Permeable metal substrate, metal-supported solid oxide fuel cell and their manufacturing methods

Patent metadata

Field	Value
Publication number	US-9905873-B2
Application number	US-201615214701-A
Country	US
Kind code	B2
Filing date	Jul 20, 2016
Priority date	Nov 3, 2015
Publication date	Feb 27, 2018
Grant date	Feb 27, 2018

Abstract

The invention provides a permeable metal substrate and its manufacturing method. The permeable metal substrate includes a substrate body and a permeable powder layer. The permeable powder layer is located on the top of the substrate body. The substrate body can be a thick substrate or formed of a thick substrate and a thin substrate that are welded together. Both the thick and thin substrates have a plurality of permeable straight gas channels. In addition, a metal-supported solid oxide fuel cell and its manufacturing method are also provided.

First claim

What is claimed is:

1. A metal-supported solid oxide fuel cell, comprising:
a permeable metal substrate, further comprising a substrate body and a permeable powder layer, wherein:
the substrate body is substantially a metallic interconnect that is perforated by a drilling process and is formed with a plurality of gas channels; and the permeable powder layer is disposed on the substrate body;
a porous anode layer, disposed on the permeable powder layer of the permeable metal substrate;
a dense anode isolation layer, disposed on the porous anode layer;
a dense electrolyte layer, disposed on the dense anode isolation layer;
a dense cathode isolation layer, disposed on the dense electrolyte layer; and
a porous cathode layer, disposed on the dense cathode isolation layer.

2. The metal-supported solid oxide fuel cell of claim 1 , wherein the porous anode layer is composed of a first anode layer and a second anode layer in a manner that the second anode layer is sandwiched between the first anode layer and the dense anode isolation layer; the first anode layer is disposed on the permeable powder layer of the permeable metal substrate; the second anode layer is a nano-sized structure; the first anode layer is a micron-sized structure or a submicron-sized structure; the first anode layer with the micron-sized or submicron-sized structure is substantially a YSZ-NiO layer that is formed by mixing a material of YSZ and a material of NiO uniformly in a weight ratio of 40:60, 50:50 or 60:40, while the particle sizes of the YSZ material and the NiO material are micron-scaled or submicron-scaled; and the second anode layer with the nano-sized structure is substantially a LDC-NiO layer that is formed by mixing a material of LDC and a material of NiO uniformly in a weight ratio of 40:60, 50:50 or 60:40, while the particle sizes of the LDC material and the NiO material are nano-scaled.

3. The metal-supported solid oxide fuel cell of claim 1 , wherein the dense anode isolation layer is substantially a SDC layer or an LDC layer, while SDC particles or the LDC particles that are used for manufacturing the dense anode isolation layer are nano-scaled particles.

4. The metal-supported solid oxide fuel cell of claim 1 , wherein the dense electrolyte layer is an LSGM layer or a layer formed by a mixture of LSGM (10˜20 wt %) and LDC (80˜90 wt %), the dense electrolyte layer is an airtight structure.

5. The metal-supported solid oxide fuel cell of claim 1 , wherein the dense cathode isolation layer is substantially a SDC layer or an LDC layer, while SDC particles or the LDC particles that are used for manufacturing the dense cathode isolation layer are nano-scaled particles.

6. The metal-supported solid oxide fuel cell of claim 1 , wherein the porous cathode layer is composed of a cathode interlayer and a cathode current collecting layer in a manner that the cathode interlayer is sandwiched between the cathode current collecting layer and the dense cathode isolation layer; the cathode interlayer is a layer selected from the group consisting of: a LDC-LSCo layer, a LDC-LSCF layer, a LDC-SSC layer, a SDC-LSCo layer, a SDC-LSCF layer and a SDC-SSC layer, and the weight ratio of LDC or SDC to LSCo or LSCF or SSC is 40:60, 50:50 or 60:40, while the particle size of the LDC or SDC material is nano-scaled, and the particle size of the LSCo or LSCF or SSC material is submicron-scaled; and the cathode current collecting layer is a layer selected from the group consisting of: a LSCo layer, a LSCF layer, and a SSC layer, while the particle size of the LSCo or LSCF or SSC material is submicron-scaled.

7. The metal-supported solid oxide fuel cell of claim 1 , wherein the substrate body is formed of a thick substrate or a laminate consisting of a thick substrate and a thin substrate that are welded together by a high temperature brazing process, while the thickness of the thick substrate is ranged from 0.5 to 1.5 mm, the thickness of the thin substrate is ranged from 0.1 to 0.2 mm, and both the area sizes of the thick substrate and the thin substrate are ranged from 5×5 cm 2 to 20×20 cm 2 ; when the substrate body is formed of the thick substrate, the plural gas channels formed in the thick substrate is substantially a plurality of permeable straight first gas channels, and when the substrate body is formed of the laminate consisting of the thick substrate and the thin substrate, the plural gas channels includes a plurality of permeable straight first gas channels formed in the thick substrate and a plurality of permeable straight second gas channels formed in the thin substrate, while allowing each of the first gas channels and the second channels to be formed in a shape selected from the group consisting of: a column, a pentagonal prism, hexagonal prism and an octagonal prism, and enabling each of first gas channels to be formed with a hole size ranged from 0.3 to 1.5 mm, and each of the second gas channels to be formed with a hole size ranged from 0.08 to 0.15 mm.

8. The metal-supported solid oxide fuel cell of claim 1 , wherein the drilling process is a process selected from the group consisting of: a laser drilling process, a mechanical drilling process and the combination of the two; and the hole sizes or the distribution densities of the first or the second gas channels are maintained unchanged or increasing along directions that are parallel and perpendicular to a fuel flowing direction.

9. The metal-supported solid oxide fuel cell of claim 1 , wherein the metallic interconnect is formed of a chromium-containing ferritic stainless steel, and the chromium-containing ferritic stainless steel contains Crofer 22 and ZMG232.

10. The metal-supported solid oxide fuel cell of claim 1 , wherein the permeable powder layer has surface pores smaller than 30 μm, while the permeable powder layer is formed of a powder material with particle sizes ranged from 5 to 75 μm; and the powder material is a material selected from the group consisting of: nickel, a nickel-iron alloy and a nickel-cobalt alloy; and the thickness of the permeable powder layer is ranged from 50 to 200 μm.

11. A method for manufacturing a metal-supported solid oxide fuel cell, comprising the steps of:
providing a substrate body;
forming a plurality of gas channels on the substrate body by using a drilling process;
forming a permeable powder layer on the substrate body by using further steps of: forming a green layer of permeable powder layer by a tape caster, sintering the green layer into a permeable powder layer by using a high temperature sintering process, disposing the sintered permeable powder layer onto the substrate body and making them laminated and connected together by using high temperature pressing process;
reducing the surface pore sizes of the permeable powder layer to be smaller than 30 μm;
using a high temperature pressing process to flatten a permeable metal substrate; and
using an atmospheric plasma spraying process to sequentially form a porous anode layer, a dense anode isolation layer, a dense electrolyte layer, a dense cathode isolation layer and a porous cathode layer on the permeable metal substrate.

12. The method of claim 11 , wherein the porous anode layer is composed of a first anode layer and a second anode layer in a manner that the second anode layer is sandwiched between the first anode layer and the dense anode isolation layer; the first anode layer is disposed on the permeable powder layer of the permeable metal substrate; the second anode layer is a nano-sized structure; the first anode layer is a micron-sized structure or a submicron-sized structure; the first anode layer with the micron-sized or submicron-sized structure is

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
• Wu Ming Hsiu
• Lin jing kai

Classifications

• H01M8/1286

  Fuel cells applied on a support, e.g. miniature fuel cells deposited on silica supports · CPC title

• H01M8/1226 Primary

  characterised by the supporting layer · CPC title

• H01M2008/1293

  Fuel cells with solid oxide electrolytes · CPC title

• H01M8/0236

  Glass; Ceramics; Cermets · CPC title

• H01M8/0271

  Sealing or supporting means around electrodes, matrices or membranes · CPC title