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Research paper : Challenge for the development of micro SOFC manufacturing technology (Y. Fujishiro et al.)−47−Synthesiology - English edition Vol.4 No.1 (2011) fuel or oxygen (air). To create a unit structure of ordinary SOFC, the ceramic members are manufactured by forming the ceramic powder that exerts various functions into required shapes, by coating and laminating, and then firing. Therefore, according to the shape and size of the cell and integrated module, various ceramics manufacturing process technologies are employed. Moreover, since the cell and integrated modules are manufactured by multiple lamination of various functional materials with different thermal expansion, electric, and strength properties, the design of each material at nano-,micro- and macro-size levels and structural control in the fabrication process strongly affects the final power generation performance.The challenge for the integrated module using the new micro SOFC was a difficulty of the ceramic manufacturing process technology, and it was necessary to return to the manufacturing of the cell and integrated module as ceramic parts. However, it would take too long a time to develop if we built the individual elemental technologies one at a time. It was necessary to conduct the development of ceramic parts with thermal management properties and ceramic material with electrochemical structure that increased the generation performance at low temperature, as well as the revolutionary manufacturing technology.With such a background, the “center for the development of functional ceramic manufacturing technology” was established and the R&D was conducted under the “ceramic integration manufacturing process technology” of the “The Advanced Ceramic Reactor Development (subcontracted by NEDO, 2005-2010)” to realize the new product and to solve the issues of the highly integrated micro SOFC manufacturing technology[6][7].As shown in Fig. 3, the PDCA of design-manufacture-analysis was conducted at the center for the development of functional ceramic manufacturing technology, and the core technology and the product realization technology were developed simultaneously. As a result, the open innovation system where the engineers and researchers of the ceramic manufacturing companies and user companies collaborated was established. As an output, it functioned as the opportunity to train industrial human resource where people could obtain academic degrees as well as produce research results. Specifically, for the development of highly integrated ceramic electrochemical module based on the new concept such as the realization of high-performance SOFC at low temperature, of integration, of high performance, and of mass production, the developments were done from the material selection and cell design (manufacturing design such as structure and size) to the prototype cell and module fabrication (structural control process in clay forming, coating, firing condition, etc.), the establishment of original evaluation and analysis technology for the new cell and module structure (thermal behavior, electrochemical property, generation property), and the general evaluation of the cell and module (improvements in structure and manufacturing process). These were discussed directly among the engineers and researchers of the manufacturer and user companies at the center. Proposals were made for the new process technology, the structural control technology upon discovery of a new phenomenon, and the utilization of new technology in industry. Through collaborations between the researchers and the corporate engineers, a flow was built toward the solution of issues for the new highly integrated module prototype and the development of materials and the elemental process technologies.In the R&D at the center, the development of fine ceramic manufacturing process was done in collaboration with the ceramics industry in the Chubu region that has traditionally engaged in this industry. They helped build and accumulate the manufacturing technology. An optimal cycle of Fig. 3 R&D model for the new micro SOFC module manufacturing technology1cmRealization of micro SOFC technologyTechnologyScienceUser company researchersAIST researchersDiscussion on comprehensive evaluation of cell/module(Improvements in structure and manufacturing process)Original evaluation and analysis technologies for new cell/module(Thermal behavior, electrochemical property, generation property)Cell/module prototype technology(Structural control process in clay forming, coating, firing conditions, etc.)・Proposal of the structural control technology through discovery of new phenomenon・Proposal of the new original process technologyMaterial selection and cell design(Manufacturing design such as structure, size, etc.)ACDPProposal to industry for the usages of new technologyMarket pioneering, standardsFunctional ceramic manufacturingtechnology development center◯Demand and issues1. Low temperature2. Integration3. High performance4. Mass production・・・・・・・・Hopes for realizing the new highly integrated ceramic electrochemical module and the high-performance micro SOFC (expectation of industry)Ceramic integration technologyManufacturing company researchers

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