural elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-step fabrication processes are used, then manufacturing precision and reliability are maintained, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent combines multiple conventional fabrication steps (tape casting, screen printing, firing, shaping, and thermal treatments) into a single integrated 3D printing process. This merging of processes maintains manufacturing precision through computer-controlled layer-by-layer deposition while dramatically reducing production time and eliminating the need for multiple handling and transfer operations between steps.
Solution Approach 2:
The invention changes the fundamental parameters of the fabrication process by transitioning from traditional ceramic processing techniques to additive manufacturing. This involves changing the deposition method from 2D layering to 3D printing, modifying the firing schedule to accommodate green body strength, and adjusting material formulations for printability while maintaining final product quality.
2Strength
If conventional fabrication processes are used, then structural integrity is maintained, but design flexibility is restricted
Solution Approach 1:
The patent segments the SOC stack into customizable functional units that can be independently designed and printed. Each cell layer (anode, electrolyte, cathode, interconnector) can be tailored with specific geometries, channel configurations, and thicknesses while maintaining overall structural integrity through the layer-by-layer additive manufacturing approach that ensures proper bonding and alignment.
Solution Approach 2:
The invention transitions from 2D planar fabrication to 3D additive manufacturing, enabling complex three-dimensional structures such as integrated fluid channels, varying thickness profiles, and spatially distributed features that cannot be achieved with conventional flat fabrication techniques. This dimensional change maintains structural integrity while providing unprecedented design freedom.
3Reliability
If conventional fabrication processes are used, then manufacturing reliability is maintained, but material waste increases significantly
Solution Approach 1:
The 3D printing process is self-service in nature, depositing material only where needed layer by layer according to the digital model. This eliminates the need for extensive material removal, trimming, and rework that characterizes conventional fabrication, thereby minimizing waste while maintaining manufacturing reliability through precise computer-controlled deposition and in-situ bonding.
Solution Approach 2:
The patent employs sacrificial materials (such as wax or soluble polymers) that are intentionally deposited and then completely removed to create void spaces for fluid channels and pores. These sacrificial objects are consumed during the process but enable the creation of complex internal structures without wasting precious ceramic materials, as only the minimum necessary material is used to form the final functional 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 process reduces manufacturing costs by over 60% per kW, minimizes material waste by 80%, and enhances durability and performance by enabling complex designs and reducing layer thickness, while maintaining mechanical and thermal stability.
Implementation Method 1
a stereolithography equipment (SLA) with direct ink-writing (DIW) equipment; which process comprises independently the steps (1, 2, 3, 4, 5) of: 1) making a fuel electrode as a layer by a. depositing a film of 5-500 μm of a ceramic or metal-ceramic (cermet) material over the electrolyte, interconnector or the bottom part of the housing, wherein said deposition is total or partial; b. selectively photo-curing the film formed in 1a) with a light source
Implementation Method 2
An integrated single 3D printing process using stereolithography and direct ink-writing techniques to layer-by-layer stack active materials
Data Source
Figure 1a~1f
Figure 2a~2f
Figure 3a~3f
AI summary
The present invention relates to a process of manufacturing a monolithic solid oxide cell (SOC) stack and to the solid oxide cell obtained through this process.