Layered Hydrogen Electrode Structure for Carbon-Resistant Solid Oxide Cells

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Solution Overview

Problem

Solid oxide cells (SOCs) require improved reactivity of the hydrogen electrode for main reactions and increased strength to support the cell, while also preventing undesirable side reactions such as carbon deposition during CO2 electrolysis or CO2/H2O co-electrolysis.

Innovation Solution

The SOC design includes a first hydrogen electrode layer with a sintered compound of metal particles and metal oxide particles, and a second hydrogen electrode layer with composite particles of metal oxide supporting metal particles, which enhances both reactivity and structural strength. This configuration promotes the main reaction CO2→CO+1/2O2 and reduces side reactions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the hydrogen electrode uses a porous structure for gas diffusion and electrical conduction, then the reactivity and electrical conduction are improved, but the structural strength is reduced

Engineering Contradiction:

ImprovereactivityVSAvoidstructural strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The hydrogen electrode is divided into multiple layers: a first hydrogen electrode layer with high reactivity (containing metal particles and metal oxide particles) and a second hydrogen electrode layer with high strength (containing composite particles of metal oxide supporting metal particles). This segmentation allows each layer to specialize in one function, resolving the contradiction between reactivity and structural strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the hydrogen electrode are given different properties: the first layer near the electrolyte has optimized composition for catalytic activity, while the second layer has optimized composition for mechanical support. This local differentiation allows simultaneous optimization of reactivity and strength in different locations.

Inventive Principle:

Principle #3Local quality

2Productivity

If the hydrogen electrode promotes CO2 electrolysis, then the main reaction CO2→CO+1/2O2 is enhanced, but undesirable side reactions CO2→C+O2 and CO→C+1/2O2 occur causing carbon deposition

Engineering Contradiction:

Improvemain reaction rateVSAvoidcarbon deposition

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The metal oxide particles (such as CeO2, Gd-doped CeO2, or Y-stabilized ZrO2) act as oxygen storage and release materials that suppress carbon deposition by providing oxygen to gasify carbon deposits, converting the harmful carbon deposition into beneficial CO/CO2 while maintaining high main reaction rates.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The hydrogen electrode uses composite materials combining metal particles (Ni, Cu, Fe, or Co) with metal oxide particles (CeO2, Gd-doped CeO2, or Y-stabilized ZrO2). This composite structure synergistically enhances CO2 electrolysis activity while the metal oxide component suppresses carbon deposition through oxygen storage and release, resolving the contradiction between main reaction promotion and side reaction suppression.

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 enhanced hydrogen electrode reactivity and structural strength improve the efficiency of the SOC in CO2 electrolysis and CO2/H2O co-electrolysis, while minimizing carbon deposition, thus achieving higher main reaction percentages and longer cell durability.

Implementation Method 1

The characteristic of the cell is decided by the activity of the electrocatalyst and the resistance loss depending on the ohmic resistance between terminals, and the catalyst activity on the hydrogen electrode side is particularly important during the electrolytic reaction

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

For the electrolyte of the SOC, a stabilized zirconia-based or lanthanum-gallium-based oxide (LaGaO3 system) having high conductivity is generally used

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 3

The first hydrogen electrode layer has a sintered compound of metal particles and metal oxide particles

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS20250027217A1Solid oxide cell and solid oxide cell stack

Publication Date: 2025.01.23 TOSHIBA ENERGY SYST & SOLUTIONS CORP

AI summary

A solid oxide cell includes a hydrogen electrode, a solid oxide electrolyte layer, and an oxygen electrode. The hydrogen electrode includes: a first hydrogen electrode layer having a first surface and a second surface, the first surface being in contact with the oxide electrolyte layer, the second surface being opposite to the first surface; and a second hydrogen electrode layer in contact with the second surface. The first hydrogen electrode layer has a first metal particle and a first metal oxide particle. The second hydrogen electrode layer has a second metal oxide particle with a second metal particle supported with the second metal oxide particle.