Reversible Solid Oxide Cell Lamination Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing solid oxide cells are expensive and inefficient, leading to high waste material and waste product, with a need for a cost-effective and accurate large-scale production method that minimizes waste.
Innovation Solution
The method involves tape casting an anode support and electrolyte layers, followed by lamination under controlled pressure and temperature, with optional removal of supports, and subsequent sintering, to produce a reversible solid oxide cell suitable for both fuel cells and electrolysis cells, reducing waste and improving quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wet powder processing techniques with spray painting or screen printing are used, then cell manufacturing is achieved, but fabrication costs are very expensive and waste material is high
Solution Approach 1:
The patent combines multiple layers (support layer, functional layers, and protective layers) into a single integrated structure manufactured in one continuous process. This merging eliminates the need for separate manufacturing steps for each layer, reducing both fabrication costs and waste material from multiple production cycles.
Solution Approach 2:
The patent utilizes controlled atmospheric conditions (oxidizing, neutral, or reducing atmospheres) and temperature parameters during the sintering process to achieve optimal layer formation and bonding. By adjusting these parameters, the process achieves high-quality cell manufacturing with reduced material waste and lower overall costs compared to conventional methods.
2Manufacturing precision
If multiple separate manufacturing steps are used for each layer, then layer formation is achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent implements a continuous manufacturing process where the support layer, functional layers, and protective layers are deposited and sintered in one uninterrupted sequence. This continuous action eliminates idle time between steps while maintaining precise layer formation quality, thereby significantly improving productivity.
Solution Approach 2:
The support layer is prepared in advance with appropriate surface characteristics and structural properties before the functional layers are deposited. This preliminary preparation ensures optimal adhesion and integration of subsequent layers during the single sintering step, maintaining high manufacturing precision while accelerating the overall process.
3Strength
If conventional sintering processes are used, then layer bonding is achieved, but energy consumption is high and production efficiency is low
Solution Approach 1:
The patent employs controlled atmospheric conditions (oxidizing, neutral, or reducing atmospheres) and optimized temperature profiles during sintering to achieve strong layer bonding at reduced energy consumption. By carefully adjusting these parameters, the process maintains high bonding strength while improving production efficiency and reducing energy use compared to conventional sintering.
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 results in a cost-effective, high-quality, reversible solid oxide cell with reduced waste and improved layer homogeneity, suitable for both solid oxide fuel cells and electrolysis cells, enhancing operational reliability and reducing production costs.
Implementation Method 1
lamination of layers under a pressure of 1 to 5 bar and a temperature between 20°C and 250°C
Implementation Method 2
sintering the multilayer structure
Data Source
AI summary
The present invention provides a method of producing a reversible solid oxide cell, comprising the steps of: - tape casting an anode support layer on a support (1); - tape casting an electrolyte layer on a support (3); and either - tape casting an anode layer on top of said anode support layer; - laminating said electrolyte layer on top of said anode layer; - optionally removing support (1) and /or (3) from the anode support layer and/or the electrolyte layer; and - sintering the multilayer structure; or - tape casting an anode layer on top of said electrolyte layer; - laminating said anode support layer on top of said anode layer; - optionally removing support (1) and /or (3) from the anode support layer and/or the electrolyte layer; and - sintering the multilayer structure, wherein at least one lamination step is carried out under a pressure of 1 to 5 bar and a temperature between 20°C and 250°C.