Beam-Reinforced Electrochemical Cell Structure for Warping Suppression
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Solution Overview
Problem
Electrochemical cells face warping issues due to the lack of sufficient rigidity in electrode layers acting as support bodies, particularly when temperature changes occur during reduction treatment or operation.
Innovation Solution
The electrochemical cell design incorporates a support body with a current collecting layer containing embedded beam portions, where the first electrode layer has overlapping and non-overlapping regions with varying Ni particle sizes and a lattice-structured beam structural body to enhance rigidity and uniform electrode activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the electrode layer functioning as a support body is increased, then the rigidity should be improved, but the electrode layer remains porous and insufficient rigidity is obtained, causing warping during temperature changes
Solution Approach 1:
The patent combines a porous electrode layer with a dense beam structural body to create a composite support structure. The beam structural body provides the necessary rigidity and dimensional stability, while the porous electrode layer maintains its electrochemical functionality. This composite approach resolves the contradiction by integrating materials with complementary properties - the dense beam structure prevents warping during temperature changes while the porous electrode layer enables gas diffusion and electrochemical reactions.
Solution Approach 2:
The support body is segmented into two distinct functional components: a porous electrode layer and a dense beam structural body. This segmentation allows each component to perform its specialized function - the electrode layer handles electrochemical reactions and gas diffusion, while the beam structure provides mechanical support and rigidity. The segmented design resolves the contradiction by separating the conflicting requirements of porosity for electrochemical function and density for structural stability.
2Object-generated harmful factors
If the electrode layer is made porous to enable gas diffusion, then gas diffusion is improved, but the rigidity decreases causing warping during temperature changes
Solution Approach 1:
The patent creates a composite structure where the porous electrode layer is integrated with a dense beam structural body. The porous electrode layer maintains high gas diffusion capability for electrochemical reactions, while the dense beam structure compensates for the low rigidity of the porous material. This composite material approach allows both gas diffusion and rigidity requirements to be satisfied simultaneously.
Solution Approach 2:
Different regions of the support body have different structural qualities - the electrode layer region is porous to facilitate gas diffusion and electrochemical reactions, while the beam structural body region is dense to provide rigidity and prevent warping. This local differentiation of structural quality allows each region to optimize its function without compromising the other, resolving the contradiction between gas diffusion and rigidity.
3Reliability
If beam portions are embedded in the current collecting layer to improve rigidity, then warping is suppressed, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the current collecting layer and beam structural body into an integrated support body structure. The beam portions are embedded within the current collecting layer, combining the electrical current collection function with the mechanical support function in a single integrated component. This merging reduces manufacturing complexity compared to assembling separate components, while still achieving the desired rigidity and warping suppression.
Data Source
AI summary
An electrochemical cell according to a first aspect of the present invention includes a support body, a first electrode layer, an electrolyte layer, and a second electrode layer. The first electrode layer is disposed on the support body. The electrolyte layer is disposed on the first electrode layer. The second electrode layer is disposed on the side opposite to the first electrode layer with respect to the electrolyte layer. The support body has a current collecting layer and a beam portion embedded in the current collecting layer. The first electrode layer includes an overlapping portion that overlaps the beam portion in a stacking direction, and a non-overlapping portion that does not overlap the beam portion in the stacking direction. The average particle size of Ni particles contained in the overlapping portion is smaller than the average particle size of Ni particles contained in the non-overlapping portion.