Fuel Cell Adaptation Layer for Gas-Tight Electrolyte
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The construction of high-temperature fuel cells is complicated by the need for a gas-tight electrolyte on metallic porous substrates, which have large surface roughness and pore sizes, making it difficult to achieve a thin, gas-tight electrolyte layer, and the reduced process conditions for anode production result in coarser roughness, hindering the application of a gas-tight electrolyte.
Innovation Solution
An adaptation layer with a smaller mean pore size than the electrode layer is introduced between the electrode and the electrolyte, allowing for the application of a thin, gas-tight electrolyte layer using PVD or sol-gel processes, and the adaptation layer is designed to have a specific micro-roughness and thickness to ensure proper electrolyte application and reduce internal cell resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic porous carrier substrate with large pore size and high surface roughness is used, then mechanical stability and thermal adaptation are improved, but the application of a thin gas-tight electrolyte layer becomes difficult
Solution Approach 1:
An adaptation layer is introduced as an intermediary between the metallic porous carrier substrate and the electrolyte layer. This adaptation layer has a pore structure with mean pore size smaller than that of the substrate, creating a transition zone that enables gas-tight electrolyte application while maintaining the mechanical stability benefits of the metallic substrate
Solution Approach 2:
The adaptation layer creates a local change in pore size distribution, with the region adjacent to the electrolyte having smaller mean pore size compared to the bulk substrate. This local modification of the pore structure allows the electrolyte to form a gas-tight layer without compromising the overall mechanical stability provided by the metallic substrate
2Power
If the electrolyte layer is made thinner to reduce internal cell resistance, then power yield increases, but gas-tightness becomes difficult to achieve on rough surfaces
Solution Approach 1:
The adaptation layer serves as a mediator that enables thin electrolyte layers to achieve gas-tightness. By providing a surface with smaller mean pore size, it allows the electrolyte to form a continuous, gas-tight barrier even at reduced thickness, thereby enabling both high power yield and reliable gas-tightness
Solution Approach 2:
The adaptation layer changes the surface parameter (mean pore size) in the region where the electrolyte is applied. This parameter modification allows the electrolyte to achieve gas-tightness at thinner dimensions than would be possible on the original rough substrate surface
3Ease of manufacture
If reduced process conditions are used for anode production to lower manufacturing costs, then manufacturing simplicity improves, but surface roughness increases making electrolyte application difficult
Solution Approach 1:
The adaptation layer acts as a mediator that compensates for the increased surface roughness resulting from reduced process conditions in anode production. It provides a suitable surface morphology for electrolyte application without requiring complex high-precision manufacturing processes
Solution Approach 2:
The anode structure is segmented into multiple functional layers: the metallic porous carrier substrate providing mechanical stability, and the adaptation layer providing the suitable surface for electrolyte application. This segmentation allows each layer to be optimized independently for its specific function
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
This solution enables the application of a single thin electrolyte layer, reducing internal cell resistance and increasing power yield, while simplifying the fuel cell construction and ensuring long-term stability by preventing metallic interdiffusions and reactions.
Implementation Method 1
allowing for the application of a thin, gas-tight electrolyte layer using PVD or sol-gel processes
Implementation Method 2
allowing for the application of a thin, gas-tight electrolyte layer using PVD or sol-gel processes
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an assembly comprising an electrode, an electrolyte (E) and a carrier substrate. The assembly is suited for a fuel cell. An adaption layer (AD) for adapting the electrolyte (E) to the electrode is arranged between the electrode and the electrolyte (E), wherein the mean pore size of the adaption layer (AD) is smaller than the mean pore size of the electrode.