Upload
taylor
View
32
Download
2
Tags:
Embed Size (px)
DESCRIPTION
CARTS 2013 Novel Ceramic and Metal Materials for Energy Storage and Clean Tech. Brian Foster & Dr. Gordon Dayton. Foster Rush Electronics, Nano Technology and Clean Tech. Outline. Introduction Fuel Cell Materials Lithium Ion Battery Materials Solar Cells Conclusions. Introduction. - PowerPoint PPT Presentation
Citation preview
Foster RushElectronics, Nano Technology and Clean Tech
CARTS 2013
Novel Ceramic and Metal Materials for Energy Storage
and Clean Tech
Brian Foster & Dr. Gordon Dayton
Foster RushLeading Edge Materials Technology Consulting
Outline
• Introduction• Fuel Cell Materials• Lithium Ion Battery Materials• Solar Cells• Conclusions
Foster RushLeading Edge Materials Technology Consulting
Introduction
• Passive component value chain trends:- Passive component price erosion continues to outpace
unit growth by 5-10%/year Component miniaturization Migration of manufacturing to low cost geographic regions Aggressive competition for high value component market space
- Increasing raw material costs Consolidation in the electronic materials supply chain Supply/demand imbalance Competition among end use applications
- Macro-economic pressures Continuation of European economic malaise Reduced growth expectations for US Moderation of growth rate in China
Foster RushLeading Edge Materials Technology Consulting
Introduction
• Search for Adjacent Market Spaces- New and Trending
- Not commoditized
- Value-added materials
- Leverage existing technology platforms and manufacturing competencies to maximize return on investment
- Benefit from development incentives
• Candidate Markets:- Clean Technology (SOFC, Solar Cells)
- Energy Storage (Li Batteries)
Foster RushLeading Edge Materials Technology Consulting
Heated Solid Oxide Fuel Cells
• 1930’s development• Early versions difficult to commercialize• Clean technology trends are driving new
development
• Byproducts: H2O, O2-depleted Air, electricity
• Potential for small, highly efficient source of clean energy
Foster RushLeading Edge Materials Technology Consulting
Heated SOFC
• Fuel: hydrocarbon gas (i.e., methane)
• Air (Oxygen source)• Electrolyte: ZrO2-based
(YSZ, ScSZ, GDC)• Anode: Ni-ZrO2 Cermet
• Cathode: (La,Sr)MnO3
• Temperature: 500-1000C
• Cathode is bulk material
Foster RushLeading Edge Materials Technology Consulting
Hydrothermal Zirconia Process
• High purity raw materials• Co-doping possible• Low-temperature
precipitation• Synthesis at ~400C• PSD can be tailored by
process conditions• Potential for low-
agglomeration
CA 102447125A
Foster RushLeading Edge Materials Technology Consulting
Hydrothermal ZrO2 Properties
Sinocera GC-ZO-3Y Hydrothermal YSZ
Parameter Units Value Method
Mean Particle nm ~50 SEM
Surface Area m2/g 18.6 BET
PSD-90 m 0.11 LS 230
PSD-50 m 0.15 LS 230
PSD-10 m 0.24 LS 230
Moisture Wt % 0.69 105 oC, 2-hr
Ignition Loss Wt % 1.17 1100 oC, 1-hr
Crystal Phase Symmetry Cubic X-ray Diffraction
ZrO2+HfO2+Y2O3 Purity % 99.9 Spectroscopy
Foster RushLeading Edge Materials Technology Consulting
Sinocera Hydrothermal YSZ
• High surface area• Fine particle size• Highly dispersed• Easily handled• Easily processed
Foster RushLeading Edge Materials Technology Consulting
Sinocera YSZ Ceramic
• Uniform microstructure• High density• Fine grain size• Low firing temperature
- Forming: 100 Mpa
- Tsinter: 1360 oC
- Density: 6.03 g/cc
Foster RushLeading Edge Materials Technology Consulting
Lithium Ion Battery Technology
• Applications:- Consumer Electronics – established/expanding
- Military/Aerospace – growing
- Electronic Vehicle – development (huge potential)
• Advantages- High energy density
- No memory effect
- Low static drain
Foster RushLeading Edge Materials Technology Consulting
Lithium Ion Battery (LIB)
• Cathodes: - Li,Co-Oxide*
- Li,Fe-Phosphate
- Li,Mn-Oxide,
- Li,Mn,Ni,Co-Oxide
• Anode: Graphite• Separator: permeable
membrane**• Electrolytes: Li-salts*LCO cathode is preferred for energy density,
but has safety issues, especially if damaged
**Separator must be permeable to liquidelectrolytes to facilitate charge/discharge
Foster RushLeading Edge Materials Technology Consulting
LIB Separator Technology
• Porous polymer Membrane- Typically Polyethylene or Polyproplyene
- Porosity > 40%
- Not developed solely for LIB applications
- Prone to development of Li-dendrites
Foster RushLeading Edge Materials Technology Consulting
LIB Separator Failure Mode
• Separator Matrix:- Polyethylene- Polypropylene- Other: PVDF, etc.
• Separator Porosity- > 40%
• Failure mode- Li dendrite growth- Electrical shorting- Overheating- Separator melting / fireLithium metal precipitates in porous membrane and
forms dendrites under EMF - EP1401037, Mar 2010
EP1401037
Foster RushLeading Edge Materials Technology Consulting
Lithium Ion Battery Risks
Foster RushLeading Edge Materials Technology Consulting
LIB Composite Separators
Entek Exxon Degussa Celgard
Product Teklon Tonen Separion 2325
Thickness 25 m 25 m 25 m 25 m
Layers Single Single Trilayer Trilayer
Materials PE PE Cer-PET-Cer PP-PE-PP
Process Wet extrude Wet extrude Wet-lay mat Dry extrude
Porosity 38% 36% > 40% 41%
Melt Temp 135 oC 135 oC 220 oC 134/166 oC
KEY: PE = Polyethylene, PP = Polypropylene, PET = Polyethylene terpathalate, Cer = Ceramic
Foster RushLeading Edge Materials Technology Consulting
LIB Separator Filler Materials
• Limit growth of Li-dendrites• Established options:
- CaCO3, SiO2, Al2O3, TiO2, SiS2, SiPO4
• Development: high K filler enhances electrolyte dissociation- BaTiO3
Foster RushLeading Edge Materials Technology Consulting
High Purity BaTiO3 for Fillers
• High purity raw materials• Fine control of reactant
ratio• Low-temperature
reaction• Highly crystalline output
powder
Samsung Oxalate BaTiO3 Process
Foster RushLeading Edge Materials Technology Consulting
Samsung Fine Chemical Oxalate BaTiO3 - SBT Powder
Foster RushLeading Edge Materials Technology Consulting
Samsung Fine Chemical Oxalate BaTiO3 Properties
Samsung Fine Chemical – SBT Powder
Property SBT Series MethodBa/Ti Ratio 0.999 +/- 0.002 X-ray Fluor.
Impurity (wt %)
SrO < 0.10
ICP
CaO < 0.005
Na2O < 0.005
SiO2< 0.01
Al2O3< 0.005
Fe2O3< 0.005
Moisture (wt %) < 0.30 120 oC, 30-m
Ignition Loss (wt %) < 1.0 1200 oC, 2-hr
Foster RushLeading Edge Materials Technology Consulting
Solar Cell Technology
• Established Technology- Trend for clean energy
- Potential for off grid or grid connected applications
- Recent government subsidies drive growth
• Competition in material market for cost and performance - Aluminum backside conductor
- Highly engineered silvers for front conductor
Foster RushLeading Edge Materials Technology Consulting
Solar Cell Technology
• Front Conductor- Silver powder ink
• Cell Material- Doped silicon wafer
• Back Conductor- Silver powder ink
- Aluminum powder ink
Foster RushLeading Edge Materials Technology Consulting
Silver conductor Technology
• Fine powders for conduction efficiency• Good adhesion to Si-wafer
- “Ohmic” contact critical to efficiency
• Resinate additives improve function- Lower processing temperature
- Increase network development
Foster RushLeading Edge Materials Technology Consulting
Daiken Chemical Company Resinate Technology
Metal Product Metal Solvent Application
Pt Pt-R06YL 5% BC Film catalyst
Pd Pd-R06YL 5% BC Film catalyst
Rh Rh-R01YL 5% BCA Additive Catalyst
Ru Ru-R01YL 5% IB Additive Catalyst
Ir Ir-R02YL 5% BA Additive Catalyst
Ni Ni-R02YL 5% BC Additive
KEY: BC = butyl carbonate, BCA = butyl carbonate acetate,IB = isobutanol, BA = butyl acetate
Foster RushLeading Edge Materials Technology Consulting
Typical Resinate Performance
• Low temperature sintering• Halogen and sulfur free to
eliminate corrosive decomposition products
• Thin film formation on a nano scale
• Homogeneous mixing at molecular level for conductive paste additive applications
Foster RushLeading Edge Materials Technology Consulting
Conclusions
• High price pressure on passive component value chain
• Adjacent markets may offer profitable opportunities• Leveraging existing core competencies combined
with development incentives offers attractive return on investment
• Follow global megatrends• Market examples include:
- Clean Technology: SOFC, Solar Ceramic Fuel Cells alliance with Chaozhou Three Circle Group Murata Ag paste for solar cell (metal wrap through technology)
- Energy Storage: Li Batteries EnerSys and Ioxus joint development agreement