EP1836138A2 - Hochfeste isolierungsverbindungen für feste brennstoffzellen und andere hochtemperaturanwendungen sowie herstellungsverfahren dafür - Google Patents

Hochfeste isolierungsverbindungen für feste brennstoffzellen und andere hochtemperaturanwendungen sowie herstellungsverfahren dafür

Info

Publication number
EP1836138A2
EP1836138A2 EP05858161A EP05858161A EP1836138A2 EP 1836138 A2 EP1836138 A2 EP 1836138A2 EP 05858161 A EP05858161 A EP 05858161A EP 05858161 A EP05858161 A EP 05858161A EP 1836138 A2 EP1836138 A2 EP 1836138A2
Authority
EP
European Patent Office
Prior art keywords
glass
metal part
mole
metal
joint
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP05858161A
Other languages
English (en)
French (fr)
Inventor
K. Scott Weil
Lawrence A. Chick
Christopher A. Coyle
John S. Hardy
Guanguang Xia
Kerry D. Meinhardt
Vincent L. Sprenkle
Dean M. Paxton
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Battelle Memorial Institute Inc
Original Assignee
Battelle Memorial Institute Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/948,359 external-priority patent/US20060063057A1/en
Priority claimed from US10/948,346 external-priority patent/US20060060633A1/en
Application filed by Battelle Memorial Institute Inc filed Critical Battelle Memorial Institute Inc
Publication of EP1836138A2 publication Critical patent/EP1836138A2/de
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings, jackets or wrappings of a single cell or a single battery
    • H01M50/183—Sealing members
    • H01M50/186—Sealing members characterised by the disposition of the sealing members
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C27/00—Joining pieces of glass to pieces of other inorganic material; Joining glass to glass other than by fusing
    • C03C27/04—Joining glass to metal by means of an interlayer
    • C03C27/042—Joining glass to metal by means of an interlayer consisting of a combination of materials selected from glass, glass-ceramic or ceramic material with metals, metal oxides or metal salts
    • C03C27/044—Joining glass to metal by means of an interlayer consisting of a combination of materials selected from glass, glass-ceramic or ceramic material with metals, metal oxides or metal salts of glass, glass-ceramic or ceramic material only
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C27/00—Joining pieces of glass to pieces of other inorganic material; Joining glass to glass other than by fusing
    • C03C27/04—Joining glass to metal by means of an interlayer
    • C03C27/042—Joining glass to metal by means of an interlayer consisting of a combination of materials selected from glass, glass-ceramic or ceramic material with metals, metal oxides or metal salts
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
    • C03C8/24—Fusion seal compositions being frit compositions having non-frit additions, i.e. for use as seals between dissimilar materials, e.g. glass and metal; Glass solders
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/70—Forming laminates or joined articles comprising layers of a specific, unusual thickness
    • C04B2237/708—Forming laminates or joined articles comprising layers of a specific, unusual thickness of one or more of the interlayers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to a system and method for forming high strength, gas-tight, insulating joints between parts used in high temperature applications, and the joints made thereby. While not meant to be limiting, the present invention has particular utility when used in the fabrication and operation of solid oxide fuel cells.
  • Solid Oxide Fuel Cells are solid state devices that convert chemical energy of the incoming fuel directly to electricity via an electrochemical reaction. Due to their high efficiency and low emissions, SOFCs have become increasingly attractive to a number of industries, such as utility and automotive industries. Among different SOFCs, the planar type is expected to be more mechanically robust, have a high power-density, and provide a more cost- effective design for large scale manufacturing. In the SOFC stacks, the interconnect is used to physically separate the fuel at the anode side and the air or oxidant at the cathode side.
  • the interconnect has to be hermetically sealed to the adjacent components, i.e. the PEN or a metallic frame holding the PEN.
  • the seals between adjacent interconnects must be electrically insulating to prevent shorting.
  • the electrically insulating sealing is often carried out using a glass-ceramic, though other sealing technologies are also under consideration.
  • the sealing materials are required to be chemically compatible to the interconnect. [0004] In most planar SOFC stacks that operate at an intermediate temperature (700-800 0 C), the interconnect is typically made from a ferritic stainless steel and has to be hermitically sealed to its adjacent components by a sealing glass.
  • a metallic reinforcing material such as a porous mesh or series of metallic protuberances (including but not limited to metal spheres, particles, wires, screens and fibers), is then attached to the first metal part.
  • Any prior art method for attaching the reinforcing material to the metal part that will form a durable, strong connection between the screen or other reinforcing material and the first metal part is suitable, including without limitation, brazing, welding, sintering, and the like.
  • a glass forming material is then positioned in between the first metal part and the second part, a seal is formed between the first metal part and the second part by heating the glass to a temperature suitable to soften the glass forming material. In this manner, a glass or glass-ceramic layer is formed which is bonded on one side to the first metal part and bonded on the opposing side to the second part.
  • the molten glass thus formed will infiltrate through the reinforcing material and thereby encapsulate at least a portion of the attached metal screen or metal protuberances.
  • the metal-to-metal bonds will bear substantially higher loads than will the planar glass-oxide scale- metal interfaces present in traditional glass-metal joints.
  • the reinforcing material also acts as a metal reinforcement phase within the glass or glass-ceramic matrix and thereby enhances the fracture toughness of the base glass material via various crack deflection and crack blunting mechanisms. Both effects significantly increase the strength of the composite seal over that of traditional glass-metal seals.
  • the present invention should be in no way construed as being limited to applications involving seals between two metal parts, whether in a solid oxide fuel cell or otherwise, and should instead be interpreted as encompassing any and all applications wherein a robust insulating joint is required between any two parts wherein at least one of the parts is metal.
  • the metal parts and the metallic reinforcing material(s) used in the present invention are selected as high temperature stainless steels and high temperature superalloys.
  • Exemplary high temperature stainless steels would include Durafoil (alpha-4), Fecralloy, Alumina-coated stainless steel and Crofer-22APU.
  • Exemplary superalloys would include Haynes 214, Nicrofer 6025, and Ducralloy.
  • the metal parts and reinforcing components need not be the same alloy, but should be compatible with one another under the conditions intended for sealing and eventual service.
  • the thickness of the joints formed by the present invention is within the range of approximately .1 mm to 2mm.
  • a ceramic material may be juxtaposed between the first metal part and the second part.
  • the ceramic material may serve more than one function.
  • the ceramic material may assist in forming an insulating barrier between the first metal part and the second part integral to the glass formed from the glass forming material. Further, the ceramic material may assist in regulating the viscosity of the glass during the heating step.
  • the ceramic material modifies the molten glass such that it becomes sufficiently viscous to maintain separation between the metal part and the second part, the reinforcing material attached to the metal part and the second part, or the reinforcing material attached to a first metal part and the reinforcing material attached to a second metal part, thereby preventing the formation of an electrical pathway between the two parts.
  • the ceramic material allow the molten glass to maintain sufficient fluidity so as to allow the glass to infiltrate and penetrate the reinforcing material(s) attached to the part(s), thereby encapsulating and adhering directly to the reinforcing material(s) and underlying metal substrate(s). In this manner, the glass is bonded directly to the parts, producing a gas tight seal between the parts and at the same time, infiltrates into the reinforcing material to produce a highly durable bond.
  • the ceramic material is selected as zirconia, stabilized zirconia, alumina, nickel oxide, and combinations thereof.
  • this invention contemplates, but not to be limiting, incorporating small monosize ceramic (exemplary yttria stabilized zirconia) spheres at approximately about 2 to 5 % volumetric loading into the glass-forming material prior to use in the seal.
  • the ceramic spheres remain geometrically stable and retain their rigid solid form at the sealing temperature, whereas the glass softens and flows.
  • the spheres act simultaneously as load columns and geometric spacers to prevent an excessive amount of glass from squeezing out between the two sealing surfaces during the heating and compression step employed in seal formation.
  • the spheres also eliminate potential metal to metal contact in the cell frame, thereby preventing the stack from electrically shorting.
  • the ceramic is
  • small fibers approximately 1 mm in length by 20 ⁇ m in diameter
  • glass forming material which are homogeneously distributed within the glass forming material prior to the heating and seal formation.
  • a suitable ceramic of this type is Type ZYBF material which may be purchased from Zircar Zirconia, Inc. of Florida, NY.
  • glass-forming material containing no ceramic fiber or particulate is applied locally to each of the reinforcing surfaces on the two metal parts, for example as a paste, and allowed to infiltrate.
  • a second glass-forming material containing ceramic fibers, spheres, or porous matting is placed between the two parts and heated to seal. In this way, both glass infiltration into the reinforcing material and formation of an electrically insulating seal can be readily ensured.
  • the glass itself may comprises, but is not limited to, about 10 mole
  • the glass is preferably mixed with organic binder materials, such as those that may be purchased from the Ferro Corporation, of Cleveland, Ohio. Appropriate choice of the binder and accompanying solvent(s) allows either a glass-forming paste to be formulated or thin sheets or tapes of glass-forming material to be prepared. In particular, a paste allows the glass forming materials to be applied to the metal part and the second part in precise locations, and in precise quantities, to allow the formation of the gas tight seal.
  • the metal part and the second part are then placed together and heated at a sufficient time and at a sufficient temperature to completely oxidize, gasify, and thus remove the organic binder materials, and to allow the glass forming materials to melt and form a glass that infiltrates and at least partially if not completely encapsulates the bonded reinforcing material, thereby forming the gas tight, insulating joint of the present invention.
  • heating at 825 0 C for 1 hour is sufficient to form the joint.
  • Figure 1 is a diagram comparison of a SOFC window frame component to the rupture test specimen (not shown to comparative scale);
  • Figure 2 is a diagram of a cassette to cassette seal.
  • Figure 3 is a schematic diagram of the rupture test apparatus
  • This invention contemplates using reinforcing material, for example, a metal powder, metal wire, mesh screen or a series of metallic protuberances which are sintered, etched or machined to the metal substrate or any other form of metal that can be firmly anchored to the substrate and subsequently surrounded by the sealing glass.
  • reinforcing material for example, a metal powder, metal wire, mesh screen or a series of metallic protuberances which are sintered, etched or machined to the metal substrate or any other form of metal that can be firmly anchored to the substrate and subsequently surrounded by the sealing glass.
  • One concept of this invention is that, when tensile or shear or torsion forces are applied to the joint, the load is transferred to the metal-to-metal joins between the reinforcing materials and the substrate. These metal-to-metal joins will bear much higher loads than will the glass-oxide scale-metal interfaces.
  • a series of parts were joined together.
  • a first part consisting of a metal ring resembling a common washer, having an inside diameter of 15mm and an outside diameter of 44mm, was joined to a second part consisting of a flat disk, 25mm in diameter.
  • Various metals were selected, and then joined together by placing glass forming materials between the parts and then heating them at sufficient temperature for a sufficient time to melt the glass forming materials, thereby forming them into a glass and adhering the glass to the surfaces of the metal parts.
  • a SOFC window frame consist of a metal support, glass forming materials, and an anode/electrolyte.
  • a SOFC cassette consists of the previously described window frame bonded (laser welded) to a metallic separator plate.
  • the sealed metal ring to ceramic bilayer disk test specimens approximate sealing in the window frame component, while the sealed metal ring to metal disks specimens approximate the sealing between cassettes, which is used when forming a complete SOFC stack.
  • the sealing specimens were configured using a 20 mil Crofer-22 APU and Ni-YSZ/YSZ bilayers prepared as described herein. The sealing was conducted at 825 0 C for 1 hour, then annealed at 750 0 C for 4 hours prior to cooling to room temperature. Thermal cycle testing was conducted by heating from air temperature to 750°C in 10 minutes, holding at 750°C for 10 minutes, and cooling back to room temperature in 40 minutes. Age testing (soaking) was conducted in static air at 75O 0 C.
  • the glass identified as "G-18" is formed of about 10 mole % B 2 O 3 , about 35 mole % SiO 2 , about 5 mole % AI 2 O 3 , about 35 mole % BaO, about 15 mole % CaO, and an organic binder that is gasified during the heating step, described as a preferred embodiment in the foregoing summary of the invention.
  • Fig. 1 shows how the testing of the present invention was carried out. The test employs essentially a miniaturized version of the main fuel cell components, i.e. window frame and cassette, as the test specimen. According to Fig. 1, a metal washer 1 acts a the metal frame of a SOFC.
  • a 25mm diameter ceramic bi-layer coupon 2 or metal disk is sealed with a glass seal 3 directly to a metal washer 1.
  • a frame 4 of the same composition used in the pSOFC stack that measures 44mm in outside diameter with a 15mm diameter concentric hole, is sealed with a glass seal 3 to an anode- supported bi-layer coupon 5.
  • the anode- supported bi-layer coupons 2 and 5 consist of NiO-5YSZ as the anode and 5YSZ as the electrolyte.
  • the bi-layer coupons were fabricated by tape casting and co-sintering techniques developed at Pacific Northwest National Laboratory. To prepare the anode layer, NiO (J. T.
  • Reinforcing materials by example metal screens of nominally the same size and geometry as the ring and disk pieces, were cut and spot welded to the corresponding flat metal parts to form the reinforcing surface for the glass matrix in the seal.
  • the glass seal composition for example designated as G-18, was an in-house designed barium calcium aluminosilicate based glass originally melted from the following mixture of oxides: 10 mole % B 2 O 3 , 35 mole % SiO 2 , 5 mole % AI 2 O 3 , 35 mole % BaO, and 15 mole % CaO.
  • the G-18 powder was
  • the binder system to form a paste that could be dispensed onto the substrate surfaces at a uniform rate of 0.075g/linear cm using an automated syringe dispenser.
  • the glass paste was dispensed onto the YSZ side of the bilayer disks or reinforcing material side of a metal disk.
  • Each disk was then concentrically positioned on a washer specimen, loaded with a 5Og weight, and heated in air under the following sealing schedule: heat from room temperature to 85O 0 C at 10°C/min, hold at 85O 0 C for one hour, cool to 75O 0 C at 5°C/min, hold at 75O 0 C for four hours, and cool to room temperature at 5°C/min.
  • the SOFC cassette is the repeat unit of the SOFC stack. It consists of the ceramic PEN 10 (bilayer with cathode layer applied) sealed into a metallic frame 12, forming the previously described window frame, which is bonded (laser welded) to a metallic separator plate 14.
  • the reinforcing material 16 e.g. mesh
  • FIG. 3 A schematic of the experimental set-up used in rupture testing is illustrated in Figure 3.
  • the test sample was placed within a fixture that consists of a bottom 30 and top flange 32, a coupling 34 secures and centers the two flanges 30,32, and an o-ring 36 is squeezed against the bottom surface of the washer.
  • Compressed air pumped through air line 40 was used to pressurize the backside of the washer specimen up to a maximum rated pressure of 150psi.
  • a digital regulator 38 allows the pressure behind the joined bi-layer disk 33 to be slowly increased to a given set point. This volume of compressed gas can be isolated between the specimen and a valve, making it possible to identify a leak in the seal by a decay in pressure.
  • the device can be used to measure the hermeticity of a given seal configuration without causing destructive failure of the seal.
EP05858161A 2004-09-22 2005-09-19 Hochfeste isolierungsverbindungen für feste brennstoffzellen und andere hochtemperaturanwendungen sowie herstellungsverfahren dafür Withdrawn EP1836138A2 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/948,359 US20060063057A1 (en) 2004-09-22 2004-09-22 High strength insulating metal-to-metal joints for solid oxide fuel cells and other high temperature applications and method of making
US10/948,346 US20060060633A1 (en) 2004-09-22 2004-09-22 High strength insulating metal-to-ceramic joints for solid oxide fuel cells and other high temperature applications and method of making
PCT/US2005/033755 WO2007001380A2 (en) 2004-09-22 2005-09-19 High strength insulating joints for solid oxide fuel cells and other high temperature applications and method of making

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EP1836138A2 true EP1836138A2 (de) 2007-09-26

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JP (1) JP2008513346A (de)
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DE102010035251B4 (de) * 2010-02-15 2013-09-26 Schott Ag Hochtemperatur-Glaslot und dessen Verwendung
CN103443978A (zh) * 2011-03-24 2013-12-11 株式会社村田制作所 固体氧化物燃料电池用接合材料、固体氧化物燃料电池以及固体氧化物燃料电池模块
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WO2012133087A1 (ja) * 2011-03-30 2012-10-04 株式会社村田製作所 固体酸化物形燃料電池用接合材、固体酸化物形燃料電池及び固体酸化物形燃料電池モジュール
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WO2007001380A3 (en) 2007-07-26
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CA2579781A1 (en) 2007-01-04
WO2007001380A2 (en) 2007-01-04
KR20070059159A (ko) 2007-06-11

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