eere qc workshop: overview of relevant processes · atmospheric coating . o. knife/die –...
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NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
EERE QC Workshop: Overview of Relevant Processes
Michael Ulsh, NREL
December 9, 2013
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Materials
NREL Image Gallery #03541 NREL Image Gallery #27981
NREL Image Gallery #18745
J. Morgan, “Reduction in Fabrication Costs of Gas Diffusion Layers,” DOE Hydrogen
Program Annual Merit Review, May, 2011.
Corning, Inc. Courtesy of Sean Garner
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Outline
• Line types o Continuous sheet o Continuous part
• Process types o Atmospheric coating o Vacuum coating o Sawing/surfacing o Drying/curing
NREL Image Gallery #13414
D. Wood, “Advanced Materials Processing for Lithium Ion Batteries,” ECS PRiME 2012, October, 2012.
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Line Types
• Continuous sheet o Roll-to-roll o Float o Belt
Used with permission, Ballard Power Systems
NREL Image Gallery #08527
Used with permission, Sonotek Corporation
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Line Types
• Continuous part o Conveyor
L. Thrun, “Manufacturing System Design Analysis of Solid Oxide Fuel Cell Stacks,” final report under DOE contract number DE-SC0004845,
April, 2011.
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Process Types
• Atmospheric coating o Roll
E. Cohen, E. Gutoff, “Modern Coating and Drying Technology,” John Wiley & Sons, 1992.
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Process Types
• Atmospheric coating o Knife/die
– Multi-layer / slide – Curtain – Screen printing
E. Cohen, E. Gutoff, “Modern Coating and Drying Technology,” John Wiley & Sons, 1992.
M. Richards, “Solid Oxide Fuel Cell Manufacturing Overview,” DOE/NREL Hydrogen and Fuel Cell Manufacturing R&D Workshop, August, 2011.
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Process Types
• Atmospheric coating o Spray
– Low temperature (jet, ultrasonic)
– High temperature (arc, plasma)
http://www.directindustry.com/prod/afs-gmbh/plasma-thermal-spray-guns-61471-575137.html
NREL Image Gallery #17120
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Process Types
• Vacuum coating o Sputter o Vapor deposition o Evaporation
NREL Image Gallery #03837-FP
NREL Image Gallery #13419
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Process Types Schematic of Various Process-steps for Si Solar
Cell Fabrication
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Process Types
• Drying/curing o Oven
– Convective, IR – Air, inert, reactive
o Sintering
M. Richards, “Solid Oxide Fuel Cell Manufacturing Overview,” DOE/NREL Hydrogen and Fuel Cell Manufacturing R&D Workshop, August, 2011.
J. Morgan, “Reduction in Fabrication Costs of Gas Diffusion Layers,” DOE Hydrogen Program Annual Merit Review, June, 2010.
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Process Types
• Drying/curing o Radiation
– UV, IR, electron-beam – Air, inert