Ceramic Support Rib Electrochemical Cells for Thin Electrolyte Stability

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Solution Overview

Problem

Solid oxide fuel cells face challenges such as redox instability, cambering during fabrication, and increased ohmic resistance due to thin electrolyte layers, which can lead to reduced performance and reliability.

Innovation Solution

Incorporating ceramic support ribs into the electrochemical cell structure, specifically within the anode and electrolyte layers, to enhance mechanical stability and reduce ohmic resistance, while allowing for thinner electrolyte layers that maintain high ionic conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If thin electrolyte layers are used to provide high ionic conductivity, then ionic conductivity is improved, but mechanical strength and reliability deteriorate

Engineering Contradiction:

Improveionic conductivityVSAvoidmechanical strength

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The patent employs composite materials by integrating ceramic support ribs (providing mechanical strength) with the ceramic electrolyte matrix (providing ionic conductivity). This composite structure allows the electrolyte to maintain thin dimensions for high ionic conductivity while the embedded ceramic ribs provide the necessary mechanical reinforcement to prevent damage during manufacturing and operation.

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If thin electrolyte layers are used to reduce ohmic resistance, then ohmic resistance is reduced, but susceptibility to damage during manufacturing and thermal cycling increases

Engineering Contradiction:

Improveohmic resistanceVSAvoidsusceptibility to damage

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The ceramic support ribs are embedded within the electrolyte layer before operation to provide preemptive mechanical reinforcement. This beforehand cushioning prevents the thin electrolyte from succumbing to mechanical stresses during manufacturing processes like stacking and assembly, as well as during operational thermal cycling, thereby reducing susceptibility to damage while maintaining the thin-layer benefits.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Strength

If ceramic support ribs are added to enhance mechanical stability, then mechanical stability is improved, but device complexity increases

Engineering Contradiction:

Improvemechanical stabilityVSAvoidstructural complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the support function with the electrolyte structure itself by embedding ceramic support ribs directly within the electrolyte layer. This integration combines the electrolyte's ionic conductivity function with the ribs' mechanical support function into a single unified component, thereby enhancing mechanical stability without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Use of energy by moving object

If thinner electrolyte layers are used to maintain high ionic conductivity, then ionic conductivity is maintained, but vulnerability during reduction-oxidation cycling increases

Engineering Contradiction:

Improveionic conductivityVSAvoidvulnerability during redox cycling

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The composite structure of ceramic ribs embedded in the ceramic electrolyte matrix provides differential reinforcement that specifically addresses vulnerability during reduction-oxidation cycling. The ceramic ribs maintain structural integrity during redox transitions, preventing crack propagation and material degradation while allowing the thin electrolyte to maintain its high ionic conductivity.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The use of ceramic support ribs improves the mechanical stability and reliability of solid oxide fuel cells, reduces ohmic resistance, and allows for thinner electrolyte layers that maintain high ionic conductivity, thereby enhancing performance and reducing manufacturing complexities.

Implementation Method 1

Incorporating ceramic support ribs into the electrochemical cell structure, specifically within the anode and electrolyte layers, to enhance mechanical stability

Methodology Applied

Scientific EffectMechanical support:

Implementation Method 2

reduces ohmic resistance, and allows for thinner electrolyte layers that maintain high ionic conductivity

Methodology Applied

Scientific EffectOhmic conduction: Conduction (electrical)

Implementation Method 3

thin electrolyte layers are desired to provide high ionic conductivity

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Data Source

PatentUS20240379983A1Electrochemical cells with support ribs and manufacturing methods thereof

Publication Date: 2024.11.14 BLOOM ENERGY CORP

AI summary

An electrochemical cell includes an electrolyte layer, an anode electrode disposed over a first surface of the electrolyte layer, a ceramic anode support laterally surrounding the anode electrode and embedded in the anode electrode, such that a recess configured to receive a seal is located above a periphery of the ceramic anode support, and a cathode disposed over a second surface of the electrolyte layer.