Solid Oxide Fuel Cell Plasma Spray Manufacturing
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Solution Overview
Problem
Solid oxide fuel cells face challenges with high-temperature sintering processes that lead to warping, cracking, and unfavorable chemical reactions, reducing their efficiency and increasing manufacturing costs, especially due to issues like lanthanum strontium gallate magnesite (LSGM) reacting with nickel in the anode layer and cobalt diffusion into the electrolyte, resulting in high energy loss and reduced open-circuit voltage.
Innovation Solution
A solid oxide fuel cell design incorporating a metal support with a porous metal substrate and nano-structured anode and cathode layers, formed using a medium current and high voltage tri-gas atmospheric plasma spray process, which avoids high-temperature sintering and reduces electrode erosion, enhancing thermal conductivity and mechanical strength while maintaining electrochemical activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high-temperature sintering process is used to manufacture solid oxide fuel cells, then the electrolyte layer and electrode layers can be formed, but warping, cracking, and unfavorable chemical reactions occur reducing efficiency and increasing manufacturing costs
Solution Approach 1:
The patent changes the temperature parameter from high-temperature sintering (above 900°C) to low-temperature atmospheric plasma spray process, which prevents warping, cracking, and unfavorable chemical reactions while still forming the electrolyte layer and electrode layers effectively
Solution Approach 2:
The patent replaces the traditional thermal sintering mechanism with atmospheric plasma spray technology, using plasma energy instead of conventional heat to form and sinter the fuel cell layers, thereby avoiding the harmful effects of high-temperature processing
2Loss of energy
If LSGM electrolyte material is used to achieve high ion conductivity at intermediate temperature, then ion conductivity is improved, but LSGM reacts with nickel in the anode layer causing energy loss and reduced open-circuit voltage
Solution Approach 1:
The patent introduces a protective barrier layer between the LSGM electrolyte and the nickel anode, preventing direct contact and chemical reaction between the two materials while maintaining the high ion conductivity of the LSGM electrolyte
3Loss of energy
If cobalt is used in the cathode material to improve electrochemical activity, then cathode performance is enhanced, but cobalt diffuses into the electrolyte resulting in high energy loss and reduced open-circuit voltage
Solution Approach 1:
The patent introduces a protective barrier layer between the cobalt-containing cathode material and the electrolyte, preventing cobalt diffusion into the electrolyte while maintaining the high electrochemical activity of the cobalt-based cathode
4Loss of time
If conventional thermal process is used to remove binder and heat powders, then binder removal is achieved, but the process is time-consuming and causes aggregation of powders
Solution Approach 1:
The patent replaces conventional thermal binder removal with atmospheric plasma spray technology, where the plasma environment rapidly decomposes and removes the binder while simultaneously heating and melting the powders, significantly reducing processing time and preventing powder aggregation
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 improves the electric characteristics and thermal conductivity of solid oxide fuel cells, reduces manufacturing costs, and extends the lifetime of electrodes by preventing aggregation and chemical reactions, resulting in higher output power density and reliability.
Implementation Method 1
medium current and high voltage tri-gas atmospheric plasma spray process
Implementation Method 2
atmospheric plasma spray process
Implementation Method 3
The plasma flame removes the polyvinyl alcohol binder and heats up the remaining nano powders to be melted or semi-melted
Implementation Method 4
The medium current and high voltage tri-gas atmospheric plasma spray process prevents aggregation of the nano-particles
Data Source
AI summary
A solid oxide fuel cell including a metal frame, a pre-treated porous metal substrate, an anode layer, an electrolyte layer, a cathode interlayer and a cathode current collecting layer is provided. The pre-treated porous metal substrate is disposed inside the metal frame. The anode layer is disposed on the porous metal substrate. The electrolyte layer is disposed on the anode layer. The cathode interlayer is disposed on the electrolyte layer. The cathode current collecting layer is disposed on the cathode interlayer. The anode layer is porous and nano-structured. Moreover, a manufacturing method of the solid oxide fuel cell mentioned above is also provided.