Porous Electrode Catalyst Layer for CO2 Diffusion and Current Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing carbon dioxide electrolysis cells face challenges in achieving high partial current density and efficient gas diffusion due to the lack of large pores in the catalyst layer, which impedes uniform carbon dioxide supply and reaction efficiency.
Innovation Solution
Incorporating a porous catalyst layer with pore diameters ranging from 5 to 200 μm and a volume of 3.0 to 10 mL/g, balanced to enhance gas diffusion and electroconductivity, using carbonous catalyst carriers, metallic catalysts, and an ion-conductive material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cathode catalyst layer is made porous to increase CO2 supply, then gas diffusion is improved, but the partial current density of carbon compound decreases
Solution Approach 1:
The catalyst layer is designed with spatially differentiated pore structures: large pores (5-200 μm) are distributed throughout to enable efficient CO2 gas diffusion, while the overall layer maintains appropriate porosity (3.0-10 mL/g) to balance gas supply with electrochemical reaction efficiency. This local optimization of pore quality resolves the contradiction between gas diffusion and current density.
Solution Approach 2:
The invention optimizes the pore diameter distribution parameter, introducing large pores of 5-200 μm into the catalyst layer structure. This parameter change enables improved CO2 gas diffusion while maintaining acceptable porosity levels (3.0-10 mL/g), thereby increasing partial current density without sacrificing gas supply efficiency.
2Productivity
If the catalyst layer porosity is increased to improve gas diffusion, then CO2 supply is enhanced, but electroconductivity deteriorates
Solution Approach 1:
The catalyst layer employs a dual-pore structure where large pores (5-200 μm) are strategically distributed to facilitate gas diffusion, while the overall porosity is controlled at 3.0-10 mL/g to maintain electroconductivity. The carbonous catalyst carriers provide conductive pathways that remain effective even with the introduced large pores, resolving the contradiction between gas diffusion and electroconductivity.
Solution Approach 2:
The catalyst layer is constructed as a composite material system combining carbonous catalyst carriers with metallic catalysts and ion-conductive materials. This composite structure maintains electroconductivity while accommodating the large pore structure needed for gas diffusion, as the carbonous carriers and metallic catalysts provide conductive networks independent of the pore distribution.
3Productivity
If large pores are introduced to the catalyst layer to enhance gas diffusion, then CO2 supply is improved, but the catalyst layer structure becomes more complex
Solution Approach 1:
Rather than creating a completely new pore structure, the invention modifies the pore diameter distribution parameter of the existing catalyst layer by introducing large pores of 5-200 μm. This parameter change achieves improved gas diffusion while maintaining the overall catalyst layer structure and requiring minimal structural modification, thus avoiding excessive complexity.
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 optimized pore structure significantly enhances the partial current density and catalytic efficiency of carbon dioxide reduction, allowing for efficient production of carbon compounds.
Implementation Method 1
pores serving as gas-transport paths in the catalyst layer have been variously studied in developments of PEFCs
Implementation Method 2
an ion-conductive material
Implementation Method 3
a metallic catalyst loaded on said carriers
Implementation Method 4
an electrochemical reaction apparatus comprising, for example, a cathode which reduces carbon dioxide
Data Source
AI summary
The embodiments provide an electrode catalyst layer for an electrolysis cell, and also an electrolysis cell and a carbon dioxide electrolysis apparatus comprising that layer. The catalyst layer has a controlled porous structure, and can realize a high partial current density. The catalyst layer of the embodiment comprises carbonous catalyst carriers, a metallic catalyst loaded on the carriers, and an ion-conductive material. The catalyst layer contains pores of 5 to 200 μm diameters, and the pores have a volume per weight of the catalyst layer in the range of 3.0 to 10 mL/g in total.