Solid Oxide Fuel Cell Interlayer for Low-Resistance Boundaries
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Solution Overview
Problem
Fuel battery cells with existing designs face challenges in maintaining efficient power generation due to high electric resistance at the boundary regions between the solid electrolyte and air electrode layers, which is exacerbated by reactions between components.
Innovation Solution
Incorporating a middle layer of CeO2 containing a rare earth element other than Ce between the solid electrolyte and air electrode layers, with a specific molarity ratio of Ce and Zr at the boundary region to minimize reaction and resistance, and using a physical/chemical vapor deposition method to form the middle layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a middle layer is added between the solid electrolyte layer and air electrode layer, then the electric resistance at the boundary region is reduced, but the device complexity increases
Solution Approach 1:
A middle layer composed of CeO2 into which a rare earth element other than Ce is solid-dissolved is introduced between the solid electrolyte layer and air electrode layer. This intermediate layer acts as a buffer zone that reduces electric resistance at the boundary region by preventing direct contact and adverse reactions between the solid electrolyte and air electrode, while also improving thermal compatibility.
2Stability of the object's composition
If the middle layer is placed between the solid electrolyte layer and air electrode layer, then thermal compatibility is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The middle layer is designed with specific compositional parameters - CeO2 into which a rare earth element other than Ce is solid-dissolved - to achieve optimal thermal compatibility. By controlling the chemical composition and phase structure of the middle layer, thermal expansion coefficients are matched between layers, reducing stress and improving reliability during thermal cycling.
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 configuration reduces the electric resistance at the boundary regions, enhancing power generation efficiency by minimizing the formation of high-resistance components and maintaining thermal compatibility with the solid electrolyte and air electrode layers.
Implementation Method 1
a solid electrolyte layer containing ZrO2 into which a rare earth element is solid-dissolved
Implementation Method 2
using a physical/chemical vapor deposition method to form the middle layer
Implementation Method 3
using a physical/chemical vapor deposition method to form the middle layer
Data Source
AI summary
A cell according to the present disclosure includes: a first electrode layer; a solid electrolyte layer on the first electrode layer, the solid electrolyte layer containing Zr; a middle layer on the solid electrolyte layer, the middle layer containing CeO2 which contains Ce and a rare earth element other than Ce; a second electrode layer on the middle layer; and a boundary region between the solid electrolyte layer and the middle layer, the boundary region including a basing point at which a molarity of Ce and a molarity of Zr are equal. An average molarity of the Ce within a range from the basing point up to 3 μm toward the solid electrolyte layer is equal to or less than 10 mol % with respect to a total of Ce, Zr, and other rare earth elements, an average molarity of Zr within the range is equal to or more than 70 mol % with respect to a total of Ce, Zr, and other rare earth elements, or a molarity ratio of Ce with respect to Zr within the range is equal to or less than 0.143.