Proton-conducting ceramic fuel cell sintering stress balancing
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Solution Overview
Problem
Proton-conducting ceramic fuel cell (PCFC) manufacturing processes face challenges in producing commercially viable sizes due to high-temperature sintering requirements, material warpage, and bonding issues with kiln furniture, leading to increased production costs and deformation.
Innovation Solution
The implementation of a lower-temperature solid-state reactive sintering process with a stress balancing layer and the use of a coarse NiO layer or yttria paper to prevent warpage and bonding with kiln furniture, allowing for the production of larger PCFCs without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature calcination and sintering processes are used to manufacture PCFC, then the PCFC can be produced, but the processing time increases and production cost increases
Solution Approach 1:
The patent changes the sintering temperature parameter from conventional high temperatures (900-1000°C) to lower temperatures (100-500°C) by using a support structure that enables low-temperature sintering. This parameter change reduces processing time and cost while maintaining PCFC production feasibility through the use of a porous support structure that facilitates material formation at lower temperatures.
2Reliability
If solid state reaction sintering (SSRS) is used to manufacture PCFC, then the PCFC can be produced, but material warpage and bonding to kiln furniture occur
Solution Approach 1:
The patent introduces a porous support structure as an intermediary between the green body and the kiln furniture. This support structure prevents direct contact and bonding between the green body and kiln furniture, and also prevents material warpage during sintering. The support structure acts as a mediator that enables SSRS production while eliminating the harmful effects of warpage and bonding.
3Reliability
If conventional sintering processes are used, then PCFC can be manufactured, but bonding to kiln furniture occurs causing deformation
Solution Approach 1:
The porous support structure serves as an intermediary layer between the green body and kiln furniture, preventing direct contact that would cause bonding and deformation. The support structure maintains the shape of the green body during sintering and can be removed after sintering to leave the finished PCFC without deformation.
Solution Approach 2:
The patent segments the sintering process into two distinct stages: first sintering the green body on the porous support structure to prevent bonding and deformation, then removing the support structure in a second step. This segmentation allows the PCFC to be manufactured without shape distortion while maintaining production reliability.
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 approach enables the production of PCFCs with peak power densities of up to 521 mW/cm2 at 550°C, more than double that of solid oxide fuel cells at similar temperatures, while preventing warpage and material deformation, thus overcoming previous manufacturing limitations.
Implementation Method 1
a coarse NiO layer or yttria paper to prevent warpage and bonding with kiln furniture
Implementation Method 2
sintering the green anode-electrolyte half-cell using SSRS to an anode-electrolyte half-cell
Implementation Method 3
forming a stress balancing layer on the lower surface of the anode substrate layer
Data Source
AI summary
A method of manufacturing a proton-conducting fuel cell (PCFC) includes assembling a green anode-electrolyte half-cell. The green anode-electrolyte half-cell includes an electrolyte layer, an anode functional layer adjacent the electrolyte layer, an anode substrate layer adjacent the electrolyte layer, and a stress balancing layer adjacent the anode substrate layer. The method further includes sintering the green anode-electrolyte half-cell using solid state reaction sintering to form an anode-electrolyte half-cell.