foster rush electronics, nano technology and clean tech carts 2013 novel ceramic and metal materials...
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![Page 1: Foster Rush Electronics, Nano Technology and Clean Tech CARTS 2013 Novel Ceramic and Metal Materials for Energy Storage and Clean Tech Brian Foster & Dr](https://reader034.vdocuments.us/reader034/viewer/2022050802/56649e2a5503460f94b17b40/html5/thumbnails/1.jpg)
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
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Foster RushLeading Edge Materials Technology Consulting
Outline
• Introduction• Fuel Cell Materials• Lithium Ion Battery Materials• Solar Cells• Conclusions
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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
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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)
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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
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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
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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
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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
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Foster RushLeading Edge Materials Technology Consulting
Sinocera Hydrothermal YSZ
• High surface area• Fine particle size• Highly dispersed• Easily handled• Easily processed
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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
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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
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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
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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
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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
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Foster RushLeading Edge Materials Technology Consulting
Lithium Ion Battery Risks
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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
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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
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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
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Foster RushLeading Edge Materials Technology Consulting
Samsung Fine Chemical Oxalate BaTiO3 - SBT Powder
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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
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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
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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
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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
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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
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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
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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