WO2002072281A2 - A method for making thick and/or thin film - Google Patents
A method for making thick and/or thin film Download PDFInfo
- Publication number
- WO2002072281A2 WO2002072281A2 PCT/US2002/006613 US0206613W WO02072281A2 WO 2002072281 A2 WO2002072281 A2 WO 2002072281A2 US 0206613 W US0206613 W US 0206613W WO 02072281 A2 WO02072281 A2 WO 02072281A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- solution
- improvement
- solvent
- atomizer
- carried out
- Prior art date
Links
Classifications
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
- C04B41/4535—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a solution, emulsion, dispersion or suspension
- C04B41/4543—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a solution, emulsion, dispersion or suspension by spraying, e.g. by atomising
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
-
- 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 the fabrication of films, particularly to a low cost method for making thick or thin films, and more particularly to a method of making films wherein a prepared solution is deposited on a substrate to be coated using an atomizer to produce films of various thickness and with flexibility.
- a number of low cost non-vacuum based thick/thin ceramic film casting techniques are readily available. These include tape casting, tape calendering, colloidal dip coating and spin coating, screen-printing, gel casting, slip casting, pressure casting, etc. All of the above techniques require somewhat similar preparations of the slips containing the ceramic powder with different additives and solvents.
- colloidal dip coating consists of dipping the substrate in the colloidal solution followed by withdrawing the substrate at constant speed. After complete evaporation of the solvent, a film is formed. There is little active control of the film thickness, the process must be done using trials and errors approach to find the right viscosity and the right solid loading in the solution in order to obtain the right film thickness.
- This technique is not limited by the size or shape of the substrate but there is a limit in the maximum film thickness (typically lO ⁇ m) beyond which film cracking occurs because of drying shrinkage.
- Tape casting requires the preparation of a more viscous slip and more additives such as binders, plasticizers.
- the slip is spread on a flat surface to a controlled thickness with the knife edge of a doctor blade, and the solvents are allowed to dry.
- the resulting tape, containing ceramic powders, plasticizers and binders is flexible. It can then be stripped from the casting surface, cut to size, then fired at high temperatures.
- Multilayer tapes are fabricated by sequential casting one layer on top of another. This technique is largely used in a number of areas including the microelectronic industry and the energy industry. Due to the use of the doctor blade, tape casting is limited to flat samples only. Also due to the use of the doctor blade that need to be kept parallel but separated from the substrate at a constant distance, tape casting is typically limited to films of thickness greater than say 50 ⁇ m.
- the present invention is a simple technique that can replace and /or complement the conventional tape casting technique while providing more flexibility with simplicity.
- the invention involves a method using a solution or slip similar to the prior techniques but with high volatility and lower viscosity.
- the method involves depositing the solution via an atomizer and upon hitting a desired substrate the solution solvent evaporates, leaving a green tape or film containing a desired powder and other additives.
- the spraying can be carried out at room temperature and above, and deposited on a slightly heated substrate to accelerate the evaporation of the solvent.
- a further object of the invention is to provide a film forming method using an atomizer.
- Another object of the invention is to provide a method for producing films that can replace and /or complement the conventional tape casting technique while provide more flexibility with simplicity.
- Another object of the invention is to provide a method for producing films wherein the solution contains a powder to be coated dispersed in a volatile solvent such as ethanol, and containing other desire ingredients, and wherein the solution is sprayed on a substrate using an atomizer, and upon hitting the substrate the solvent evaporates.
- a volatile solvent such as ethanol
- Another object of the invention is to provide an aerosol spray casting (ASC) technique for producing green flexible films, which can be punched, cut and heated.
- ASC aerosol spray casting
- Another object of the invention is to provide an ASC technique which can be carried out at room temperature or at elevated temperatures below the evaporation temperature of the solvent used, and which can be carried out using heated substrates.
- the invention is directed to a method for making thin and thick films at very low cost and which films are more flexible and versatile than films produced by the conventional tape casting technique, for example.
- the method involves ASC and produces a green flexible film, similar to the tape casted film but with several advantages:
- the method is not limited to flat surfaces but can be considered for use on substrates of any size and shape, such as thin film casting on tubes.
- the method can be used to deposit much thinner films than conventional tape casting because there is no requirement of exact distance between the spray nozzle (atomizer) and the substrate.
- the method can be carried out at room temperature or at an elevated temperature with or without the substrate being heated.
- the composition of the slip or solution used may be similar to that of the conventional tape casting slip, but includes a dispersant to prevent agglomeration, and the solvent has a higher volatility and the solution or slip has a low viscosity, whereby, solution is deposited as a fine mist, and the solvent evaporates upon hitting the substrate.
- the method can be used in a variety of applications requiring thin or thick films, such as in the fabrication of solid oxide fuel cells, ceramic membranes, multilayer films, etc.
- the present invention involves a method for producing thin or thick films carried out using an atomizer for depositing the film producing solution.
- the invention is a simple aerosol spray casting (ACS) technique that can replace and/or complement the conventional tape casting technique while providing much more flexibility with simplicity.
- the ASC method of this invention is not limited to flat substrates but can be used for coating substrates of any size and shape.
- the ASC method can deposit much thinner films than the conventional tape casting approach because there is no requirement of exact distance between the spray nozzle and the substrate to be coated.
- the method of this invention can be utilized to complement the tape casing techniques in applications where thick and thin films are required, with the thick film produced by tape casing and the thin film produced by ASC.
- the ASC method of this invention basically involves two (2) operations. The first is the slip or solution preparation, and the second is the deposition of the solution onto a substrate by the use of an atomizer, each operation being separately described hereinafter.
- the first operation consists of the preparation of the slip or solution to be used for a specific application.
- This operation is somewhat similar to solution or slip preparations for other techniques, such as tape casting, and is generally described as follows: [0019] A desired powder to be coated is dispersed in a solvent, preferably organic. An appropriate dispersant is added to prevent agglomeration. Plasticizers and binders are subsequently added.
- this slip is very similar to the slip used in tape casting, except that the solvent will have higher volatility and the solution has lower viscosity.
- the second operation is carried out to deposit the slip or solution formed in the first operation on substrate, as follows:
- the solution is sprayed on a substrate to be coated using an atomizer defining ASC.
- the atomizer can be a pressure-based nozzle or preferably an ultrasonic device.
- the atomizer spreads the solution over the substrate in a fine mist.
- the solvent evaporates, leaving a green tape container the powder and the other additives (binder, plasticizers, etc).
- the spraying can be done at room temperature using a very slow deposition rate to allow the solvent to evaporate.
- Spraying can be done using a slightly heated substrate in order to accelerate the evaporation.
- the temperature should never exceed the evaporation or decomposition temperature of the organic binder and plasticizers.
- the heating can be done either by heating directly the substrate or by blowing hot air over the substrate.
- Typical solvents can be ethanol or methanol, for which typical process temperatures is below 60-70° C.
- the result of this method involving ASC is a green flexible film that can be punched, cut, and /or heated (annealed) as required for its intended use.
- the green flexible film is very similar to tape cast films but with several advantages:
- the ASC technique is not limited to flat samples or surfaces, but can be utilized for surfaces of any size and shape. In particular, thin film casting on tubes can be easily accomplished.
- ASC can be used to deposit much thinner films than conventional tape casting because there is no requirement of exact distance between the spray nozzle and the substrate.
- the ASC method can be carried out as follows:
- a power of is dispersed in a solvent of , a dispersant composed of is added to prevent agglomeration, a plasticizer composed of and a binder composed of are added to produce a slip or solution for forming a film of on a substrate.
- the solution or slip is then sprayed on a substrate, such as using a slow deposition rate ( to ) at room temperature, with the substrate being heated to °C.
- the evaporated solvent may be drawn away by .
- the thus produced green flexible film is then annealed or otherwise processed for its intended use.
- the ASC is a good complement to the tape casting.
- the electrode which serves also as support of the structure, has typical thickness in the range of 100 to lOOO ⁇ m.
- the thickness of the electrolyte is typically lO ⁇ m.
- Such a bilayer must be made using other techniques such as tape calendering or a combination of tape casting to make the electrode layer followed by a screen-printing step to make the electrolyte layer.
- Such a bilayer can be easily processed using tape casting to make the electrode layer followed by ASC to deposit the thin electrolyte layer. The result is a green flexible bilayer that can be punched and /or cut in different sizes. Also, the bilayer can be entirely formed by the ASC method which has the capability to produce both thick and thin films.
- the present invention enable the formation of thin and /or thick films at low cost.
- This simple method can replace and /or complement the conventional tape casting technique while providing more flexibility with simplicity.
- the method of the invention which involves aerosol spray casting can be used for application involving any size and shape substrates, such as thin film casting on tubes.
- the method can be used to provide thin ( ⁇ 10 ⁇ m) film to thick films of several lOO ⁇ m.
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP02750568A EP1429869A2 (en) | 2001-03-08 | 2002-03-05 | A method for making thick and/or thin film |
AU2002306649A AU2002306649A1 (en) | 2001-03-08 | 2002-03-05 | A method for making thick and/or thin film |
JP2002571233A JP2005508723A (en) | 2001-03-08 | 2002-03-05 | Method for manufacturing thick film and / or thin film |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US27419701P | 2001-03-08 | 2001-03-08 | |
US60/274,197 | 2001-03-08 | ||
US09/919,075 US6811741B2 (en) | 2001-03-08 | 2001-07-30 | Method for making thick and/or thin film |
US09/919,075 | 2001-07-30 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2002072281A2 true WO2002072281A2 (en) | 2002-09-19 |
WO2002072281A3 WO2002072281A3 (en) | 2004-04-15 |
Family
ID=26956658
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2002/006613 WO2002072281A2 (en) | 2001-03-08 | 2002-03-05 | A method for making thick and/or thin film |
Country Status (5)
Country | Link |
---|---|
US (1) | US6811741B2 (en) |
EP (1) | EP1429869A2 (en) |
JP (1) | JP2005508723A (en) |
AU (1) | AU2002306649A1 (en) |
WO (1) | WO2002072281A2 (en) |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7368145B2 (en) * | 2002-09-19 | 2008-05-06 | Dai Nippon Printing Co., Ltd. | Method and apparatus for manufacturing organic EL display and color filter by ink jet method |
JP4440523B2 (en) * | 2002-09-19 | 2010-03-24 | 大日本印刷株式会社 | Organic EL display device by inkjet method, color filter manufacturing method, manufacturing device |
US7351491B2 (en) | 2003-04-28 | 2008-04-01 | Battelle Memorial Institute | Supporting electrodes for solid oxide fuel cells and other electrochemical devices |
US7244526B1 (en) | 2003-04-28 | 2007-07-17 | Battelle Memorial Institute | Solid oxide fuel cell anodes and electrodes for other electrochemical devices |
US7531261B2 (en) * | 2003-06-30 | 2009-05-12 | Corning Incorporated | Textured electrolyte sheet for solid oxide fuel cell |
US7820332B2 (en) | 2006-09-27 | 2010-10-26 | Corning Incorporated | Electrolyte sheet with regions of different compositions and fuel cell device including such |
US9120245B1 (en) | 2007-05-09 | 2015-09-01 | The United States Of America As Represented By The Secretary Of The Air Force | Methods for fabrication of parts from bulk low-cost interface-defined nanolaminated materials |
US9162931B1 (en) | 2007-05-09 | 2015-10-20 | The United States Of America As Represented By The Secretary Of The Air Force | Tailored interfaces between two dissimilar nano-materials and method of manufacture |
US8617456B1 (en) * | 2010-03-22 | 2013-12-31 | The United States Of America As Represented By The Secretary Of The Air Force | Bulk low-cost interface-defined laminated materials and their method of fabrication |
US8475705B1 (en) * | 2009-03-23 | 2013-07-02 | The United States Of America As Represented By The Secretary Of The Air Force | Bulk low cost interface-defined laminated metallic and ceramic energy barrier materials and their method of fabrication |
FR2935843B1 (en) * | 2008-09-11 | 2011-02-11 | Commissariat Energie Atomique | ELECTROLYTE FOR SOFC CELL AND METHOD FOR MANUFACTURING THE SAME |
WO2018183190A1 (en) * | 2017-03-28 | 2018-10-04 | Phillips 66 Company | Co-casting process for solid oxide reactor fabrication |
Citations (5)
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US5021304A (en) * | 1989-03-22 | 1991-06-04 | Westinghouse Electric Corp. | Modified cermet fuel electrodes for solid oxide electrochemical cells |
US5445903A (en) * | 1993-09-09 | 1995-08-29 | Technology Management, Inc. | Electrochemical apparatus |
DE19709571C1 (en) * | 1997-03-08 | 1998-06-04 | Forschungszentrum Juelich Gmbh | Electrode-electrolyte unit useful for fuel cell |
DE19801440A1 (en) * | 1998-01-16 | 1999-07-29 | Forschungszentrum Juelich Gmbh | Electrode-electrolyte unit is inexpensively produced e.g. for a high temperature fuel cell |
US6074771A (en) * | 1998-02-06 | 2000-06-13 | Igr Enterprises, Inc. | Ceramic composite electrolytic device and method for manufacture thereof |
Family Cites Families (13)
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US3970591A (en) * | 1974-06-17 | 1976-07-20 | The Bendix Corporation | Electrical discharge device comprising an insulator body having an electrically semi-conducting coating formed thereon |
JPS5278939A (en) * | 1975-12-26 | 1977-07-02 | Dainippon Toryo Co Ltd | Application of thin coating film |
JPS5420054A (en) * | 1977-07-15 | 1979-02-15 | Canon Inc | Coating process |
JPH0785790B2 (en) * | 1989-01-17 | 1995-09-20 | ノードソン株式会社 | Aerosol application method |
DE4204611A1 (en) * | 1992-02-15 | 1993-08-19 | Herberts Gmbh | COATING AGENTS, THEIR USE AS CLEAR VARNISHES AND METHOD FOR THE PRODUCTION OF MULTILAYER LACQUERINGS |
US5443770A (en) * | 1993-09-20 | 1995-08-22 | Krstic; Vladimir D. | High toughness carbide ceramics by slip casting and method thereof |
JPH08330303A (en) * | 1995-05-30 | 1996-12-13 | Mitsubishi Electric Corp | Method and system for preparing thin film |
US5900277A (en) * | 1996-12-09 | 1999-05-04 | The Dow Chemical Company | Method of controlling infiltration of complex-shaped ceramic-metal composite articles and the products produced thereby |
JPH10272614A (en) * | 1997-03-31 | 1998-10-13 | Jgc Corp | Manufacture of bonded sintered product of high-purity ceramics |
US6268014B1 (en) * | 1997-10-02 | 2001-07-31 | Chris Eberspacher | Method for forming solar cell materials from particulars |
DE69909701T2 (en) * | 1998-10-07 | 2004-06-03 | Haldor Topsoe A/S | Ceramic laminate material |
US6358567B2 (en) * | 1998-12-23 | 2002-03-19 | The Regents Of The University Of California | Colloidal spray method for low cost thin coating deposition |
WO2001087798A2 (en) * | 2000-05-19 | 2001-11-22 | The University Of British Columbia | Process for making chemically bonded composite hydroxide ceramics |
-
2001
- 2001-07-30 US US09/919,075 patent/US6811741B2/en not_active Expired - Fee Related
-
2002
- 2002-03-05 AU AU2002306649A patent/AU2002306649A1/en not_active Abandoned
- 2002-03-05 WO PCT/US2002/006613 patent/WO2002072281A2/en active Application Filing
- 2002-03-05 EP EP02750568A patent/EP1429869A2/en not_active Withdrawn
- 2002-03-05 JP JP2002571233A patent/JP2005508723A/en active Pending
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5021304A (en) * | 1989-03-22 | 1991-06-04 | Westinghouse Electric Corp. | Modified cermet fuel electrodes for solid oxide electrochemical cells |
US5445903A (en) * | 1993-09-09 | 1995-08-29 | Technology Management, Inc. | Electrochemical apparatus |
DE19709571C1 (en) * | 1997-03-08 | 1998-06-04 | Forschungszentrum Juelich Gmbh | Electrode-electrolyte unit useful for fuel cell |
DE19801440A1 (en) * | 1998-01-16 | 1999-07-29 | Forschungszentrum Juelich Gmbh | Electrode-electrolyte unit is inexpensively produced e.g. for a high temperature fuel cell |
US6074771A (en) * | 1998-02-06 | 2000-06-13 | Igr Enterprises, Inc. | Ceramic composite electrolytic device and method for manufacture thereof |
Also Published As
Publication number | Publication date |
---|---|
JP2005508723A (en) | 2005-04-07 |
AU2002306649A1 (en) | 2002-09-24 |
US6811741B2 (en) | 2004-11-02 |
WO2002072281A3 (en) | 2004-04-15 |
EP1429869A2 (en) | 2004-06-23 |
US20020127344A1 (en) | 2002-09-12 |
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