Porous Metal Substrate with Gradient Porosity for SOFC
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Solution Overview
Problem
Current high temperature electrolyzer and fuel cell technologies face challenges in achieving excellent adherence and anchoring of ceramic layers on porous metal supports, while also ensuring resistance to oxidation and maintaining mechanical properties, which are crucial for efficient operation and cost-effectiveness.
Innovation Solution
A partly oxidized porous metal substrate with a porosity gradient is created through a pressing-sintering method, where the substrate is subjected to partial oxidation by an oxidizing gas, resulting in a high porosity layer and a low porosity layer with controlled porosity and oxidation, enhancing adherence and resistance to oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the porous metal support is made highly porous to improve gas distribution, then gas distribution is enhanced, but mechanical strength and resistance to oxidation deteriorate
Solution Approach 1:
The patent applies local quality by creating a porosity gradient within the metal support structure. The support has different porosity levels in different regions: higher porosity in areas requiring gas distribution and lower porosity in areas requiring mechanical strength. This gradient structure allows each region to optimize its local properties for its specific function, resolving the contradiction between gas distribution and mechanical strength.
2Strength
If the porous metal support is partially oxidized to improve adherence of ceramic layers, then adherence is enhanced, but resistance to oxidation deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the oxidation state of the metal support. Instead of complete oxidation or no oxidation, the support is partially oxidized to a specific extent that optimizes ceramic layer adherence while maintaining sufficient resistance to further oxidation. This controlled parameter change allows optimization of adherence without sacrificing oxidation resistance.
3Temperature
If the thickness of the porous metal support is reduced to lower operating temperature, then operating temperature is reduced, but mechanical support capability deteriorates
Solution Approach 1:
The patent applies local quality by creating a porosity gradient within the metal support structure. The support has different porosity levels in different regions: higher porosity in areas requiring gas distribution and lower porosity in areas requiring mechanical strength. This gradient structure allows each region to optimize its local properties for its specific function, resolving the contradiction between gas distribution and mechanical strength.
4Stability of the object's composition
If conventional metallurgy or powder metallurgy is used to produce metal alloys for the support, then material properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies porous materials by using a porous metal support structure with controlled porosity gradient. This porous structure provides the necessary mechanical strength and gas distribution capabilities while allowing for simpler manufacturing processes compared to conventional dense metal alloys. The porous structure inherently provides both mechanical support and gas distribution functions.
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 method provides a substrate that effectively supports ceramic layers, promotes gas distribution, and maintains electrical conductivity, while reducing oxidation and cost, thus improving the performance and durability of high temperature electrolyzer and fuel cell cells.
Implementation Method 1
said substrate being subjected to partial oxidation by an oxidizing gas
Implementation Method 2
substrate made of porous metal or metal alloy comprising particles of at least one metal or metal alloy bound by sintering
Data Source
AI summary
A partly oxidized substrate is disclosed. According to one aspect, the substrate is formed by subjecting a substrate made of a porous metal or metal alloy including particles of at least one metal or metal alloy bound by sintering. The substrate includes a first main surface and a second main surface. The porosity of the substrate gradually changes from the first main surface to the second main surface. The substrate is partially oxidized by an oxidizing gas such as oxygen and/or air. A method for preparing the substrate and high temperature electrolyzer (THE) cell including the substrate are also disclosed.