JP6095692B2 - 完全安定化ジルコニア及び部分安定化ジルコニアから成る複合電解質 - Google Patents

完全安定化ジルコニア及び部分安定化ジルコニアから成る複合電解質 Download PDF

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JP6095692B2
JP6095692B2 JP2014555781A JP2014555781A JP6095692B2 JP 6095692 B2 JP6095692 B2 JP 6095692B2 JP 2014555781 A JP2014555781 A JP 2014555781A JP 2014555781 A JP2014555781 A JP 2014555781A JP 6095692 B2 JP6095692 B2 JP 6095692B2
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stabilized zirconia
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ウー、ツオンリン
モンツイク、コートニー・ジェイ
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Cobham Mission Systems Davenport LSS Inc
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Description

関連出願の相互参照
この出願は、２０１２年２月１日に出願された米国仮出願第６１／５９３５９６号の利益を主張する。
固体酸化物形燃料電池及びセラミック酸素分離膜などの電気化学デバイスの性能は、典型的に、固体電解質材料の電気抵抗によって制限される。高いイオン伝導性を有する固体電解質材料は、電気化学デバイスの電気的性能を向上させるだけでなく、デバイスをより低い温度で作動させるようことができ、そのことによってより安価な金属成分を使用することが可能になる。イットリア（Ｙ２Ｏ３）安定化ジルコニア（ＹＳＺ）はこれらの用途のためにかねてから研究されている。過去数年の間には、酸化スカンジウム（Ｓｃ２Ｏ３）安定化ジルコニア（ＳｃＳＺ）がこれらのデバイスのＹＳＺに代わる実行可能な電解質材料として浮上している。ジルコニアの安定化は、（例えば、イットリアなどの）ドーパントの種類及び量に応じて、完全または部分的であり得る。本出願人のセラミック酸素生成システム（ＣＯＧＳ）等のように高い機械的強度と靭性を必要とする用途において、完全安定化ジルコニア化合物は、その比較的低い強度と強靭化機構の欠如により、最適な候補ではない場合がある。ドーパント含有量がより少ない部分安定化ジルコニアは、優れた機械的強度及び靭性を持っているが、イオン伝導性は低い。
いくつかの、完全安定化（８ＹＳＺ、１０Ｓｃ１ＣｅＳＺ等）及び部分安定化（３ＹＳＺ、６Ｓｃ１ＣｅＳＺ、６ＳｃＳＺ等）ジルコニアベースの電解質材料が共に評価された。６Ｓｃ１ＣｅＳＺ電解質を用いたセラミック酸素生成システムユニットが製造され、過酷な環境条件下の実地において適性を証明した。しかしながら、６Ｓｃ１ＣｅＳＺの伝導性は１０Ｓｃ１ＣｅＳＺの伝導性よりずっと低く、その結果、同じ作動条件において性能が低い。
従って、セラミック酸素生成システム等の固体電気化学デバイスにおいて使用するのに適した、最適化された伝導性及び機械的強度を有する固体電解質が必要とされている。
本発明は、固体電気化学デバイス用の電解質材料として、完全安定化ジルコニア（１０Ｓｃ１ＣｅＳＺ等）からの少なくとも一つの成分と、部分安定化ジルコニア（６Ｓｃ１ＣｅＳＺ等）からの少なくとも一つの成分とを含む複合電解質材料を教示する。
図１は、１０Ｓｃ１ＣｅＳＺ含有量の関数として１０Ｓｃ１ＣｅＳＺ−６Ｓｃ１ＣｅＳＺ複合材料の伝導性を示すグラフである。 図２は、１０Ｓｃ１ＣｅＳＺ含有量の関数として１０Ｓｃ１ＣｅＳＺ−６Ｓｃ１ＣｅＳＺ複合材料のバー破壊強度を示すグラフである。
本発明は、固体電気化学デバイスのための電解質材料として、完全安定化ジルコニア（例えば、１０Ｓｃ１ＣｅＳＺ等）からの少なくとも一つの成分と、部分安定化ジルコニア（例えば、６Ｓｃ１ＣｅＳＺ等）からの少なくとも一つの成分とで構成される複合電解質材料を教示する。複合材料は、完全安定化ジルコニアの電解質粉末と部分安定化ジルコニアから成る電解質粉末とを混合する工程を介し、典型的なセラミック製造プロセスに従って得ることができる。例えば、１０Ｓｃ１ＣｅＳＺ粉末と６Ｓｃ１ＣｅＳＺ粉末とが、１：１０ないし１０：１の範囲の重量比で一緒に混合され得る。混合物は次いで処理され、固体電気化学デバイスの構成要素が作製され得る。混合物中の１０Ｓｃ１ＣｅＳＺと６Ｓｃ１ＣｅＳＺの好ましい重量比は、３：７ないし７：３である。
異なる１０Ｓｃ１ＣｅＳＺ：６Ｓｃ１ＣｅＳＺ比を有するディスクとバーのサンプルが製造され、複合材料のイオン伝導性と強度が評価された。伝導性はＤＣ法を用いて、セラミック膜の典型的に意図される作動条件下と同様の電流密度において測定された。バーの強度は４点曲げ試験を介して得られた。図１は、１０Ｓｃ１ＣｅＳＺ−６Ｓｃ１ＣｅＳＺ複合材料の伝導性を示す。明らかに、複合材料の伝導性は、パーコレーション型の挙動を示す。例えば、６０％の１０Ｓｃ１ＣｅＳＺと４０％の６Ｓｃ１ＣｅＳＺから作製された複合材料は、６Ｓｃ１ＣｅＳＺの伝導性の２．２倍の伝導性を有する。図２は、複合材料のバーの強度を示す。複合材料の強度は、６Ｓｃ１ＣｅＳＺの強度の約６０％であり、１０Ｓｃ１ＣｅＳＺの約１２５％である。
以下の表1に示すように、さらなる評価のために、６０％１０Ｓｃ１ＣｅＳＺ−４０％６Ｓｃ１ＣｅＳＺの組成物が選択された。
電解質の性能低下について、定電流（酸素イオン）を生成するための電圧が時間の関数として評価される。上記の表1について、低下率（電圧の上昇）が各１００時間間隔について計算され、１０００時間毎の低下率（％）として記録された。このデータを、t検定を用いて統計的に分析したところ、１０Ｓｃ１ＣｅＳＺの低下率が他の２つのいずれかより小さい確率は９９％以上であったが、６Ｓｃ１ＣｅＳＺの低下率が複合電解質の低下率より優れ得る確率はわずか５２％だった。
好ましい実施形態において、本発明は、Ｚｒ（０．９３）Ｓｃ（０．０６）Ｃｅ（０．０１）Ｏ（２）粉末と、Ｚｒ（０．８９）Ｓｃ（０．１０）Ｃｅ（０．０１）Ｏ（２）粉末とを混合し、得られた粉体を開気孔の除去のために十分な密度まで焼結することによって形成される電解質であって、第１の粉末と第２の粉末の重量比が１０：１ないし１：１０の範囲にある電解質を含む。粉末の混合は、例えば、湿式ボールミル処理により粒子サイズまで完全に実施される。
条件を満たす緻密化の焼結は、以下のように、複合材料の「理論密度」を用いて計算された。
実施例１：
トライバッハ（Ｔｒｅｉｂａｃｈｅｒ） ＥＡ８０／１０．２ １０Ｓｃ１ＣｅＳＺ Ｃａｌ ９７５Ｃ１２時間処理後、次いでＥＡ８１／１０．２ ６Ｓｃ１ＣｅＳＺ ＡＲと混合し、一緒に処理して作製された。
粉末はふるいにかけられなかった。
ペレットはグリーン密度を示すように１３ｍｍのダイで圧縮された（グリーン密度計算として５．９３ｇ／ｃｃを想定）。
１４７５Ｃ４時間で小さな（small CM）焼結体に焼結された。
５８％グリーン密度（１．７０９３ｇ粉末）。
dry 1.6881 1.6848 1.6844 1.6847
susp 1.4575 1.4546 1.4543 1.4547
sat 1.6887 1.6853 1.6846 1.6852
密度 5.765241 5.766442 5.775086 5.771102
%理論密度 97.2216 97.24185 97.38762 97.32045
平均＝97.29288
この測定の平均は、約５．７７ｇ／ｃｃの密度となり、実施例１において理論の９７．３％にしかならないことが分かる。しかしながら、使用された理論密度（５．９３ｇ／ｃｃ）は、実際には、複合材料ではなく６Ｓｃ１ＣｅＳＺについてのものである。複合材料について理論密度を計算するための複合則を用いると、約５．８３ｇ／ｃｃとなる。この理論密度を測定値と比較すると、このサンプルは理論密度の約９９％が達成されたことを示しており、非常によい、条件を満たす緻密化であると考えられる。

Claims (3)

  1. 電解質の製造方法であって、
    ａ）Ｚｒ（０．９３）Ｓｃ（０．０６）Ｃｅ（０．０１）Ｏ（２）から成る第１の粉末と、Ｚｒ（０．８９）Ｓｃ（０．１０）Ｃｅ（０．０１）Ｏ（２）から成る第２の粉末とを混合する工程と、
    ｂ）前記第１の粉末と前記第２の粉末の重量比を１０：１ないし１：１０の範囲として、得られた粉末成形体を開気孔の除去のために十分な密度に焼結する工程と、を含む製造方法。
  2. Ｚｒ（０．９３）Ｓｃ（０．０６）Ｃｅ（０．０１）Ｏ（２）から成る第１の粉末と、Ｚｒ（０．８９）Ｓｃ（０．１０）Ｃｅ（０．０１）Ｏ（２）から成る第２の粉末とから成る固体電解質であって、前記第１及び第２の粉末が１０：１ないし１：１０の範囲の重量比で開気孔の除去のために十分な密度に焼結された固体電解質。
  3. 請求項２の固体電解質を含むセラミック酸素発生システム。
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