Abstract:
An anode for use in an anode-supported planar solid oxide fuel cell (SOFC) is formed from a Ni-YSZ cermet composition that includes a sintering aid selected from the group consisting of an oxide, a carbonate, and mixtures thereof of at least one metal of Group 2 of the Periodic Table.
Abstract:
A nozzle assembly (48) for a kinetic spray system includes a convergent portion (72) , a throat portion (82) , and a divergent portion (76) , each cooperating together to define a passage (66) therethrough for passing a mixture of powder particles (22) suspended in a flow of a high pressure heated gas. The nozzle assembly (48) further includes an extension portion (86) attached to the divergent portion (76) and extending to a distal end (88) a pre-determined length (L) from the divergent portion (76) of the nozzle assembly (48) . The extension portion (86) permits a dragging force exerted on the powder particles (22) by the flow of high pressure heated gas to act upon the powder particles (22) for a longer duration of time, thereby permitting the powder particles (22) to accelerate to a greater velocity than has been previously achievable.
Abstract:
A gas collimator (40') for use in a kinetic powder spray system is disclosed. The collimator (40') reduces turbulence of the main gas and results in significant increases in the amount of particles deposited on a substrate using the system. The collimator (40') enables the main gas temperature to be reduced. Also disclosed is a low pressure injection method for a kinetic spray system. The coaxial, low pressure injection method enables the use of low pressure powder feeders, which are low cost, technologically mature, and widely available commercially.
Abstract:
An SOFC structure having segmentation of the mixed layer on a cathode electrode to allow a higher fraction of ionic phase in a mixed layer, resulting in improved microstructure that provides higher specific surface area for electrochemical reaction. This is accomplished by using a mixed ionic and electronic conductor (MIEC) layer (14) over the segmented layer (116) that supplies electrons laterally and vertically through the thickness of the mixed layer. Adequate connectivity between the cathode current collector (130) and electrolyte (20) for electrons is established, assuring efficient charge transfer and improved activity of the electrocatalyst in the porous cathode. Cell resistance is reduced and power output is improved. Further, the invention can efficiently incorporate a variety of functional layers on the anode electrode to improve protection from poisons and certain fuel mixtures that degrade cell performance, and can reduce stresses between fuel cell components while maintaining adequate connectivity with the anode current collector and electrolyte via an Ni-YSZ anode.
Abstract:
An improved kinetic spray nozzle system design is disclosed. The nozzle includes an improved powder injector having an injector tube and a sleeve wherein the injector tube is received in the sleeve and secured to the sleeve. The powder injector further includes an air gap defined between an inner diameter of the sleeve and an outer diameter of the injector tube wherein the air gap is from 50 to 200 microns. The improved injector is capable of spraying a variety of powder materials including hard and "gummy" powders without clogging for extended periods of time. The improved injector design allows the use of higher main gas temperatures to achieve improved coating formation and deposition efficiencies. Most importantly, the improved design makes it possible to use the kinetic spray system with a wide range of powder materials in a manufacturing setting without interruptions caused by powder injector clogging.
Abstract:
An SOFC structure having segmentation of the mixed layer on a cathode electrode to allow a higher fraction of ionic phase in a mixed layer, resulting in improved microstructure that provides higher specific surface area for electrochemical reaction. This is accomplished by using a mixed ionic and electronic conductor (MIEC) layer (14) over the segmented layer (116) that supplies electrons laterally and vertically through the thickness of the mixed layer. Adequate connectivity between the cathode current collector (130) and electrolyte (20) for electrons is established, assuring efficient charge transfer and improved activity of the electrocatalyst in the porous cathode. Cell resistance is reduced and power output is improved. Further, the invention can efficiently incorporate a variety of functional layers on the anode electrode to improve protection from poisons and certain fuel mixtures that degrade cell performance, and can reduce stresses between fuel cell components while maintaining adequate connectivity with the anode current collector and electrolyte via an Ni-YSZ anode.