High permeable porous substrate for a solid oxide fuel cell and the production method thereof

Patent metadata

Field	Value
Publication number	US-9716277-B2
Application number	US-201514681532-A
Country	US
Kind code	B2
Filing date	Apr 8, 2015
Priority date	Oct 30, 2014
Publication date	Jul 25, 2017
Grant date	Jul 25, 2017

Abstract

A high permeable porous substrate for a solid oxide fuel cell and a production method to produce the substrate are provided. The high permeable porous substrate for a solid oxide fuel cell includes a porous substrate body and a plurality of channels. The plurality of channels penetrate the first surface of the porous substrate body and does not penetrate the second surface of the porous substrate body. In addition, a production method for the high permeable porous substrate of a solid oxide fuel cell is also provided.

First claim

What is claimed is:

1. A production method of permeable porous substrates for solid oxide fuel cells, comprising the steps of:
providing a mold, which has a base formed with a plurality of protrusions on a surface of the base;
injecting a slurry containing a first powder into the mold;
performing a molding/demolding process for producing a green part; and
sintering the green part in reducing atmosphere at a temperature to form a porous substrate body that has a plurality of channels, a first surface and a second surface in a manner that the first surface is disposed opposite to the second surface; the plural channels are arranged penetrating the first surface but not penetrating the second surface while allowing the plural channels to be formed in shapes corresponding to the shapes of the plural protrusions.

2. The production method of claim 1 , wherein in the step of providing the mold, the mold is formed with a peripheral part at the periphery of the base while allowing the peripheral part to be formed with a height higher than the heights of the plural protrusions.

3. The production method of claim 2 , wherein the peripheral part is made of a metal.

4. The production method of claim 1 , wherein in the step of providing the mold, the base is made of a material selected from the group consisting of: a metal or a plastic.

5. The production method of claim 4 , wherein in a condition when the base is made of a plastic, the plastic is polytetrafluoroethylene (PTFE).

6. The production method of claim 4 , wherein in a condition when the base is made of a metal, the metal is a stainless steel.

7. The production method of claim 1 , wherein the amount of the plural protrusions ranges from 3 pieces per cm 2 to 20 pieces per cm 2 .

8. The production method of claim 1 , wherein each of the plural protrusions in a cylindrical shape is formed with a diameter ranging from 0.5 mm to 3 mm.

9. The production method of claim 1 , wherein each of the plural protrusions is formed with a height ranging from 0.2 mm to 1.0 mm.

10. The production method of claim 1 , wherein the first powder includes nickel particles that have particle sizes ranging from 60 μm to 220 μm.

11. The production method of claim 1 , wherein in the step of injecting the slurry containing the first powder into the mold, the first powder is made of a material selected from the group consisting of: a nickel, a nickel-molybdenum alloy, a nickel-iron alloy, a nickel-cobalt alloy, and a nickel-molybdenum-iron-cobalt alloy.

12. The production method of claim 11 , wherein in a condition when the first powder is made of a material selected from the group consisting of: nickel, nickel-molybdenum alloy, nickel-iron alloy, nickel-cobalt alloy, and nickel-molybdenum-iron-cobalt alloy, the weight percentages of molybdenum in the nickel-molybdenum alloy, iron in the nickel-iron alloy, cobalt in the nickel-cobalt alloy range from 2 wt % to 10 wt %, and the weight percentages of molybdenum, iron and cobalt in the nickel-molybdenum-iron-cobalt alloy range from 2 wt % to 10 wt %.

13. The production method of claim 12 , wherein the sizes of a molybdenum particle, an iron particle and a cobalt particle of the nickel-molybdenum-iron-cobalt alloy range from 0.3 μm to 3 μm.

14. The production method of claim 1 , wherein in the step of sintering the green part in reducing atmosphere at a high temperature, the high temperature is defined to be from 1300° C. to 1500° C., while allowing the sintering step to last a time interval from 4 hrs to 8 hrs.

15. The production method of claim 1 , wherein in the case that the first powder is made of an iron-based alloy, the iron-based alloy is ferritic stainless steel.

16. The production method of claim 15 , wherein the iron based alloy has a iron weight ratio ranging from 60% to 80% and a chromium weight ratio ranging from 20% to 30%.

17. The production method of claim 1 , wherein in the case that the first powder is made of a cermet, the cermet is a mixture of oxygen ion conducting particles and electron conducting metal catalytic particles and the weight ratios of oxygen ion conducting particles and electron conducting metal catalytic particles in the cermet range from 35% to 65%.

18. The production method of claim 1 , further comprising the steps of:
paving the second surface of the porous substrate body with the slurry containing a second powder that has a particle size smaller than that of the first powder; and
performing a sintering process in reducing atmosphere at a temperature for forming a powder layer on the second surface of the porous substrate body.

19. The production method of claim 18 , wherein in the step of performing a sintering process in reducing atmosphere is performed at a temperature from 1150° C. to 1250° C., while allowing the sintering process to last a time interval from 4 hrs to 8 hrs for enabling the surface pores of the powder layer to be smaller than 30 μm.

20. The production method of claim 18 , wherein in the step of paving the second surface of the porous substrate body with the slurry containing the second powder, the second powder is made of a material selected from the group consisting of: a nickel, a nickel-molybdenum alloy, a nickel-iron alloy, a nickel-cobalt alloy, and a nickel-molybdenum-iron-cobalt alloy.

21. The production method of claim 20 , wherein in a condition when the second powder is made of a material selected from the group consisting of: nickel, nickel-molybdenum alloy, nickel-iron alloy, nickel-cobalt alloy, and nickel-molybdenum-iron-cobalt alloy, the weight percentages of molybdenum in the nickel-molybdenum alloy, iron in the nickel-iron alloy, cobalt in the nickel-cobalt alloy range from 2 wt % to 10 wt %, and the weight percentages of molybdenum, iron and cobalt in the nickel-molybdenum-iron-cobalt alloy range from 2 wt % to 10 wt %.

22. The production method of claim 21 , wherein the sizes of a molybdenum particle, an iron particle and a cobalt particle of the nickel-molybdenum-iron-cobalt alloy range from 0.3 μm to 3 μm.

23. The production method of claim 18 , wherein the second powder includes nickel particles that have particle sizes ranging from 5 μm to 40 μm.

24. The production method of claim 18 , further comprising the step of:
after the paving of the second surface of the porous substrate body with the slurry containing the second powder, performing a permeability measurement process and the measured permeability ranges from 1.5 darcy to 3.5 darcy.

Assignees

• Iner Aec Executive Yuan

Inventors

• Hwang Chang-Sing
• Tsai Chun-Huang
• Chang Chun-Liang
• Chuang Shie Zong-Yang
• Yang Sheng-Fu
• Huang Te-Jung
• Cheng Shih-Wei

Classifications

• H01M2008/1293

  Fuel cells with solid oxide electrolytes · CPC title

• H01M4/8803

  Supports for the deposition of the catalytic active composition (H01M4/90 takes precedence) · CPC title

• H01M4/8878

  Treatment steps after deposition of the catalytic active composition or after shaping of the electrode being free-standing body · CPC title

• H01M4/9066

  of metal-ceramic composites or mixtures, e.g. cermets · CPC title

• H01M4/861

  with a gradient in the porosity · CPC title