Continuous Solid Oxide Fuel Cell Manufacturing Line
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Solution Overview
Problem
Conventional batch plants for manufacturing solid oxide fuel cells result in increased manufacturing times and costs due to lengthy transport and staging times, potential damage during layer deposition, and high raw material waste, along with micro-cracks from laser cutting.
Innovation Solution
A continuous manufacturing line with interconnected plant units and a belt conveyor system for sequential deposition and processing of anode, electrolyte, and cathode layers, using techniques like ink-jet or screen printing, and heat treatments to reduce processing time and minimize material waste, while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batch plant with separate stations is used, then each manufacturing step can be performed with dedicated equipment, but manufacturing time increases due to transport and staging delays
Solution Approach 1:
The patent combines multiple separate manufacturing stations into a single integrated continuous manufacturing line where depositing, drying, and sintering operations are performed sequentially in one continuous process flow, eliminating the need to transport semi-finished products between separate stations and reducing staging times
Solution Approach 2:
The patent implements continuous manufacturing where the fuel cell substrate moves continuously through the production line without interruption, with material deposition, drying, and sintering operations occurring in continuous sequence rather than discrete batch operations, thereby eliminating idle transport and staging time
2Ease of manufacture
If tape casting and flat screen printing are used for layer deposition, then layers can be deposited directly on semi-finished product, but the semi-finished product can be damaged causing breakage
Solution Approach 1:
The patent performs material deposition on a moving substrate belt before the substrate is fully formed and handled, allowing the green body to be created in-situ during the deposition process itself, thereby avoiding the need to handle and transport fragile semi-finished products between operations
Solution Approach 2:
The patent replaces traditional mechanical handling and transport of semi-finished products with a continuous belt conveyance system where the substrate moves passively through the process, eliminating mechanical contact that could cause damage during transfer between separate manufacturing stations
3Ease of manufacture
If tape casting is used for layer deposition, then layers can be formed, but drying time increases which lengthens manufacturing cycle
Solution Approach 1:
The patent implements continuous drying as the substrate moves through the deposition zone and into a drying zone, eliminating the need for separate batch drying cycles and allowing the drying process to occur continuously as part of the overall manufacturing flow
Solution Approach 2:
The patent begins the drying process immediately as the substrate enters the deposition zone, performing preliminary drying during the deposition itself rather than waiting for complete deposition before initiating drying, thereby overlapping process steps and reducing total cycle time
4Manufacturing precision
If laser cutting is used to define cell shape, then precise geometry can be achieved, but micro-cracks are created that lead to breakage during operation
Solution Approach 1:
The patent changes the manufacturing approach from post-forming laser cutting to in-situ digital definition of cell geometry during the deposition process itself, using digital control of the deposition system to create the final cell shape without requiring subsequent cutting operations that would introduce micro-cracks
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 significantly reduces manufacturing times, optimizes mass production, and lowers costs by enabling continuous production with improved mechanical properties and reduced waste, avoiding micro-cracks and direct contact damage.
Implementation Method 1
a belt conveyor (N) connecting the plant units (10) to one another in series and configured to convey raw materials and semi-finished and finished products from one plant unit (10) to the next
Implementation Method 2
a depositing unit (20) configured to deposit layers of processed raw material one on top of another on said belt conveyor (N) to thereby define an anode and an electrolyte
Implementation Method 3
a heat treatment unit (30) configured to perform a heat treatment on the anode and the electrolyte
Implementation Method 4
a printing unit (40) configured to deposit a cathode on the anode and the electrolyte heat-treated by the heat treatment unit (30)
Implementation Method 5
an atomizing unit (60) configured to produce atomized raw material from crude raw material
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Plant (1) for manufacturing solid oxide fuel cells, each cell comprising at least one cathode, one anode and one electrolyte, said anode comprising an anode support and an active anode, said plant comprising a plurality of plant units (10) comprising a depositing and pressing unit (20) configured to produce the anode and the electrolyte from processed raw material by depositing: one or more layers to form said anode support, one or more layers on the anode support to form said active anode; one or more layers on the active anode to form said electrolyte; a first heating unit (30) configured to perform a first heat treatment on the anode and the electrolyte by heating said anode and said electrolyte; a first printing unit (40) configured to at least partially deposit a cathode layer on the electrolyte to define the cathode of the solid oxide fuel cell; a second heating unit (50) configured to perform a second heat treatment on the anode, the electrolyte and the cathode layer by heating them to produce said fuel cell; said plant units (20, 30, 40, 50) being connected in series by means of a belt conveyor (N).