WO2022138192A1 - 固体酸化物形燃料電池用電解質シート、固体酸化物形燃料電池用電解質シートの製造方法、及び、固体酸化物形燃料電池用単セル - Google Patents
固体酸化物形燃料電池用電解質シート、固体酸化物形燃料電池用電解質シートの製造方法、及び、固体酸化物形燃料電池用単セル Download PDFInfo
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- WO2022138192A1 WO2022138192A1 PCT/JP2021/045281 JP2021045281W WO2022138192A1 WO 2022138192 A1 WO2022138192 A1 WO 2022138192A1 JP 2021045281 W JP2021045281 W JP 2021045281W WO 2022138192 A1 WO2022138192 A1 WO 2022138192A1
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- particle size
- electrolyte sheet
- solid oxide
- oxide fuel
- ceramic
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- 239000003792 electrolyte Substances 0.000 title claims abstract description 180
- 239000000446 fuel Substances 0.000 title claims abstract description 120
- 239000007787 solid Substances 0.000 title claims abstract description 94
- 238000004519 manufacturing process Methods 0.000 title claims description 41
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 316
- 239000002245 particle Substances 0.000 claims abstract description 176
- 239000000919 ceramic Substances 0.000 claims abstract description 153
- 230000001186 cumulative effect Effects 0.000 claims abstract description 76
- 238000009826 distribution Methods 0.000 claims abstract description 69
- 239000000843 powder Substances 0.000 claims description 157
- 239000002002 slurry Substances 0.000 claims description 41
- 238000000034 method Methods 0.000 claims description 29
- 238000005245 sintering Methods 0.000 claims description 9
- 238000000465 moulding Methods 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 2
- 235000013339 cereals Nutrition 0.000 description 60
- 239000010987 cubic zirconia Substances 0.000 description 29
- 230000000052 comparative effect Effects 0.000 description 26
- 229910002076 stabilized zirconia Inorganic materials 0.000 description 16
- 241000968352 Scandia <hydrozoan> Species 0.000 description 12
- HJGMWXTVGKLUAQ-UHFFFAOYSA-N oxygen(2-);scandium(3+) Chemical compound [O-2].[O-2].[O-2].[Sc+3].[Sc+3] HJGMWXTVGKLUAQ-UHFFFAOYSA-N 0.000 description 12
- 238000010248 power generation Methods 0.000 description 12
- 238000010298 pulverizing process Methods 0.000 description 12
- 238000010304 firing Methods 0.000 description 8
- 239000000463 material Substances 0.000 description 7
- 229910052761 rare earth metal Inorganic materials 0.000 description 6
- 229910052706 scandium Inorganic materials 0.000 description 6
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 5
- 239000002270 dispersing agent Substances 0.000 description 5
- 229910052727 yttrium Inorganic materials 0.000 description 5
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 5
- 238000005266 casting Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 239000011267 electrode slurry Substances 0.000 description 4
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 239000011362 coarse particle Substances 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 239000003960 organic solvent Substances 0.000 description 3
- 230000000149 penetrating effect Effects 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 238000002788 crimping Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000005238 degreasing Methods 0.000 description 2
- 238000010191 image analysis Methods 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000000790 scattering method Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 description 2
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000012790 confirmation Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000007606 doctor blade method Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000284 extract Substances 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000012046 mixed solvent Substances 0.000 description 1
- 229910002077 partially stabilized zirconia Inorganic materials 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- -1 polyethylene terephthalate Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 235000020985 whole grains Nutrition 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/10—Fuel cells with solid electrolytes
- H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
- H01M8/124—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte
- H01M8/1246—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides
- H01M8/1253—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte the electrolyte consisting of oxides the electrolyte containing zirconium oxide
-
- 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
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
- C04B35/486—Fine ceramics
-
- 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
- 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/10—Fuel cells with solid electrolytes
- H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/10—Fuel cells with solid electrolytes
- H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
- H01M8/1213—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the electrode/electrolyte combination or the supporting material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/10—Fuel cells with solid electrolytes
- H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
- H01M2008/1293—Fuel cells with solid oxide electrolytes
-
- 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 an electrolyte sheet for a solid oxide fuel cell, a method for manufacturing an electrolyte sheet for a solid oxide fuel cell, and a single cell for a solid oxide fuel cell.
- a solid oxide fuel cell is a device that extracts electrical energy by the reaction of fuel electrode: H 2 + O 2- ⁇ H 2 O + 2e- , air electrode: (1/2) O 2 + 2e- ⁇ O 2- .
- the solid oxide fuel cell has a laminated structure in which a plurality of single cells for a solid oxide fuel cell having a fuel electrode and an air electrode provided on an electrolyte sheet for a solid oxide fuel cell made of a ceramic plate are stacked. And used.
- Patent Document 1 states that a sintered body of Scandia-stabilized zirconia is pulverized and the average particle size De measured by a transmission electron microscope is more than 0.3 ⁇ m. , 1.5 ⁇ m or less, average particle size Dr measured by laser scattering method is more than 0.3 ⁇ m, 3.0 ⁇ m or less, and Dr / De is 1.0 or more and 2.5 or less.
- Scandia stability including a step of preparing a slurry having a yttria-stabil ratio of 2% by mass or more and 40% by mass or less, a step of molding the slurry into a sheet, and a step of sintering the obtained molded body.
- a method for producing a zirconia sheet is disclosed.
- the present invention has been made to solve the above problems, and an object of the present invention is to provide an electrolyte sheet for a solid oxide fuel cell having high strength. Another object of the present invention is to provide a method for producing a high-strength solid oxide fuel cell electrolyte sheet. Furthermore, it is an object of the present invention to provide a single cell for a solid oxide fuel cell having the above-mentioned electrolyte sheet for a solid oxide fuel cell.
- the electrolyte sheet for a solid oxide fuel cell of the present invention is made of a ceramic plate-like body containing a sintered body of zirconia, and has a particle size D 90 having a cumulative probability of 90% in the cumulative particle size distribution based on the number of ceramic grains.
- the difference between the particle size D 10 and the particle size D 10 having a cumulative probability of 10% is 2.5 ⁇ m or more.
- the particle size D 50 at which the cumulative probability is 50% is 3 ⁇ m or less, and the cumulative probability is 99%.
- the single cell for a solid oxide fuel cell of the present invention includes a fuel electrode, an air electrode, and an electrolyte sheet for a solid oxide fuel cell of the present invention provided between the fuel electrode and the air electrode. It is characterized by having.
- an electrolyte sheet for a solid oxide fuel cell having high strength it is possible to provide a method for producing an electrolyte sheet for a solid oxide fuel cell having high strength. Further, according to the present invention, it is possible to provide a single cell for a solid oxide fuel cell having the above-mentioned electrolyte sheet for a solid oxide fuel cell.
- the electrolyte sheet for a solid oxide fuel cell of the present invention (hereinafter, also referred to as an electrolyte sheet) and the method for producing an electrolyte sheet for a solid oxide fuel cell of the present invention (hereinafter, also referred to as a method for producing an electrolyte sheet).
- a single cell for a solid oxide fuel cell (hereinafter, also referred to as a single cell) of the present invention will be described.
- the present invention is not limited to the following configuration, and may be appropriately modified without departing from the gist of the present invention.
- a combination of a plurality of individual preferred configurations described below is also the present invention.
- Electrolyte sheet for solid oxide fuel cell An example of the electrolyte sheet for a solid oxide fuel cell of the present invention will be described below.
- FIG. 1 is a schematic plan view showing an example of an electrolyte sheet for a solid oxide fuel cell of the present invention.
- FIG. 2 is a schematic cross-sectional view showing a portion corresponding to the line segments A1-A2 in FIG.
- the electrolyte sheet 10 for a solid oxide fuel cell shown in FIGS. 1 and 2 is made of a ceramic plate-like body containing a sintered body of zirconia.
- zirconia sintered body examples include a zirconia sintered body stabilized with an oxide of a rare earth element such as scandium and yttria, and more specifically, a scandia-stabilized zirconia sintered body.
- a zirconia sintered body stabilized with an oxide of a rare earth element such as scandium and yttria examples include bodies, yttria-stabilized zirconia sintered bodies, and the like.
- the zirconia sintered body is preferably a scandia-stabilized zirconia sintered body. Since the electrolyte sheet 10 is made of a ceramic plate-like body containing a zirconia-stabilized zirconia sintered body, the conductivity of the electrolyte sheet 10 is increased. In this case, by incorporating the electrolyte sheet 10 into the solid oxide fuel cell, the power generation efficiency of the solid oxide fuel cell is enhanced.
- the zirconia sintered body is preferably a cubic zirconia sintered body. Since the electrolyte sheet 10 is made of a ceramic plate-like body containing a sintered body of cubic zirconia, the conductivity of the electrolyte sheet 10 is increased. In this case, by incorporating the electrolyte sheet 10 into the solid oxide fuel cell, the power generation efficiency of the solid oxide fuel cell is enhanced.
- cubic zirconia sintered body examples include cubic zirconia sintered bodies stabilized with oxides of rare earth elements such as scandium and yttrium, and more specifically, stabilized with scandia. Examples thereof include a cubic zirconia sintered body, a cubic zirconia stabilized body stabilized with yttrium, and the like.
- the cubic zirconia sintered body is preferably a scandia-stabilized cubic zirconia sintered body. Since the electrolyte sheet 10 is made of a ceramic plate-like body containing a cubic zirconia sintered body stabilized by scandia, the conductivity of the electrolyte sheet 10 is significantly increased. In this case, by incorporating the electrolyte sheet 10 into the solid oxide fuel cell, the power generation efficiency of the solid oxide fuel cell is remarkably increased.
- the electrolyte sheet 10 When viewed in a plan view from the thickness direction, the electrolyte sheet 10 has, for example, a square shape as shown in FIG.
- the electrolyte sheet 10 When viewed in a plan view from the thickness direction, the electrolyte sheet 10 is not shown, but is preferably a substantially rectangular shape having rounded corners, and more preferably a substantially square shape having rounded corners. In this case, the electrolyte sheet 10 may have roundness at all corners or may have roundness at some corners.
- the electrolyte sheet 10 is provided with a through hole penetrating in the thickness direction. Such a through hole functions as a gas flow path in the solid oxide fuel cell.
- the number of through holes may be only one or two or more.
- the through hole When viewed in a plan view from the thickness direction, the through hole may have a circular shape or another shape.
- the position of the through hole is not particularly limited.
- the size of the electrolyte sheet 10 is, for example, 50 mm ⁇ 50 mm, 100 mm ⁇ 100 mm, 110 mm ⁇ 110 mm, 120 mm ⁇ 120 mm, 200 mm ⁇ 200 mm, and the like.
- the thickness of the electrolyte sheet 10 (ceramic plate-like body) is preferably 200 ⁇ m or less, more preferably 130 ⁇ m or less.
- the thickness of the electrolyte sheet 10 is preferably 30 ⁇ m or more, more preferably 50 ⁇ m or more.
- the thickness of the electrolyte sheet 10 is determined as follows. First, the thickness of any nine points in the region inside 5 mm from the outer edge of the electrolyte sheet 10 is measured with a U-shaped steel plate micrometer "PMU-MX" manufactured by Mitutoyo. Then, the average value calculated from the measured values of the thicknesses at the nine points is defined as the thickness of the electrolyte sheet 10.
- recesses are scattered on at least one main surface of the electrolyte sheet 10. Since the recesses are scattered on at least one main surface of the electrolyte sheet 10, when the electrolyte sheet 10 is incorporated into a solid oxide fuel cell, the contact area between the electrode and the gas becomes large, so that the solid oxide fuel cell is formed. The power generation efficiency of the fuel cell is increased.
- the recesses may be scattered only on one main surface of the electrolyte sheet 10, but it is particularly preferable that the recesses are scattered on both the main surface and the other main surface.
- the difference between the particle size D 90 having a cumulative probability of 90% and the particle size D 10 having a cumulative probability of 10% is 2.5 ⁇ m or more. ..
- the electrolyte sheet When the electrolyte sheet is incorporated into a solid oxide fuel cell, a single cell having a fuel electrode slurry and an air electrode slurry coated on the electrolyte sheet or a fuel electrode and an air electrode provided on the electrolyte sheet is a separator. By stacking together, a load is applied to the electrolyte sheet. Therefore, the low-strength electrolyte sheet is liable to break when a load is applied as described above. When the electrolyte sheet breaks, cracks in the electrolyte sheet usually propagate through the grains of ceramic grains.
- the probability distribution of the particle size of the ceramic grains is widened by satisfying the above-mentioned condition for the cumulative particle size distribution based on the number of ceramic grains, and the ceramic grains having a large particle size are present. become. Therefore, in the electrolyte sheet 10, ceramic grains having a large particle size suppress the growth of cracks and contribute to the suppression of the decrease in strength. As a result, the electrolyte sheet 10 having high strength is realized. Such a high-strength electrolyte sheet 10 is unlikely to break even when the above-mentioned load is applied when it is incorporated into a solid oxide fuel cell.
- the cumulative particle size distribution based on the number of ceramic grains in the electrolyte sheet is determined as follows. First, 100 or more ceramic grains were present at an arbitrary location (for example, the central portion) of the electrolyte sheet with a magnification of 3000 times using a tabletop microscope "TM3000" manufactured by Hitachi High-Technologies Corporation. In addition, an image of a region having a size of 30 ⁇ m ⁇ 30 ⁇ m is taken. Next, by performing image analysis on the obtained image using the image analysis measurement system "WinROOF2018 grain boundary extraction module" manufactured by Mitani Shoji Co., Ltd., the particle size of 100 or more ceramic grains is equivalent to an equivalent circle. Measure as a diameter.
- the function "NORMDIST” (or the function "NORM.DIST") of the spreadsheet software "Microsoft Excel” manufactured by Microsoft is used to "TRUE” in the function format.
- the cumulative probability that the grain size of the ceramic grain will be less than or equal to the particle size is calculated.
- the cumulative particle size distribution based on the number of ceramic grains is determined.
- the electrolyte sheet 10 In the cumulative particle size distribution based on the number of ceramic grains defined as described above, when the particle size D 90 having a cumulative probability of 90% and the particle size D 10 having a cumulative probability of 10% are defined, the electrolyte sheet 10 The difference between the particle size D 90 and the particle size D 10 is 2.5 ⁇ m or more. In the electrolyte sheet 10, the difference between the particle size D 90 and the particle size D 10 is preferably 2.6 ⁇ m or more in the cumulative particle size distribution based on the number of ceramic grains.
- the difference between the particle size D 90 and the particle size D 10 is preferably 3.5 ⁇ m or less, and more preferably 3.1 ⁇ m or less in the cumulative particle size distribution based on the number of ceramic grains.
- the particle size D 90 in the cumulative particle size distribution based on the number of ceramic grains is preferably 3 ⁇ m or more and 4 ⁇ m or less, and more preferably 3.2 ⁇ m or more and 3.8 ⁇ m or less.
- the particle size D 10 in the cumulative particle size distribution based on the number of ceramic grains is preferably 0.5 ⁇ m or more and 1 ⁇ m or less, and more preferably 0.7 ⁇ m or more and 0.9 ⁇ m or less.
- the function "NORMDIST” (or the function "NORM.DIST") of the spreadsheet software "Microsoft Excel” manufactured by Microsoft Corporation is used in a functional format.
- FALSE the probability density of the particle size of the ceramic grain can be calculated.
- the probability distribution of the particle size of the ceramic grain can be determined.
- the particle size D 50 (also called the median diameter) having a cumulative probability of 50% is 3 ⁇ m or less, and the particle size D 99 having a cumulative probability of 99% is 6 ⁇ m or more.
- the cracks in the electrolyte sheet usually propagate through the inside of the ceramic grain grains. Therefore, in the electrolyte sheet, if the probability distribution of the particle size of the ceramic grain is wide and the presence of the ceramic grain having a large particle size, the growth of cracks is likely to be suppressed.
- an electrolyte sheet is produced by forming a ceramic slurry containing a mixture of zirconia sintered powder and zirconia unsintered powder and then sintering the ceramic slurry. Therefore, in order to realize sinterability close to that of zirconia unsintered powder, it is important to use zirconia sintered powder having a particle size D 50 of 3 ⁇ m or less in the cumulative particle size distribution on a volume basis.
- the zirconia sintered powder by setting the particle size D 99 in the volume-based cumulative particle size distribution to 6 ⁇ m or more, the coarse particles having a particle size of 6 ⁇ m or more become the core of grain growth during the sintering of the ceramic slurry. , Promote overall grain growth. As a result, as will be described later, an electrolyte sheet having a wide probability distribution of the particle size of the ceramic grain and the presence of the ceramic grain having a large particle size can be obtained.
- the volume-based cumulative particle size distribution of zirconia sintered powder is determined as follows. First, the particle size distribution of the zirconia sintered powder is measured by a laser scattering method using a laser diffraction type particle size distribution measuring device or the like. At this time, the particle size of the zirconia sintered powder is measured as an equivalent circle equivalent diameter. Then, by converting the particle size distribution of the obtained zirconia sintered powder into one represented by the cumulative probability, the cumulative particle size distribution based on the volume of the zirconia sintered powder is determined.
- the present invention is used.
- the zirconia sintered powder used in the production method has a particle size D 50 of 3 ⁇ m or less and a particle size D 99 of 6 ⁇ m or more.
- the particle size D 50 in the volume-based cumulative particle size distribution is 3 ⁇ m or less, preferably 2.5 ⁇ m or less.
- the particle size D 50 in the volume-based cumulative particle size distribution is preferably 0.5 ⁇ m or more, more preferably 1.5 ⁇ m or more.
- the particle size D 99 in the volume-based cumulative particle size distribution is 6 ⁇ m or more, preferably 6.1 ⁇ m or more.
- the particle size D 99 in the volume-based cumulative particle size distribution is preferably 8.5 ⁇ m or less, more preferably 7.9 ⁇ m or less.
- the zirconia sintered powder by crushing the zirconia sintered body.
- the zirconia sintered body that is the raw material of the zirconia sintered powder is, for example, a sintered zirconia unsintered powder.
- an electrolyte sheet made of a zirconia sintered body may be used, and from the viewpoint of recycling, an electrolyte sheet having defects such as warpage and breakage, and a solid oxide fuel cell. It is preferable to use an electrolyte sheet or the like incorporated in the battery.
- the electrolyte sheet incorporated in the solid oxide fuel cell is used, for example, the electrolyte sheet is taken out by removing the fuel electrode and the air electrode from a used single cell, a defective single cell, or the like. May be good.
- zirconia sintered body for example, a zirconia sintered body stabilized with an oxide of a rare earth element such as scandium or yttria is used, and more specifically, a scandia-stabilized zirconia sintered body is used. A body, yttria-stabilized zirconia sintered body, or the like is used.
- the zirconia sintered body it is preferable to use a scandia-stabilized zirconia sintered body. That is, as the zirconia sintered powder, it is preferable to use scandia-stabilized zirconia sintered powder.
- the zirconia sintered powder stabilized in Scandia an electrolyte sheet having high conductivity can be produced. In this case, the power generation efficiency of the solid oxide fuel cell can be improved by incorporating the manufactured electrolyte sheet into the solid oxide fuel cell.
- the zirconia sintered body it is preferable to use a cubic zirconia sintered body. That is, as the zirconia sintered powder, it is preferable to use cubic zirconia sintered powder.
- the cubic zirconia sintered powder an electrolyte sheet having high conductivity can be produced. In this case, the power generation efficiency of the solid oxide fuel cell can be improved by incorporating the manufactured electrolyte sheet into the solid oxide fuel cell.
- cubic zirconia sintered body for example, a cubic zirconia sintered body stabilized with an oxide of a rare earth element such as scandium or yttrium is used, and more specifically, stabilized with scandia.
- a cubic zirconia sintered body, an Itria-stabilized cubic zirconia sintered body, or the like is used.
- the cubic zirconia sintered body it is preferable to use a cubic zirconia sintered body stabilized in Scandia. That is, as the zirconia sintered powder, it is preferable to use a cubic zirconia sintered powder stabilized in Scandia.
- the cubic zirconia sintered powder stabilized by scandia an electrolyte sheet having remarkably high conductivity can be produced.
- the power generation efficiency of the solid oxide fuel cell can be significantly improved.
- the sintered body of zirconia can be pulverized with a strong impact force, so that the pulverization efficiency is likely to increase.
- the dry crusher for performing dry crushing for example, a jet mill, a vibration mill, a planetary mill, a dry ball mill, a fine mill, or the like is used.
- the crushing medium for the dry crusher for example, zirconia boulders or the like is used.
- the zirconia sintered powder having the above-mentioned volume-based cumulative particle size distribution can be obtained by adjusting the pulverization conditions such as the number of revolutions of the classification rotor of the dry pulverizer and the pulverization time. Can be done.
- wet pulverization may be performed instead of dry pulverization, or dry pulverization and wet pulverization may be performed in combination, but from the viewpoint of pulverization efficiency, only dry pulverization is performed. Is preferable.
- the zirconia sintered powder and the zirconia unsintered powder are mixed so that the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder is 5% by weight or more and 50% by weight or less. By doing so, a ceramic slurry is prepared.
- the weight ratio of the zirconia sintered powder and the zirconia unsintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder is 5% by weight or more and 30% by weight or less. It is preferable to mix them so as to be.
- the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder is less than 5% by weight, the weight ratio of the coarse particles of the zirconia sintered powder is small. Because it becomes too much, the whole grain growth is not promoted when the ceramic slurry is sintered.
- the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder is larger than 50% by weight, the weight ratio of the coarse particles of the zirconia sintered powder is increased. Since it becomes too large, the sinterability of the ceramic slurry deteriorates. As a result, the strength of the electrolyte sheet obtained later is lowered.
- the particle size D 50 having a cumulative probability of 50% is 0.1 ⁇ m or more and 0.3 ⁇ m or less, and the particle size has a cumulative probability of 99%. It is preferable that D 99 is 1.5 ⁇ m or more and 2.5 ⁇ m or less.
- zirconia unsintered powder for example, zirconia unsintered powder stabilized with an oxide of a rare earth element such as scandium or yttrium is used, and more specifically, zirconia unsintered powder stabilized with scandia is used. Powder, yttrium-stabilized zirconia unsintered powder, etc. are used.
- the zirconia unsintered powder it is preferable to use scandia-stabilized zirconia unsintered powder.
- the scandia-stabilized zirconia unsintered powder an electrolyte sheet having high conductivity can be produced.
- the power generation efficiency of the solid oxide fuel cell can be improved by incorporating the manufactured electrolyte sheet into the solid oxide fuel cell.
- the zirconia unsintered powder it is preferable to use cubic zirconia unsintered powder.
- the cubic zirconia unsintered powder an electrolyte sheet having high conductivity can be produced.
- the power generation efficiency of the solid oxide fuel cell can be improved by incorporating the manufactured electrolyte sheet into the solid oxide fuel cell.
- cubic zirconia unsintered powder for example, a cubic zirconia unsintered powder stabilized with an oxide of a rare earth element such as scandium or yttrium is used, and more specifically, stabilized with scandia. Cubic zirconia unsintered powder, cubic zirconia unsintered powder stabilized with Itria, and the like are used.
- the cubic zirconia unsintered powder it is preferable to use a cubic zirconia unsintered powder stabilized in Scandia.
- a cubic zirconia unsintered powder stabilized in Scandia By using the cubic zirconia unsintered powder stabilized by scandia, an electrolyte sheet having remarkably high conductivity can be produced.
- the power generation efficiency of the solid oxide fuel cell can be significantly improved.
- a binder, a dispersant, an organic solvent and the like may be appropriately mixed.
- FIG. 4 and FIG. 5 are schematic plan views showing a process of producing a ceramic green sheet for an example of the method for producing an electrolyte sheet for a solid oxide fuel cell of the present invention.
- the ceramic green tape 1t as shown in FIG. 3 is produced by molding the ceramic slurry on one main surface of the carrier film.
- a tape molding method is preferably used, and a doctor blade method or a calendar method is more preferably used.
- the casting direction is indicated by X and the direction orthogonal to the casting direction is indicated by Y.
- the ceramic green tape 1t is punched out by a known method so as to have a predetermined size as shown in FIG. 4, and the carrier film is peeled off to prepare 1 g of the ceramic green sheet as shown in FIG.
- the order of punching of the ceramic green tape 1t and peeling of the carrier film does not matter.
- FIG. 6 is a schematic cross-sectional view showing an example of the method for producing an electrolyte sheet for a solid oxide fuel cell of the present invention, in which an unsintered plate-like body is produced in a step of producing a ceramic plate-like body.
- an unsintered plate-like body 1s is produced by laminating and crimping 1 g of two ceramic green sheets. Therefore, it can be said that the unsintered plate-shaped body 1s contains 1 g of the ceramic green sheet.
- the number of ceramic green sheets 1g for producing the unsintered plate-shaped body 1s may be two or three or more as shown in FIG. Such a plurality of ceramic green sheets 1g may be crimped or may be simply laminated without being crimped. When the unsintered plate-shaped body 1s is produced from a plurality of ceramic green sheets 1 g, the thickness of the ceramic plate-shaped body obtained later can be appropriately and easily controlled.
- the unsintered plate-like body 1s may be produced from 1 g of one ceramic green sheet. In this case, the step shown in FIG. 6 is omitted.
- recesses scattered on one main surface of the unsintered plate-like body 1s may be formed.
- the concave portions scattered on one main surface of the unsintered plate-shaped body 1s may be formed.
- the convex portions scattered on the surface of the mold may be arranged regularly or irregularly.
- recesses scattered on both the main surface of the unsintered plate-shaped body 1s and the other main surface may be formed.
- a through hole may be formed that penetrates the unsintered plate-shaped body 1s in the thickness direction.
- a drill when forming a through hole in the unsintered plate-shaped body 1s.
- the drill advances from one main surface of the unsintered plate-shaped body 1s toward the other main surface, so that a through hole penetrating the unsintered plate-shaped body 1s in the thickness direction is formed.
- the processing conditions by the drill are not particularly limited.
- Only one through hole may be formed, or two or more through holes may be formed.
- the through hole does not have to be formed.
- a ceramic plate-like body is produced by sintering the unsintered plate-like body 1s.
- FIG. 7 is a schematic cross-sectional view showing an example of the method for manufacturing an electrolyte sheet for a solid oxide fuel cell of the present invention, in which an unsintered plate-like body is fired in a step of producing a ceramic plate-like body.
- the unsintered plate-shaped body 1s By firing the unsintered plate-shaped body 1s, as shown in FIG. 7, the unsintered plate-shaped body 1s is sintered to produce a ceramic plate-shaped body 10p.
- the ceramic plate-shaped body 10p contains a sintered body of zirconia.
- the recesses scattered on one main surface of the unsintered plate-like body 1s are formed, as shown in FIG. 7, the recesses are formed so as to be scattered on one main surface of the ceramic plate-like body 10p. Become.
- the ceramic plate-like body 10p may have recesses scattered on both the main surface and the other main surface of the ceramic plate-like body 10p. The recesses will be formed so as to be scattered.
- these recesses may be arranged regularly or irregularly.
- a ceramic plate-like body may be produced in which recesses are not scattered on both the main surface and the other main surface.
- the ceramic plate-shaped body 10p is provided with a through hole penetrating in the thickness direction.
- an electrolyte sheet made of a ceramic plate-shaped body 10p is manufactured.
- the zirconia having a particle size D 50 of 3 ⁇ m or less and a particle size D 99 of 6 ⁇ m or more in the cumulative particle size distribution on a volume basis is used.
- the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder is set to 50% by weight or less. Therefore, in the ceramic plate-shaped body 10p produced by using such a ceramic slurry, the probability distribution of the particle size of the ceramic grain is wide, and the ceramic grain having a large particle size is present, and the strength is increased.
- the difference between the particle size D 90 and the particle size D 10 is 2.5 ⁇ m or more in the cumulative particle size distribution based on the number of ceramic grains, and the strength is increased. That is, according to the present manufacturing method, the electrolyte sheet for a solid oxide fuel cell of the present invention made of a ceramic plate-shaped body 10p can be manufactured.
- FIG. 8 is a schematic cross-sectional view showing an example of a single cell for a solid oxide fuel cell of the present invention.
- the single cell 100 for a solid oxide fuel cell has a fuel electrode 110, an air electrode 120, and an electrolyte sheet 130.
- the electrolyte sheet 130 is provided between the fuel electrode 110 and the air electrode 120.
- the fuel electrode 110 a known fuel electrode for a solid oxide fuel cell is used.
- the air electrode 120 a known air electrode for a solid oxide fuel cell is used.
- the electrolyte sheet 130 the electrolyte sheet for a solid oxide fuel cell of the present invention (for example, the electrolyte sheet 10 shown in FIGS. 1 and 2) is used. Therefore, when the single cell 100 is incorporated in the solid oxide fuel cell, the power generation efficiency of the solid oxide fuel cell is increased.
- a slurry for the fuel electrode is prepared by appropriately adding a binder, a dispersant, a solvent, etc. to the powder of the material of the fuel electrode. Further, a slurry for an air electrode is prepared by appropriately adding a binder, a dispersant, a solvent and the like to the powder of the material of the air electrode.
- the material of the fuel electrode As the material of the fuel electrode, a known material of the fuel electrode for a solid oxide fuel cell is used.
- the material of the air electrode a known material of the air electrode for a solid oxide fuel cell is used.
- the binder, dispersant, solvent and the like contained in the fuel electrode slurry and the air electrode slurry those known in the method for forming the fuel electrode and the air electrode for the solid oxide fuel cell are used.
- the slurry for the fuel electrode is applied on one main surface of the electrolyte sheet, and the slurry for the air electrode is applied on the other main surface of the electrolyte sheet to a predetermined thickness. Then, by drying these coating films, a green layer for a fuel electrode and a green layer for an air electrode are formed.
- the fuel electrode and the air electrode are formed by firing the green layer for the fuel electrode and the green layer for the air electrode.
- the firing conditions such as the firing temperature may be appropriately determined according to the types of materials of the fuel electrode and the air electrode.
- Example 1 The electrolyte sheet of Example 1 was produced by the following method.
- ⁇ Process of preparing zirconia sintered powder> By dry pulverizing the zirconia sintered body, a zirconia sintered powder having a particle size D 50 of 1.5 ⁇ m and a particle size D 99 of 6.1 ⁇ m was obtained in a volume-based cumulative particle size distribution. ..
- zirconia sintered body a scandia-stabilized zirconia sintered body obtained by sintering a scandia-stabilized zirconia unsintered powder was used. That is, as the zirconia sintered powder, a scandia-stabilized zirconia sintered powder was obtained.
- zirconia boulders having a diameter of 1 mm or more and 10 mm or less were used.
- the rotation speed of the classification rotor of the dry crusher was set to 4000 rotations / minute or more.
- a zirconia sintered powder, a zirconia unsintered powder, a binder, a dispersant, and an organic solvent were prepared in a predetermined ratio.
- the zirconia sintered powder and the zirconia unsintered powder were mixed so that the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder was 10% by weight.
- the obtained formulation was stirred with a medium consisting of partially stabilized zirconia at 1000 rpm for 3 hours to prepare a ceramic slurry.
- the zirconia unsintered powder As the zirconia unsintered powder, scandia-stabilized zirconia unsintered powder was used.
- the zirconia unsintered powder had a particle size D 50 of 0.2 ⁇ m and a particle size D 99 of 1.8 ⁇ m in the cumulative particle size distribution on a volume basis.
- organic solvent a mixed solvent of toluene and ethanol (weight ratio 7: 3) was used.
- a ceramic green tape was produced by tape-molding the ceramic slurry on one main surface of a carrier film made of polyethylene terephthalate by a known method.
- the ceramic green tape was punched out to a predetermined size by a known method, and the carrier film was peeled off to prepare a ceramic green sheet.
- the traveling speed was 0.04 mm / rotation and the rotation speed was 2000 rotations / minute.
- the unsintered plate-like body was degreased by holding it at 400 ° C. for a predetermined time in a baking furnace. Then, the unsintered plate-like body after the degreasing treatment was subjected to a sintering treatment in which the unsintered plate-like body was held at 1400 ° C. for 5 hours in a firing furnace.
- the unsintered plate-like body was sintered to produce a ceramic plate-like body.
- the thickness of the ceramic plate-like body was 120 ⁇ m.
- Example 1 the electrolyte sheet (ceramic plate-like body) of Example 1 was manufactured.
- Example 2 Similar to the electrolyte sheet of Example 1, except that the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder was set to 20% by weight in the step of preparing the ceramic slurry. The electrolyte sheet of Example 2 was produced.
- Example 3 Similar to the electrolyte sheet of Example 1, except that the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder was 50% by weight in the step of preparing the ceramic slurry. The electrolyte sheet of Example 3 was produced.
- Example 4 Except for obtaining a zirconia sintered powder having a particle size D 50 of 3.0 ⁇ m and a particle size D 99 of 7.9 ⁇ m in the volume-based cumulative particle size distribution in the step of preparing the zirconia sintered powder. , The electrolyte sheet of Example 4 was produced in the same manner as the electrolyte sheet of Example 1.
- Example 5 Similar to the electrolyte sheet of Example 1, except that the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder was 5% by weight in the step of preparing the ceramic slurry. The electrolyte sheet of Example 5 was produced.
- Example 6 Similar to the electrolyte sheet of Example 1, except that the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder was 30% by weight in the step of preparing the ceramic slurry. The electrolyte sheet of Example 6 was produced.
- Example 7 Similar to the electrolyte sheet of Example 1, except that the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder was 40% by weight in the step of preparing the ceramic slurry. The electrolyte sheet of Example 7 was produced.
- Comparative Example 1 The electrolyte of Comparative Example 1 was similar to the electrolyte sheet of Example 1 except that the step of preparing the zirconia sintered powder was not performed, that is, the zirconia sintered powder was not prepared in the step of preparing the ceramic slurry. Manufactured the sheet.
- Comparative Example 2 Except for obtaining a zirconia sintered powder having a particle size D 50 of 1.3 ⁇ m and a particle size D 99 of 4.1 ⁇ m in the volume-based cumulative particle size distribution in the step of preparing the zirconia sintered powder. , The electrolyte sheet of Comparative Example 2 was produced in the same manner as the electrolyte sheet of Example 1.
- Comparative Example 3 Except for obtaining a zirconia sintered powder having a particle size D 50 of 3.5 ⁇ m and a particle size D 99 of 8.2 ⁇ m in the volume-based cumulative particle size distribution in the step of preparing the zirconia sintered powder. , The electrolyte sheet of Comparative Example 3 was produced in the same manner as the electrolyte sheet of Example 1.
- Table 1 also shows the above-mentioned production conditions for producing the electrolyte sheets of Examples 1 to 7 and Comparative Examples 1 to 4.
- the particle size D 50 and the particle size D 99 of the zirconia sintered powder obtained in the step of preparing the zirconia sintered powder are shown as “D 50 ” and “D 99 ”, respectively, to prepare a ceramic slurry.
- the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder in the step is referred to as "weight ratio".
- FIG. 9 is a graph showing the probability distribution of the particle size of ceramic grains for the electrolyte sheet of Example 1.
- the electrolyte sheets of Examples 2 to 7 also had a wide probability distribution of the particle size of the ceramic grains and the presence of ceramic grains having a large particle size, as in the electrolyte sheet of Example 1.
- the electrolyte sheets of Comparative Examples 1 to 4 it was confirmed that the probability distribution of the particle size of the ceramic grains was narrower than that of the electrolyte sheets of Examples 1 to 7.
- FIG. 10 is a graph showing the cumulative particle size distribution of the electrolyte sheet of Example 1 based on the number of ceramic grains.
- the particle size D 50 (also referred to as median diameter) having a cumulative probability of 50% is 2.2 ⁇ m, which is cumulative.
- the particle size D 10 having a probability of 10% is 0.7 ⁇ m
- the particle size D 90 having a cumulative probability of 90% is 3.8 ⁇ m
- the difference between the particle size D 90 and the particle size D 10 is 3.1 ⁇ m.
- the particle size D 50 , the particle size D 10 and the particle size D 90 were read from the cumulative particle size distribution based on the number of ceramic grains, and the particle size was read. The difference between D 90 and the particle size D 10 was calculated. The results are shown in Table 1.
- Table 1 regarding the evaluation of the particle size distribution of ceramic grains, the particle size D 50 , the particle size D 10 , the particle size D 90 , and the particle size D 90 and the particle size D 10 in the cumulative particle size distribution based on the number of ceramic grains. The difference from the above is shown as “D 50 ", "D 10 ", “D 90 “, and “D 90 -D 10 ", respectively.
- the conductivity of the electrolyte sheets of Examples 1 to 7 and Comparative Examples 1 to 4 was evaluated as follows. First, a sample was prepared by forming an electrode on one main surface of the electrolyte sheet. Next, the sample was allowed to reach a high temperature state of 864 ⁇ 1 ° C. and left for 30 minutes or more, and then the resistance of the sample in the high temperature state was measured three times at 2-minute intervals. After that, the conductivity was calculated from the measured values of the three resistances, and the average value of these conductivitys was defined as the conductivity in a high temperature state. Then, the conductivity of the electrolyte sheet was evaluated according to the following criteria using the conductivity in a high temperature state. The results are shown in Table 1.
- ⁇ The conductivity in a high temperature state was 135 mS / cm or more.
- ⁇ The conductivity in a high temperature state was 125 mS / cm or more and less than 135 mS / cm.
- X The conductivity at high temperature was less than 125 mS / cm.
- the particle size D 50 is 3 ⁇ m or less and the particle size D 50 is 3 ⁇ m or less in the cumulative particle size distribution on a volume basis.
- a zirconia sintered powder having a particle size D 99 of 6 ⁇ m or more is obtained, and in the step of preparing a ceramic slurry, the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder. was 50% by weight or less.
- the difference between the particle size D 90 and the particle size D 10 was 2.5 ⁇ m or more in the cumulative particle size distribution based on the number of ceramic grains, and the strength was high. Further, in the electrolyte sheets of Examples 1 to 7, the conductivity in a high temperature state was as high as 125 mS / cm or more.
- the step of preparing the zirconia sintered powder was not performed, that is, the zirconia sintered powder was not prepared in the step of preparing the ceramic slurry.
- the difference between the particle size D 90 and the particle size D 10 was less than 2.5 ⁇ m in the cumulative particle size distribution based on the number of ceramic grains, and the strength was low.
- the particle size D 50 is 3 ⁇ m or less in the cumulative particle size distribution on a volume basis, but the particle size D A zirconia sintered powder having a 99 of less than 6 ⁇ m was obtained.
- the difference between the particle size D 90 and the particle size D 10 was less than 2.5 ⁇ m in the cumulative particle size distribution based on the number of ceramic grains, and the strength was low.
- the electrolyte sheet is manufactured by the manufacturing method described in Patent Document 1, in the step of preparing the zirconia sintered powder, as in the case of manufacturing the electrolyte sheet of Comparative Example 2, in the cumulative particle size distribution based on the volume. It was confirmed that a zirconia sintered powder having a particle size D 50 of 3 ⁇ m or less but a particle size D 99 of less than 6 ⁇ m can be obtained. Therefore, in the electrolyte sheet manufactured by the manufacturing method described in Patent Document 1, when the thickness is reduced to 120 ⁇ m as in the electrolyte sheet of Comparative Example 2, the particle size D is found in the cumulative particle size distribution based on the number of ceramic grains. It was confirmed that the difference between 90 and the particle size D 10 was less than 2.5 ⁇ m, and the strength was low.
- the particle size D 99 is 6 ⁇ m or more in the cumulative particle size distribution on a volume basis, but the particle size D A zirconia sintered powder having a size of 50 larger than 3 ⁇ m was obtained.
- the difference between the particle size D 90 and the particle size D 10 was less than 2.5 ⁇ m in the cumulative particle size distribution based on the number of ceramic grains, and the strength was low.
- the weight ratio of the zirconia sintered powder to the total weight of the zirconia sintered powder and the zirconia unsintered powder is 50. It was larger than% by weight.
- the difference between the particle size D 90 and the particle size D 10 was less than 2.5 ⁇ m in the cumulative particle size distribution based on the number of ceramic grains, and the strength was low.
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Abstract
Description
本発明の固体酸化物形燃料電池用電解質シートの一例について、以下に説明する。
本発明の固体酸化物形燃料電池用電解質シートの製造方法の一例について、以下に説明する。
体積基準の累積粒度分布において、累積確率が50%となる粒径D50(メジアン径とも言う)が3μm以下であり、かつ、累積確率が99%となる粒径D99が6μm以上であるジルコニア焼結粉末を準備する。
ジルコニア焼結粉末とジルコニア未焼結粉末とを、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合が5重量%以上、50重量%以下となるように混合することにより、セラミックスラリーを調製する。
図3、図4、及び、図5は、本発明の固体酸化物形燃料電池用電解質シートの製造方法の一例について、セラミックグリーンシートを作製する工程を示す平面模式図である。
まず、セラミックグリーンシートを含む未焼結板状体を作製する。
本発明の固体酸化物形燃料電池用単セルの一例について、以下に説明する。
本発明の固体酸化物形燃料電池用単セルの製造方法の一例について、以下に説明する。
実施例1の電解質シートを、以下の方法で製造した。
ジルコニアの焼結体を乾式粉砕することにより、体積基準の累積粒度分布において、粒径D50が1.5μmであり、かつ、粒径D99が6.1μmであるジルコニア焼結粉末を得た。
まず、ジルコニア焼結粉末、ジルコニア未焼結粉末、バインダー、分散剤、及び、有機溶媒を所定の割合で調合した。この際、ジルコニア焼結粉末とジルコニア未焼結粉末とを、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合が10重量%となるように混合した。そして、得られた調合物を、部分安定化ジルコニアからなるメディアとともに1000回転/分で3時間撹拌することにより、セラミックスラリーを調製した。
まず、セラミックスラリーを、ポリエチレンテレフタレートからなるキャリアフィルムの一方主面上で既知の手法によりテープ成形することにより、セラミックグリーンテープを作製した。
まず、2枚のセラミックグリーンシートを積層及び圧着することにより、未焼結板状体を作製した。
セラミックスラリーを調製する工程で、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合を20重量%としたこと以外、実施例1の電解質シートと同様にして、実施例2の電解質シートを製造した。
セラミックスラリーを調製する工程で、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合を50重量%としたこと以外、実施例1の電解質シートと同様にして、実施例3の電解質シートを製造した。
ジルコニア焼結粉末を準備する工程で、体積基準の累積粒度分布において、粒径D50が3.0μmであり、かつ、粒径D99が7.9μmであるジルコニア焼結粉末を得たこと以外、実施例1の電解質シートと同様にして、実施例4の電解質シートを製造した。
セラミックスラリーを調製する工程で、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合を5重量%としたこと以外、実施例1の電解質シートと同様にして、実施例5の電解質シートを製造した。
セラミックスラリーを調製する工程で、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合を30重量%としたこと以外、実施例1の電解質シートと同様にして、実施例6の電解質シートを製造した。
セラミックスラリーを調製する工程で、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合を40重量%としたこと以外、実施例1の電解質シートと同様にして、実施例7の電解質シートを製造した。
ジルコニア焼結粉末を準備する工程を行わなかった、つまり、セラミックスラリーを調製する工程でジルコニア焼結粉末を調合しなかったこと以外、実施例1の電解質シートと同様にして、比較例1の電解質シートを製造した。
ジルコニア焼結粉末を準備する工程で、体積基準の累積粒度分布において、粒径D50が1.3μmであり、かつ、粒径D99が4.1μmであるジルコニア焼結粉末を得たこと以外、実施例1の電解質シートと同様にして、比較例2の電解質シートを製造した。
ジルコニア焼結粉末を準備する工程で、体積基準の累積粒度分布において、粒径D50が3.5μmであり、かつ、粒径D99が8.2μmであるジルコニア焼結粉末を得たこと以外、実施例1の電解質シートと同様にして、比較例3の電解質シートを製造した。
セラミックスラリーを調製する工程で、ジルコニア焼結粉末とジルコニア未焼結粉末との合計重量に対するジルコニア焼結粉末の重量割合を55重量%としたこと以外、実施例1の電解質シートと同様にして、比較例4の電解質シートを製造した。
実施例1~7、及び、比較例1~4の電解質シートについて、以下の評価を行った。
実施例1~7、及び、比較例1~4の電解質シートについて、上述した方法により、セラミックグレインの粒径の確率分布を定めた。
実施例1~7、及び、比較例1~4の電解質シートについて、以下のようにして強度を評価した。まず、島津製作所製の精密万能試験機「AGS-X」において、電解質シートを中心にセットし、下部の治具を32.5mmの間隔でセットし、上部の治具を65mmの間隔でセットした。そして、上部の治具を5mm/分の速度で下降させることにより、電解質シートの4点曲げ試験を行い、電解質シートの強度を測定した。このようにして測定された電解質シートの強度を、以下の基準に基づいて表1に示す。
○:強度が200MPa以上であった。
×:強度が200MPa未満であった。
実施例1~7、及び、比較例1~4の電解質シートについて、以下のようにして導電率を評価した。まず、電解質シートの一方主面上に電極を形成することにより、試料を作製した。次に、試料を864±1℃の高温状態に到達させて30分間以上放置した後、高温状態での試料の抵抗を2分間隔で3回測定した。その後、3つの抵抗の測定値から導電率を各々算出し、これらの導電率の平均値を高温状態での導電率と定めた。そして、高温状態での導電率を用いて、以下の基準で電解質シートの導電率を評価した。結果を表1に示す。
○:高温状態での導電率が135mS/cm以上であった。
△:高温状態での導電率が125mS/cm以上、135mS/cm未満であった。
×:高温状態での導電率が125mS/cm未満であった。
1s 未焼結板状体
1t セラミックグリーンテープ
10、130 固体酸化物形燃料電池用電解質シート(電解質シート)
10p セラミック板状体
100 固体酸化物形燃料電池用単セル(単セル)
110 燃料極
120 空気極
X キャスティング方向
Y キャスティング方向に直交する方向
Claims (4)
- ジルコニアの焼結体を含むセラミック板状体からなり、
セラミックグレインの個数基準の累積粒度分布において、累積確率が90%となる粒径D90と累積確率が10%となる粒径D10との差は、2.5μm以上である、ことを特徴とする固体酸化物形燃料電池用電解質シート。 - 体積基準の累積粒度分布において、累積確率が50%となる粒径D50が3μm以下であり、かつ、累積確率が99%となる粒径D99が6μm以上であるジルコニア焼結粉末を準備する工程と、
前記ジルコニア焼結粉末とジルコニア未焼結粉末とを、前記ジルコニア焼結粉末と前記ジルコニア未焼結粉末との合計重量に対する前記ジルコニア焼結粉末の重量割合が5重量%以上、50重量%以下となるように混合することにより、セラミックスラリーを調製する工程と、
前記セラミックスラリーを成形することにより、セラミックグリーンシートを作製する工程と、
前記セラミックグリーンシートを含む未焼結板状体を焼結させることにより、セラミック板状体を作製する工程と、を備える、ことを特徴とする固体酸化物形燃料電池用電解質シートの製造方法。 - 前記セラミックスラリーを調製する工程では、前記ジルコニア焼結粉末と前記ジルコニア未焼結粉末とを、前記ジルコニア焼結粉末と前記ジルコニア未焼結粉末との合計重量に対する前記ジルコニア焼結粉末の重量割合が5重量%以上、30重量%以下となるように混合する、請求項2に記載の固体酸化物形燃料電池用電解質シートの製造方法。
- 燃料極と、
空気極と、
前記燃料極と前記空気極との間に設けられた請求項1に記載の固体酸化物形燃料電池用電解質シートと、を備える、ことを特徴とする固体酸化物形燃料電池用単セル。
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