foster rush electronics, nano technology and clean tech carts 2013 novel ceramic and metal materials...

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


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


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)


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


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


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


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


Sinocera Hydrothermal YSZ

• High surface area• Fine particle size• Highly dispersed• Easily handled• Easily processed


Sinocera YSZ Ceramic

• Uniform microstructure• High density• Fine grain size• Low firing temperature

- Forming: 100 Mpa

- Tsinter: 1360 oC

- Density: 6.03 g/cc


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


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


LIB Separator Technology

• Porous polymer Membrane- Typically Polyethylene or Polyproplyene

- Porosity > 40%

- Not developed solely for LIB applications

- Prone to development of Li-dendrites


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


Lithium Ion Battery Risks


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


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


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


Samsung Fine Chemical Oxalate BaTiO3 - SBT Powder


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


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


Solar Cell Technology

• Front Conductor- Silver powder ink

• Cell Material- Doped silicon wafer

• Back Conductor- Silver powder ink

- Aluminum powder ink


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


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


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


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

foster rush electronics, nano technology and clean tech carts 2013 novel ceramic and metal materials...

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