Porous lanthanum manganite sintered bodies and solid oxide fuel cells

Abstract: A porous sintered body is composed mainly of lanthanum manganite in which a part of lanthanum atoms at A-sites of the lanthanum manganite are substituted by atoms of a metal selected from the group consisting of alkaline earth metals and rare earth metals. The dimensional shrinkage amount of the porous sintered body in heat cycling between room temperature and 1,000°C is not more than 0.01% per one heat cycle.

Description: The present invention relates to porous lanthanum manganite sintered bodies and solid oxide fuel cells using such porous sintered bodies as materials for air electrodes. Since the solid oxide fuel cells ("SOFC"s) operate at a high temperature of around 1,000°C, an electrode reaction is extremely active, and the SOFCs need no noble metal catalyst such as platinum at all. Further, their polarization is low, and output voltage is relatively high. Thus, a energy-converting efficiency is far greater as compared with other fuel cells. In addition, since all the constituent materials are solid, the solid oxide fuel cell is stable and has a long life. In order to develop SOFCs, it is important to look for materials stable at high temperatures. As a material for the air electrodes, sintered bodies of lanthanum manganite are considered promising (Energy General Engineering, 13, 2, pp 52-68, 1990). As such lanthanum manganite sintered bodies, lanthanum manganite sintered bodies having a substantially stoichiometrical composition and lanthanum manganite sintered bodies in which a part of A-sites (lanthanum-sites) are missing (manganese-rich composition) are known. It is reported that the weight of the lanthanum manganite sintered body in which a part of the A-sites are missing decreases when the temperature is raised from room temperature to 1,000°C (J. Electrochem. Soc. 138, 5, pp 1519 to 1523, 1991). In this case, the weight of the sintered body begins to decrease from near 800°C. In particular, porous sintered bodies composed of lanthanum manganite doped with Ca or Sr at A-sites are regarded as promising materials for air electrodes involving self-supporting type air electrode tubes. However, the present inventors first found out that such porous sintered bodies have the following problems. That is, it was made clear that when the above SOFC is subjected to heating-cooling cycling between a temperature range of 900 to 1,100 in which the SOFC generates power and a temperature range of room temperature to 600°C, cracking occurs between the air electrode tube made of the above porous sintered body and other constituent materials of a cell unit, which may result in fracture of the cell unit. However, even when such a cell unit is operated at 1,000°C for a long time, the above cracking did not occur at all. Therefore, it is considered that this phenomenon is caused not by shrinkage of the above porous sintered body during the firing but by the dimensional change during the heat cycling. JP-A-1-200560 discloses various alkaline earth metal substituted lanthanum manganites, including La 0.8 Ca 0.2 Mn 0.98 Ni 0.02 O 3 Inorganic Materials, Vol. 22, No. 6, June 1986, New York, Lyubkina et al. discloses among other lanthanum manganite materials, La 0.8 Ca 0.2 Mn 0.7 Ni 0.3 O 3 . It is an object of the present invention to afford stability against the above heat cycle upon porous sintered bodies of lanthanum manganite. The present invention relates to a porous sintered body as set out in claim 1. The stability of porous sintered bodies of lanthanum manganite doped with Ca, Sr or the like at A-sites was examined by subjecting the porous sintered bodies to heating-cooling cycling between 900°C and 1,100°C and between room temperature and 600°C. As a result, it was revealed that the porous sintered bodies were shrunk in amounts of 0.01 to 0.1% per one heat cycle. In addition, it was also revealed that shrinkage due to heat cycling is not converged even after heat cycling by 100 times, and that the shrunk amount reaches as much as a few or several percentages. If an air electrode shrinks like this, cracking occurs between the air electrode and other constituent materials of the cell unit, which may result in fracture of the cell unit. Based on the above knowledge, the present inventors further continued their research, and consequently discovered that when the dimensional shrinkage caused in the porous sintered body made of lanthanum manganite by heat cycling between room temperature and 1,000°C is suppressed to not more than 0.01%, the above cracking will not occur between the air electrode and the other constituent materials. Further, the present inventors have further progressed their research on the mechanism by which dimensional shrinkage of the porous sintered body in the above heat cycling occurs. As a result, the inventors discovered that when a quotient obtained by dividing a weight of the porous sintered body at 1,000°C by that at room temperature is not less than 0.9988, the above dimensional shrinkage is conspicuously suppressed. That is, when the porous sintered body is heated from room temperature to a high temperature around 1,000°C, the weight of the porous sintered body decreases, and this weight decrease has clear correlationship to the dimensional shrinkage in the heat cycling. The mechanism of the above phenomenon is not clear at present. However, when the temperature of the sintered body is raised from room temperature to around 1,000°C, the weight of the porous sintered body slightly decreases, whereas when the sintered body is cooled to room temperature again, the weight is restored. The dimensionally shrunk amount of the porous sintered body in the above heat cycling varies somewhat depending upon the particle size of crystals constituting the sintered body, the heating rate, the cooling rate and the partial pressure of oxygen in the heat cycle. That is, it was discovered that as the crystalline particle diameter decreases, as the heating rate and/or as the cooling rate decreases, and/or as the partial pressure of oxygen in the atmosphere increases, the dimensionally shrunk amount of the porous sintered body increases. In order to decrease the dimensionally shrunk amount in the heat cycling, it is preferable to suppress the average crystalline particle diameter of the porous sintered body to not less than 3 µm. In view of the above, it is presumed that oxygen comes in or out of crystals of lanthanum manganite in a temperature range of 800°C or more in the above heat cycle, thereby causing change in weight of the porous sintered body. It is further considered that when oxygen comes in or out of the crystals, crystalline lattices are distorted, so that materials transfer between metallic atoms is promoted, and the sintering phenomenon of the porous body advances. Further, the present inventors have advanced their research, and consequently they discovered that there is a clear correlationship between an activating energy of an electric conductivity (hereinafter referred to as "activation energy") of the porous sintered body and the dimensional shrinkage in the above heat cycling. The "activation energy" of the electric conductivity of the porous sintered body means a gradient of a straight line obtained by plotting the relation between the temperature and the electric conductivity in a coordinate in which the temperature and the electric conductivity are taken along the abscissa and the ordinate, respectively. That is, the following has been made clear through the formation of Arrhenius plot diagrams over a wide range of 200°C to 1,000°C. Namely, it has been made clear that the dimensional shrinkage proceeds in the heat cycling in the case of the porous sintered body in which the activation energy in the range of 200°C to 600°C clearly differs from that in the range of 900°C to 1,000°C. More specifically, it has been clarified that if the difference between the activation energy in the range of 200°C to 600°C and the activation energy in the range of 900°C to 1,000°C is set at not more than 0.01eV, the dimensional shrinkage caused through heat cycling between room temperature and 1,000°C can be suppressed to not more than 0.01% per one heat cycle. The reason why the activating energy differs between in the range of 200°C to 600°C and in the range of 900°C to 1,000°C in this manner is not clear, but it is considered that this occurs through the distortion of the crystalline lattices of the perovskite structure when oxygen comes in or out of the crystals during the heat cycle as mentioned above. In order to suppress the difference between the activation energy in the range of 200°C to 600°C and the activation energy in the range of 900°C to 1,000°C to not more than 0.01eV, or in order to control the quotient obtained by dividing the weight of the porous sintered body at 1,000°C by that at room temperature to not less than 0.9988, it is effective that the substituting amount of calcium at the A-sites is controlled to 20% At the same time, it is effective to substitute a part of the manganese atoms at B-sites by a metal selected from aluminum, magnesium, cobalt and nickel. In this case, the substituting amount is 5% to 20%. The feature that the dimensional shrinkage in the heat cycling is not more than 0.01% per one heat cycle means the average value of dimensional changes of the porous sintered body observed in a first heat cycle to tenth heat cycling after the porous body is sintered. Presence of inevitable impurities entering lanthanum manganite during the producing steps may be allowed in the porous sintered body according to the present invention. The porous sintered body according to the present invention may be preferably used particularly as high temperature electrode materials stable against the heat cycling. As such high temperature electrode materials, air electrode materials for nuclear fusion furnaces, MHD power generators, and the like may be recited. In particular, the porous sintered bodies according to the present invention may be favorably used as air electrodes for the SOFCs. In addition, the porous sintered bodies according to the present invention are preferably used as materials for self-supporting type air electrode substrates also functioning as substrate. Such an air electrode substrate may be used as a support body of a unit cell, and constituent parts such as a solid electrolyte film, a fuel electrode film, an interconnector, and a separator are laminated on the air electrode substrate. In this case, the air electrode substrate may be shaped in a cylindrical form with opposite ends opened, a bottomed cylindrical form with one end opened and the other closed, a planar form, or other form. Among them, either of two cylindrical form is particularly preferred, because no great thermal stress is difficult to act thereupon and gas-sealing is easily effected. The porosity of the porous sintered body is preferably set at 5% to 40%. When the porous sintered body is used as a material for an air electrode in an SOFC, the porosity is more preferably 15% to 40%, most preferably 25% to 35%. When the porosity of the air electrode is set at not less than 15%, the gas-diffusing resistance can be reduced, whereas when the porosity is suppressed to not more than 40%, strength can be maintained to some extent. When the porous sintered body according to the present invention is used as the material for the air electrode in the SOFC, the coefficient of thermal expansion of the porous sintered body must be set to near those of the filmy solid electrolyte and the filmy fuel electrode. When the solid electrolyte film is formed from yttria-stabilized zirconia, it is possible to match the thermal expansion between the air electrode and the solid electrolyte film when the substituting amount of calcium at A-sites in lanthanum manganite is 20%. In Japanese patent application Laid-open No. 1-200,560, an electrode material having a composition of La 1-x A x Mn 1-y B y O 3 in a perovskite type composite oxide is disclosed, in which A is Ca or Sr, B is nickel or chronium, 0 ≦ x ≦ 0.4, and 0 < y ≦ 0.25. By using the electrode material having such a composition, bulk electric conductivity (σ) and interface electric conductivity (σ E ) are enhanced to lower electrode resistance and polarization potential. However, the problem that the porous sintered body is shrunk by heat cycling as discussed in the present invention is not recognizeed at all in this reference, and completely no motivation to make the skilled person reach the invention exists therein. Further, as is clear from Examples of Japanese patent application Laid-open No. 1-200,560, the substituting amount of calcium at the A-sites is 40% at the maximum, and therefore the above electrode material is not suitable as an air electrode for an SOFC from the standpoint of the coefficient of thermal expansion. The inventors have discovered that the dimensional shrinkage in the heat cycling is conspicuously suppressed when a part of the B-sites of lanthanum manganite constituting the porous sintered body are substituted by aluminum, cobalt, magnesium or nickel. This mechanism is not clear. It is not clear, either, why only the metal atoms specified above are effective. The substituting amount at the B-sites of lanthanum manganite by atoms of at least one metal selected from aluminum, cobalt, magnesium and nickel is not less than 5% and not more than 20%. If the substituting amount is more than 20%, the coefficient of thermal expansion increases so that incompatibility occurs between the zirconia solid electrolyte and the air electrode, and the electric conductivity greatly decrease. The porous sintered bodies according to the present invention may be generally produced as follows: As starting materials, oxides, carbonates, hydroxides, organic compounds or metal compounds of La, Ca, Mn, Al, Ni, Co and Mg are used. These starting materials are selectively employed, and given amounts thereof are measured and mixed to give desired compositional ratios. Then, a perovskite compound is synthesized from the resulting mixture at 1,000°C to 1,700°C. The synthesized product is milled to the average particle diameter (D 50 ) of 1 to 10 µm, and appropriate binder, dispersant, stabilizer, parting compound, pore-forming agent, water, etc. are mixed into the milled powder, which is molded. In this case, an appropriate molding process is selectively employed depending upon intended molding shape, microstructure, productivity, etc. The molding is fired at 1,000°C to 1,700°C to obtain a desired porous sintered body. The solid oxide fuel cell according to the present invention can be used by using such a porous sintered body as an air electrode according to a conventional process. These and other objects, features and advantages of the invention will be appreciated upon reading of the following description of the invention when taken in conjunction with the attached drawing, with the understanding that some modifications, variations and changes of the invention could be easily be made by the skilled person in the art to which the invention pertains. For a better understanding of the invention, reference is made to the attached drawings, wherein: Fig. 1 is a graph showing examples of Arrhenius plotting with respect to porous sintered bodies; Fig. 2 is a graph showing the relationship between difference ΔE in the activation energy of the electric conductivity and the dimensional shrinkage rate (%/10 cycles); Fig. 3 is a graph showing an X-ray diffracting pattern of lanthanum manganite constituting a porous sintered body in each example; and Fig. 4 is a graph showing the relationship between the substituted amount of B-sites of lanthanum manganite and the dimensional shrinkage amounts of porous sintered bodies per one cycle in the heat cycling. In the following, the present invention will be explained in more detail with reference to examples of the invention and comparative examples:- (Experiment 1) As starting materials, La 2 O 3 , Mn 3 O 4 , CaCO 3 , Al 2 O 3 and MgO powers were used. In each sample, given amounts of starting materials were measured according to a compounding recipe given in Table 1, and mixed together. The resulting mixed powder was molded under a pressure of 1 tf/cm 2 by cold isostatic pressing, thereby producing a molding. The molding was thermally treated at 1,100°C for 40 hours in air, thereby synthesizing lanthanum manganite having a composition given in Table 1. The synthesized product was milled in a ball mill, thereby preparing lanthanum manganite powder having the average particle diameter of about 3 µm. Then, polyvinyl alcohol was dispersed as a binder into the resulting lanthanum manganite powder, which was molded into a rectangular plate by uniaxially pressing. The thus obtained molding was fired at 1,250°C for 5 hours in air, thereby obtaining a sintered body. A rectangular rod having the size: a longitudinal side of 3 mm, a lateral side of 4 mm and a length of 40 mm was cut off as a experimental sample from the sintered body. (Measurements) First, the porosity of each sample was measured according to a water-replacing method. Results are shown in Table 1. Next, the weight of each sample was measured. Thereafter, each sample was heated up to 1,000°C at a heating rate of 200°C/hr in an air stream, and then kept at 1,000°C for 5 hours. Air was succeedingly blown against the sample, thereby then rapidly cooling the sample. The weight of the thus rapidly cooled sample was measured as the weight at 1,000°C. A weight ratio was calculated by dividing the weight at 1,000°C by the weight at room temperature. The "weight at room temperature" means the weight of the sample having undergone no special heat history, that is, the weight of the sample before being heated up to 1,000°C. Measured weight ratios are also given in Table 1. For each example, a similar sample was prepared separately from the sample used above for the measurement of the weight, and was heated up to 600°C at a heating rate of 200°C/hr in air. Then, the sample was subjected to heat cycling at ten times between 600°C and 1,000°C at a heating/cooling rate of 200°C/hr, finally being cooled down to room temperature. In this case, in each heat cycle, the sample was kept at each of 600°C and 1,000°C for 30 minutes. Thereafter, the dimension of each sample was measured by using a micrometer, and a dimensional shrinkage rate of the sample was calculated between before and after the above heat cycling. Measurement results are shown in Table 1. Sample No. Composition Porosity (%) Weight ratio (1000°C/ room temp.) Dimensional shrinkage rate (%/10 cycles) 1-1 La 0.8 Ca 0.2 MnO 3 30.6 0.9985 0.43 1-2 La 0.7 Ca 0.3 MnO 3 29.1 0.9997 0.00 1-3 La 0.8 Ca 0.2 Mn 0.95 Al 0.05 O 3 28.6 0.9988 0.03 1-4 La 0.8 Ca 0.2 Mn 0.95 Mg 0.05 O 3 28.4 0.9989 0.06 As is clear from Table 1, when a value (weight ratio) obtained by dividing the weight of the porous sintered body at 1,000°C by that at room temperature is not less than 0.9988 (Samples 1-2 through 1-4), the average value of dimensional shrinkage amounts caused by heat cycling at ten times in the initial stage after the firing is not more than 0.01% per one heat cycle. This value was 0.043% in Sample 1-1. Further, with respect to Sample 1-1 in Table 1, a dimensional change was measured with a thermal expansion meter by heating the sample from room temperature to 1,000°C and cooling it again. As a result, it was found out that the dimensionally shrunk phenomenon occurred in a temperature range of 900°C to 800°C during when the porous body was being cooled. Therefore, it is presumed that oxygen atoms are absorbed and metallic atoms transfer in this temperature range. Further, the results in the heat cycling over 600°C to 1,000°C are identical with those in the heat cycling over room temperature to 1,000°C. Furthermore, Sample 1-1 was kept at 1,000°C in air for 10 hours, and cooled to room temperature. Then, a dimensional change rate between before and after the heating was measured to be 0.03% shrinkage. On the other hand, it is seen from Table 1 that Sample 1-1 exhibited a dimensional shrinkage rate of 0.043% per one heat cycle in the case of heat cycling at ten times after the firing. Therefore, the above shrinkage of 0.03% substantially corresponds to the dimensional shrunk amount per one heat cycle. From this result, it can be said that the dimensional shrinkage of 0.03% occurred not during keeping the sample at 1,000°C but during the cooling step from 1,000°C to room temperature. In other words, the shrinkage phenomenon of the porous sintered body in the above heat cycling occurs according to a mechanism quite different from that by which the sintering proceeds when the porous sintered body is kept at a high temperature. (Experiment 2) As starting materials, La 2 O 3 , Mn 3 O 4 , CaCO 3 , MgO, NiO, CoO, and SrCO 3 powders were used. In each sample, given amounts of starting materials were measured according to a compounding recipe shown in Table 2, and mixed together. Then, experiment were conducted in the same manner as in Experiment 1. Results are shown in Table 2. Sample No. Composition Porosity (%) Weight ratio (1000°C/ room temp.) Dimensional shrinkage rate (%/10 cycles) Example 1-10 La 0.9 Sr 0.1 MnO 3 36.9 0.9982 0.12 Example 1-11 La 0.75 Ca 0.25 MnO 3 39.0 0.9990 0.10 Example 1-12 La 0.725 Ca 0.275 MnO 3 37.5 0.9997 0.03 Example 1-13 La 0.675 Ca 0.325 MnO 3 24.9 1.000 0.00 Example 1-14 La 0.8 Ca 0.2 Mn 0.95 Ni 0.05 O 3 24.3 0.9999 0.07 Example 1-15 La 0.8 Ca 0.2 Mn 0.9 Ni 0.1 O 3 31.7 0.9999 0.02 Example 1-16 La 0.8 Ca 0.2 Mn 0.95 Co 0.05 O 3 29.5 0.9998 0.07 Example 1-17 La 0.8 Ca 0.2 Mn 0.9 Mg 0.1 O 3 30.7 0.9999 0.01 As is seen from Example 1-10, with respect to La 0.9 Sr 0.1 MnO 3 which has been ordinary used as a material for air electrodes, it was confirmed that shrinkage in the heat cycling was observed and the above-mentioned weight ratio was less than 0.9988. In each of Examples 1-11 through 1-17, the dimensional shrinkage rate was not more than 0.01% per one heat cycle, and the weight ratio measured was not less than 0.9988 but not more than 1.0000. (Experiment 3) As starting materials, La 2 O 3 , Mn 3 O 4 , CaCO 3 , SrCO 3 , NiO, MgO and CoO powers were used. In each sample, given amounts of starting materials were measured according to a compounding recipe given in Table 3 or 4, and mixed together. The resulting mixed powder was molded under a pressure of 1 tf/cm 2 by cold isostatic pressing, thereby producing a molding. The resulting molding was thermally treated at 1,550°C for 5 hours in air, thereby synthesizing lanthanum manganite having a composition given in Table 3 or 4. The synthesized product was milled in a ball mill, thereby preparing lanthanum manganite powder having the average particle diameter of about 4 to about 6 µm. Then, polyvinyl alcohol was dispersed as a binder into the lanthanum manganite powder, which was molded into a rectangular plate by uniaxially pressing. The resulting molding was fired at 1,400°C to 1,600°C for 4 hours in air, thereby obtaining a sintered body. A rectangular rod having the size: a longitudinal side of 3 mm, a lateral side of 4 mm and a length of 40 mm was cut off as an experimental sample from the sintered body. First, the porosity of each sample was measured according to a water-replacing method. Results are shown in Table 3 and 4. Next, each sample was heated up to 600°C at a heating rate of 200°C/hr in air, which was then subjected to heat cycling at ten times between 600°C and 1,000°C at heating/cooling rate of 200°C/h, and finally cooled down to room temperature. At that time, in each heating cycle, the sample was kept at each of 600°C and 1,000°C for 3 minutes. Thereafter, the dimension of each sample was measured by using a micrometer, and the dimensional shrinkage rate between before and after the heat cycling was calculated. Measurement results are shown in Tables 3 and 4. With respect to each of porous sintered bodies having respective lanthanum manganite compositions, electric conductivity at each temperature was measured by a DC four-terminal process, and activating energies in a range of 200°C to 600°C and in a range of 900°C to 1,000°C and a difference Δ between these activating energies were calculated. Results are shown in Tables 3 and 4. In order to calculate the activation energy, an Arrhenius plot diagram was prepared as shown Table 1., That is, Fig. 1 shows the Arrhenius plot diagram with respect to the composition of La 0.9 Sr 0.1 MnO 3 and the composition of La 0.7 Ca 0.3 MnO 3 . In Fig. 1, the abscissa and the ordinate denote 1000/T(K -1 ) or T(°C) and σT(S/cm·K), respectively. σ is an electric conductivity. The activation energy was calculated from this Arrhenius plot diagram. As is seen from Fig. 1, a gradient in the range of 200°C to 600°C greatly differs from that in the range of 900°C to 1,000°C in the case of La 0.9 Sr 0.1 MnO 3 composition. More specifically, as shown in Table 2, ΔE is as much as 0.039eV. On the other hand, in the case of the composition of La 0.7 Ca 0.3 MnO 3 , ΔE between the gradient in the range of 200°C to 600°C and that in the range of 900°C to 1,000°C is smaller. Although only two examples are shown in Fig. 1, with respect to the other compositions given in Tables 3 and 4, activation energies in a range of 200°C to 600°C and in a range of 900°C to 1,000°C and a difference ΔE between these activation energies were calculated. In Fig. 2 is plotted the relationship between ΔE and the dimensional shrinkage rate (% per ten cycles) with respect to each sample. As is seen from the above results, the dimensional shrinkage rate is not more than 0.01% per one heat cycle by suppressing ΔE to a range of 0.01 to -0.01 eV. However, if ΔE is more than 0.01 eV or less than -0.01 eV, the dimensional shrinkage rate exceeds 0.01% per one heat cycle. But, no clear regularity is observed in either one of these areas. As mentioned above, since the dimensional shrinkage caused in the porous sintered body made of lanthanum manganite by the heat cycling is suppressed, no cracking occurs between the porous sintered body and the other constituent materials even when a structure involving the porous sintered body and these constituent materials is subjected to the heat cycling. (Experiment 4) As starting materials, La 2 O 3 , Mn 3 O 4 , CaCO 3 , Al 2 O 3 , CoO, MgO and NiO powers were used. In each sample, given amounts of starting materials were measured according to a compounding recipe given in Table 5, 6 or 7, and mixed together. A sintered body was obtained from the resulting mixed powder in the same manner as described in Experiment 1 in connection with the first aspect of the present invention, except that in Experiment 4, the average particle diameter of lanthanum manganite powder obtained by the ball mill was about 3 µm to about 6 µm. A rectangular rod having a longitudinal side of 3 mm, a lateral side of 4 mm and a length of 40 mm was cut off from the sintered body as an experimental sample. (Measurement) First, with respect to each sample, the porosity of the sample was measured by the water-replacing process. Results are shown in Tables 5 to 7. Further, each of Samples 2-1 through 2-5 given in Table 5 was milled again in a crucible, which was subjected to an X-ray refraction measurement by a powder process. Measurement results are shown Fig. 3. Indication of Samples 2-1 through 2-5 given to respective curves in Fig. 3 correspond to those in Table 5. As is seen from Fig. 3, the refraction pattern of each of Samples 2-2 through 2-5 as Examples of the second aspect of the present invention is substantially the same as that of Sample 2-1 as Comparative Example, and exhibits a single phase. As is judged from these X-ray refraction patterns, nickel, cobalt, magnesium, or aluminum is certainly solid solved into crystals of lanthanum manganite in Samples 2-2 through 2-5. Next, each example was heated up to 600°C at a heating rate of 200°C/hr in air, and then subjected to heat cycling at ten times between 600°C and 1,000°C at a heating/cooling rate of 200°C/hr, finally being cooled down to room temperature. In this case, in each heat cycle, the sample was kept at each of 600°C and 1,000°C for 30 minutes. Thereafter, the dimension of each sample was measured by using a micrometer, and a dimensional shrinkage rate of the sample was calculated between before and after the above heat cycle. These measurement results are shown in Tables 5, 6 and 7. Sample No. Composition Porosity (%) Dimensional shrinkage rate (%/10 cycles) 2-1 La 0.8 Ca 0.2 MnO 3 30.6 0.43 2-2 La 0.8 Ca 0.2 Mn 0.95 Ni 0.05 O 3 39.0 0.05 2-3 La 0.8 Ca 0.2 Mn 0.95 Co 0.05 O 3 28.9 0.09 2-4 La 0.8 Ca 0.2 Mn 0.95 Mg 0.05 O 3 28.4 0.06 2-5 La 0.8 Ca 0.2 Mn 0.95 Al 0.05 O 3 28.6 0.03 Sample No. Composition Composition Porosity (%) Dimensional shrinkage rate (%/10 cycles) 2-6 La 0.8 Ca 0.2 Mn 0.9999 Ni 0.0001 O 3 32.4 0.28 2-7 La 0.8 Ca 0.2 Mn 0.9999 Co 0.0001 O 3 30.9 0.22 2-8 La 0.8 Ca 0.2 Mn 0.9999 Mg 0.0001 O 3 29.3 0.25 2-9 La 0.8 Ca 0.2 Mn 0.9999 Al 0.0001 O 3 30.4 0.16 Sample No. Composition Porosity (%) Dimensional shrinkage rate (%/10 cycles) 2-10 La 0.8 Ca 0.2 Mn 0.90 Ni 0.10 O 3 31.8 0.02 2-11 La 0.8 Ca 0.2 Mn 0.90 Co 0.10 O 3 28.7 0.00 2-12 La 0.8 Ca 0.2 Mn 0.90 Mg 0.10 O 3 30.8 0.01 2-13 La 0.8 Ca 0.2 Mn 0.90 Al 0.10 O 3 27.3 0.09 2-14 La 0.8 Ca 0.2 Mn 0.85 Ni 0.15 O 3 29.8 0.00 2-15 La 0.8 Ca 0.2 Mn 0.85 Co 0.15 O 3 34.2 0.01 2-16 La 0.8 Ca 0.2 Mn 0.85 Mg 0.15 O 3 31.7 0.00 2-17 La 0.8 Ca 0.2 Mn 0.85 Al 0.15 O 3 27.6 0.02 2-18 La 0.8 Ca 0.2 Mn 0.80 Ni 0.20 O 3 28.4 0.00 2-19 La 0.8 Ca 0.2 Mn 0.80 Co 0.20 O 3 32.9 0.00 2-20 La 0.8 Ca 0.2 Mn 0.80 Mg 0.20 O 3 34.1 0.01 2-21 La 0.8 Ca 0.2 Mn 0.80 Al 0.20 O 3 27.7 0.02 In each of Samples 2-1 through 2-5 in Table 5, 20% of lanthanum atoms at the A-sites were substituted by calcium. Further, in each of Samples 2-2 through 2-5, 5% of manganese atoms at the B-sites are substituted by nickel, cobalt, magnesium, or aluminum. In each of Samples 2-2 through 2-5 as Examples of the present invention, the average dimensional shrinkage rate in the heat cycling at ten times in the initial stage after the sintering is not more than 0.01% per one heat cycle, whereas this average dimensional shrinkage rate is as much as 0.043% per one heat cycle in sample 1-1. Further, Sample 2-1 in Table 5 was heated from room temperature to 1,000°C, and then cooled. Thereafter, a dimensional change was measured by using a thermal expansion meter. As a result, it was found out that the dimensional shrunk phenomenon occurred in a temperature range of 900°C to 800° during when the temperature is decreased. Therefore, it is presumed that absorption of oxygen and transfer of metal atoms occur in this temperature range. Further, the results in the heat cycling over the range of 600°C to 1,000°C are the same as those over room temperature and 1,000°C. Furthermore, Sample 2-1 was kept at 1,000°C in air for 10 hours, and cooled down to room temperature. Then, the dimensional change was measured to be 0.03% shrinkage between before and after the heating. On the other hand, it is seen from Table 5 that the dimensional shrinkage rate in the heat cycling at ten times after the sintering was 0.043% per one heat cycle. Therefore, the shrinkage of 0.03% substantially corresponds to the dimensional shrinkage rate per one heat cycle. It can be said from the above result that the dimensional shrinkage of 0.03% occurred not during when the sample was kept at 1,000°C for 10 hours but during when the sample was cooled from 1,000°C to room temperature. In other words, the shrinkage phenomenon that the porous sintered body is shrunk during the heat cycling occurs based on a mechanism quite different from that by which the sintering proceeds when the porous sintered body is kept at a high temperature. Table 6 gives Samples in which 0.01% of manganese-sites are occupied by nickel, cobalt, magnesium or aluminum. Table 7 shows Samples in which 10%, 15% or 20% of manganese-sites are substituted by nickel, cobalt, magnesium or aluminum. In a graph of Fig. 4, results in Tables 5 through 7 are plotted in a coordinate in which an abscissa and an ordinate are taken as the substituted amount (%) of the above-recited metal atoms at the B-sites and the shrinkage amount (%) per on heat cycle, respectively. As is seen from Tables 5, 6 and 7 and in Fig. 4, although attained effects slightly differ depending upon the kinds of the substituting elements, the shrinkage in the heat cycling is suppressed by increasing the substituting amount thereof. (Experiment 5) Among samples shown in Tables 5 through 7, Samples given in Table 8 were selected, and their electric conductivity at 1,000°C was measured. The electric conductivity at 1,000°C is a characteristic required as the air electrode for the SOFC. The above measurement was effected at 1,000°C in air by a DC four-terminal process. Results are shown in Table 8. In order to remove an influence upon the electric conductivity due to difference in porosity, measurement data given in Table 8 were obtained by correcting actual data through calculation to correspond to those at the porosity of 30%. Sample No. Composition Conductivity (S/cm) 2-6 La 0.8 Ca 0.2 Mn 0.9999 Ni 0.0001 O 3 102 2-7 La 0.8 Ca 0.2 Mn 0.9999 Co 0.0001 O 3 98 2-3 La 0.8 Ca 0.2 Mn 0.95 Co 0.05 O 3 90 2-15 La 0.8 Ca 0.2 Mn 0.85 Co 0.15 O 3 56 2-8 La 0.8 Ca 0.2 Mn 0.9999 Mg 0.0001 O 3 92 2-4 La 0.8 Ca 0.2 Mn 0.95 Mg 0.05 O 3 74 2-16 La 0.8 Ca 0.2 Mn 0.85 Mg 0.15 O 3 49 As is seen from Table 8, there is a tendency that as the substituted amount of the B-sites increases, the electric conductivity decreases. In particular, when the substituted amount exceeds 15%, the electric conductivity decreases to about a half of that in the case when none of the B-sites are substituted. Such a tendency is the same with respect to cases where the substituting atoms are nickel or aluminum. The above cause is considered as follows. That is, since the electrically conductive mechanism in lanthanum manganite is based on a hopping conduction of holes formed when the valency of manganese changes from 3 to 4, the content of manganese constituting conductive paths in the crystal decreases. Anyway, the substituting amount of each of the above-recited atoms at the B-sites is preferably not more than 15%, more preferably not more than 10%. Moreover, when the above-mentioned problem of the shrinkage amount in the heat cycling is considered, the substituting amount of the metallic atoms is further preferably 5% to 15%, and most preferably 5% to 10%. With respect to a composition of La 1-x A x Mn 0.95 Ni 0.05 O 3 , the relationship between the substituting amount of X and the coefficient of thermal expansion was examined. As a reference, a coefficient of thermal expansion of 8 mol% yttria-stabilized zirconia is shown. La 2 O 3 , Mn 3 O 4 , CaCO 3 , SrCO 3 and NiO were used as starting materials. In each sample, given amounts of starting materials are weighed according to a compounding recipe in Table 5, and mixed. The resulting mixed powder was molded under a pressure of 1 tf/cm 2 by cold isostatic pressing. Thus obtained molding was heated at 1,100°C in air for 40 hours, thereby synthesizing lanthanum manganite having a composition shown in Table 5. This synthesized product was milled by a ball mill, thereby obtaining powdery lanthanum manganite having the average particle diameter of about 4 to 6 µm. Then, polyvinyl alcohol was dispersed into the resulting lanthanum manganite powder as a binder, and a rectangular plate was molded from the powder by uniaxial pressing. The molding was fired at 1,200 to 1,500°C for 5 hours in air, thereby obtaining a sintered body having a porosity of 30 ± 1%. A square rod having a shape of a vertical side: 3 mm, a lateral side: 4 mm and a height: 40 mm was cut as an experimental sample from the resulting sintered body. Composition Average coefficient of thermal expansion (×10 -6 /K, 20°C∼1000°C) LaMn 0.95 Ni 0.05 O 3 12.3 La 0.95 Ca 0.05 Mn 0.95 Ni 0.05 O 3 12.1 La 0.90 Ca 0.10 Mn 0.95 Ni 0.05 O 3 11.3 La 0.85 Ca 0.15 Mn 0.95 Ni 0.05 O 3 11.0 La 0.8 Ca 0.2 Mn 0.95 Ni 0.05 O 3 10.8 La 0.75 Ca 0.25 Mn 0.95 Ni 0.05 O 3 11.1 La 0.725 Ca 0.275 Mn 0.95 Ni 0.05 O 3 11.1 La 0.7 Ca 0.3 Mn 0.95 Ni 0.05 O 3 11.2 La 0.675 Ca 0.325 Mn 0.95 Ni 0.05 O 3 11.4 La 0.65 Ca 0.35 Mn 0.95 Ni 0.05 O 3 11.5 La 0.95 Sr 0.05 Mn 0.95 Ni 0.05 O 3 11.2 La 0.90 Sr 0.10 Mn 0.95 Ni 0.05 O 3 11.0 La 0.8 Sr 0.2 Mn 0.95 Ni 0.005 O 3 11.3 La 0.7 Sr 0.3 Mn 0.95 Ni 0.05 O 3 11.8 8mol% yttria stabilized zirconia 10.5 The coefficient of thermal expansion was minimum when the substituting amount x of Ca was about 0.2, and also minimum when the substituting amount x of Sr was about 0.1. In order to obtain a cell stable for a long time period by conforming the coefficient of thermal expansion of lanthanum manganite with that of yttria-stabilized zirconia, the substituting amount x of Ca is preferably 0.1 ≦ x ≦ 0.3, whereas the substituting amount x of Sr is preferably 0.5 ≦ x ≦ 0.20. As mentioned above, since a part of manganese atoms at the B-sites of lanthanum manganite constituting the porous sintered body are substituted by atoms of at least one metal selected from the group consisting of aluminum, cobalt, magnesium and nickel, the dimensional shrinkage of the porous sintered body in the heat cycling can be suppressed.

Claims: A porous sintered body composed of lanthanum manganite of the formula La 0.8 Ca 0.2 Mn (1-y) (Al, Co, Mg, Ni) y O 3 where 0.05 ≤ y ≤ 0.2, and wherein the dimensional shrinkage of the sintered body caused by heat cyclings between room temperature and 1,000°C is not more than 0.01% per one heat cycle. The porous sintered body set forth in Claim 1, wherein the value obtained by dividing the weight of the porous sintered body at 1,000°C by that at room temperature is not less than 0.9988 but not more than 1.000. The porous sintered body set forth in Claim 1 or 2, wherein the difference in the activation energy of the electric conductivity between the values in the range of 200°C to 600°C and in the range of 900°C to 1,000°C respectively is not more than 0.01 eV. The porous sintered body set forth in any one of Claims 1 to 3, which has a porosity of not less than 5% but not more than 40%. A solid oxide fuel cell comprising an air electrode is made of the porous sintered body set forth in any one of Claims 1 to 4. The solid oxide fuel cell set forth in Claim 5, wherein said air electrode also serves as a support body. The solid oxide fuel cell set forth in Claim 6, wherein said air electrode has a cylindrical shape.

Inventors: ITO YOSHIHIRO, KAWASAKI SHINJI, MORI KAZUYO, SOMA TAKAO, TAKAHASHI TOMONORI, YOSHIOKA KATSUKI, ITO, YOSHIHIRO, KAWASAKI, SHINJI, MORI, KAZUYO, SOMA, TAKAO, TAKAHASHI, TOMONORI, YOSHIOKA, KATSUKI, ITO, YOSHIHIRO, A-106, NGK HORAGAI APT. HOUSE, KAWASAKI, SHINJI, A-305, NGK HORAGI APT. HOUSE
Applicants: NGK INSULATORS LTD, NGK INSULATORS, LTD.
Application year: 1993
Main classification: C04B35
IPC codes: H01M4, C04B35, C04B38, H01M8