Production of a Component with a Gas-Tight, Ion-Conducting Functional Layer and Component

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This patent describes a method for manufacturing a component with a gas-tight, ion-conductive ceramic functional layer, particularly suitable for use in electrochemical cells such as proton-conducting fuel cells and electrolysis cells. The process involves pressing ceramic powder with a liquid sintering additive onto a substrate at high pressure, followed by sintering at relatively low temperatures to achieve high density and gas-tightness. The use of specific sintering additives and lower sintering temperatures enhances the electrochemical properties and allows integration with metal substrates.

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• Manufacturing of proton-conducting fuel cells (PCFCs) for clean energy generation.
• Production of proton-conducting electrolysis cells (PCECs) for hydrogen generation by water splitting.
• Creation of gas-tight, ionically conductive ceramic membranes for use in industrial gas separation or electrochemical sensors.
• Development of metal-supported solid oxide fuel cells for combined heat and power applications.
• High-density ceramic component fabrication for advanced batteries or electrochemical reactors.

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• Significantly lower sintering temperatures reduce energy consumption and production costs.
• Minimized shrinkage and thermal stress between ceramic and substrate layers prevent cracking and delamination, enhancing mechanical stability.
• Elimination of inorganic, powder-based sintering additives avoids secondary phase formation, preserving optimal electrochemical properties.
• Flexible integration with metal or cermet substrates allows for robust, high-performance electrochemical devices.
• Achieves high-density, gas-tight ceramic layers with superior ion conductivity, improving efficiency in fuel cells and electrolyzers.
• Environmentally friendly production by reducing greenhouse gas emissions through lower processing temperatures.

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Patent Abstract

The invention relates to a method for producing a component (11) with a gas-tight ion-conducting ceramic functional layer (9) comprising the following steps: - pressing ceramic powder material with a sintering additive through a pressing tool (1) at a pressure of at least 50 MPa, - sintering the pressed ceramic powder material and the sintering additive. The invention also relates to a component that can be produced using the method.