JP-2026514499-A - Method and system for commercially manufacturing tubular solid oxide fuel cells

Abstract

The present invention relates to a method and system for producing tubular ceramic green bodies that can be converted into tubular solid oxide fuel cells.

Inventors

• フィナーティー、 ケイン
• アイゼンバーグ、 マシュー
• ダガン、 アンソニー

Assignees

• ワット フュール セル コーポレーション

Dates

Publication Date

20260511

Application Date

20240424

Priority Date

20230425

Claims (20)

1. A method for manufacturing tubular ceramic green bodies, A step of providing a cartridge comprising a plurality of mandrel spindle assemblies, wherein the lengths of the plurality of mandrel spindle assemblies are parallel to each other and lie in the same horizontal plane along the cartridge, the cartridge is fitted to rotate each of the plurality of mandrel spindle assemblies, each of the mandrel spindle assemblies comprises a mandrel component and a spindle component, the mandrel component being a heat-shrinkable tube, a disappearing tube, or a coating on the spindle component, the outer surface thereof corresponding to the inner surface of the manufactured tubular ceramic green body, the inner surface defining a bore, and the spindle component being in close contact with the bore but in removable contact with the cartridge, The steps include rotating the plurality of mandrel spindle assemblies, applying an anode-forming layer to each of the mandrels of the plurality of rotating mandrel spindle assemblies of the cartridge, thereby forming a plurality of anode-forming green bodies around each of the spindles, A step of inspecting each of the plurality of anode-forming green bodies for defects, The steps include rotating the plurality of anode-forming green bodies, applying an interface-forming layer to each of the rotating anode-forming green bodies of the cartridge, thereby forming a plurality of multilayer green bodies around each of the spindles, A step of inspecting each of the aforementioned multiple multilayer green bodies for defects, The steps include rotating the plurality of multilayer green bodies, applying an electrolyte forming layer to each of the rotating multilayer green bodies of the cartridge, and forming a plurality of tubular ceramic green bodies around each of the spindles, A step of inspecting each of the plurality of tubular ceramic green bodies for defects, A method comprising the step of removing a spindle containing a tubular ceramic green body that was identified as having defects during the inspection, before firing the tubular ceramic green body.
2. The method according to claim 1, comprising the step of monitoring the outer diameter of the plurality of anode-forming green bodies in real time while applying the anode-forming layer.
3. The method according to claim 1 or 2, comprising the step of monitoring the outer diameter of the plurality of multilayer green bodies in real time while applying the interface forming layer.
4. The method according to any one of claims 1 to 3, comprising the step of monitoring the outer diameter of the plurality of tubular ceramic green bodies in real time while applying the electrolyte-forming layer.
5. The method according to any one of claims 2 to 4, wherein the step of monitoring the outer diameter in real time makes it possible to adjust the thickness of the ceramic formation layer in real time.
6. The method according to claim 5, wherein the step of adjusting the thickness of the ceramic formation layer in real time includes the step of covering small defects in a previously applied ceramic formation layer.
7. The method according to any one of claims 1 to 6, comprising the step of storing the cartridge in a storage station, wherein the storage station is adapted to store a plurality of cartridges.
8. The steps include moving the cartridge to a first printer station to coat the anode-forming layer, Next, the cartridge is moved to the first inspection station, Next, the cartridge is moved to a second printer station to apply the interface forming layer, Next, the cartridge is moved to a second inspection station, Next, the cartridge is moved to a third printer station in order to coat the electrolyte-forming layer, Next, the cartridge is moved to a third inspection station, The method according to any one of claims 1 to 7, including the method described in any one of claims 1 to 7.
9. The method according to claim 8, wherein at least two of the first printer station, the second printer station, and the third printer station are the same printer station.
10. The method according to claim 8 or 9, wherein each of the first inspection station, the second inspection station, and the third inspection station is the same inspection station.
11. The method according to any one of claims 8 to 10, wherein the moving step includes moving using a conveyor belt assembly and/or moving with a robot.
12. The method according to any one of claims 8 to 11, comprising the step of moving the cartridge from the storage station to the first printer station.
13. The method according to any one of claims 8 to 12, further comprising the step of moving the cartridge to the third inspection station, and then moving the cartridge to the storage station.
14. The method according to any one of claims 1 to 13, wherein the inspection step includes a visual inspection step.
15. The method according to claim 14, wherein the visual inspection step includes a step of visual inspection using a camera.
16. The method according to claim 14, wherein the step of visually inspecting using a camera includes the step of using a computer software program to identify defects based on images from the camera.
17. The method according to any one of claims 14 to 16, wherein the step of visually inspecting includes the step of maintaining the inspection information for a specific spindle of the cartridge.
18. The method according to any one of claims 1 to 17, wherein the step of applying the anode-forming layer includes a step of changing the composition of the anode-forming layer.
19. The method according to claim 18, wherein the step of changing the composition of the anode-forming layer includes the step of coating the anode-forming layer using different printer stations.
20. The method according to claim 17, wherein the step of changing the composition of the anode-forming layer includes the step of changing the composition of the anode-forming layer using the same printer station.

Description

Cross-reference of related applications This application claims the benefit and priority of U.S. Provisional Patent Application No. 63/498,118, filed on 25 April 2023, the full disclosure thereof, is incorporated herein by reference in its entirety for all purposes. This invention relates to a method and system for producing tubular ceramic green bodies that can be converted into tubular solid oxide fuel cells. Tubular ceramic structures are known to be used as heat exchangers, reheaters, and catalysts that encounter corrosive liquids or gases, as components of fuel cells, particularly solid oxide fuel cells (SOFCs), and in a variety of other applications. In recent years, SOFCs have attracted attention for their green energy production and as a portable and decentralized means of supplying electricity in remote areas or for residential use. Among various designs, micro or macro tubular SOFCs offer many advantages. Tubular ceramic structures for SOFCs can be manufactured using the method described in U.S. Patent No. 9,542,548, which allows for the manufacture of tubular ceramic structures over a wide range of wall thicknesses, i.e., from very thin to very thick, without requiring meticulous attention and control of drying conditions, allowing for easy modification or alteration of the composition of the tubular product for defined portions of the tubular product, and without requiring the use of a tubular substrate designated to be a permanent component of the product. While the technology described there is valid, commercial SOFC unit manufacturing requires thousands of tubular SOFCs when using bundles of micro or macro tubular SOFCs. A perspective view of one embodiment of the present invention, showing a mandrel spindle assembly coated with a partial anode-forming layer.A perspective view of one embodiment of the present invention, showing a cartridge containing seven mandrel spindle assemblies.Cross-sectional view of a mandrel spindle assembly coated with an anode layer, with its outer diameter (and thickness) being measured using an outer diameter measuring device.Cross-sectional view of a mandrel spindle assembly coated with an anode layer, with its outer diameter (and thickness) being measured using an outer diameter measuring device.Cross-sectional view of a mandrel spindle assembly coated with an anode layer, with its outer diameter (and thickness) being measured using an outer diameter measuring device.A top view of one embodiment of the system of the present invention, showing a storage station, a printer station, an inspection station including a real-time outer diameter measuring device, a laser cutting station including a laser, and a robotic tray capable of moving cartridges between each of the stations.A top view of one embodiment of the system of the present invention, showing a storage station, three printer stations, three inspection stations, a laser cutting station, and a conveyor belt that can move cartridges between each station. Currently, systems and methods exist for commercially manufacturing tubular ceramic green bodies that can be converted into tubular SOFCs, such as micro and macro tubular SOFCs for fuel cell bundles. Generally, the system and method include a plurality of printer stations for coating ceramic formation layers and one or more inspection stations. Furthermore, the system and method may include a laser cutting station that includes a laser. By including inspection of tubular ceramic green bodies while they are being prepared to identify defects and dimensional issues, it becomes possible to move such defective tubes further during manufacturing, for example, by firing them to prepare them for fuel cell units, which would then simply result in them being rejected in the final product. The method and system may, in particular, include measuring the outer diameter of the ceramic formation layer in real time as the ceramic formation layer is being applied to ensure uniformity between tubular ceramic green bodies. The system and method may include a storage station for maintaining a plurality of cartridges for use in the method of the present invention. Furthermore, this storage station can maintain cartridges that are ready for the application of the ceramic cambium and/or cartridges that have completed tubular ceramic green bodies. Furthermore, there are two or more storage stations, each equipped with appropriate active environmental control, for example, for temperature and humidity control, so that cartridges with finished products can be stored in a dedicated storage station and cartridges ready for manufacturing can be stored in another storage station. The system of the present invention may include a controller for computer-related operations of the method, for example, for the use of robotic equipment for moving cartridges to different stations of the system. Furthermore, this robotic device can take various forms, and for simplicity, in this specification,