Solid Oxide Cell Catalyst Zoning via ALD for Mode Switching
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Solution Overview
Problem
Existing solid oxide cells face challenges in efficiently managing catalyst usage and achieving precise thickness control due to the high cost and structural porosity of their electrodes, necessitating improved catalytic reactivity and reduced catalyst amounts.
Innovation Solution
The use of atomic layer deposition (ALD) to deposit catalyst materials in the form of particles in distinct regions of the substrate, allowing for alternating modes of operation that change the catalyst's form and location within the electrode, including alloy formation and grain boundary insertion/precipitation, thereby optimizing catalyst utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a deposition method using an aqueous solution containing a catalyst is used to deposit a catalyst in the solid oxide cell, then the catalyst can be deposited in the porous electrodes, but the amount of catalyst used increases and precise thickness control becomes difficult
Solution Approach 1:
The patent changes the deposition method from aqueous solution to atomic layer deposition (ALD), which provides precise control over catalyst thickness and amount through controlled deposition parameters, thereby resolving the contradiction between manufacturing precision and quantity of substance
Solution Approach 2:
The patent replaces the chemical deposition method (aqueous solution) with a physical vapor deposition method (ALD), enabling precise thickness control and reduced catalyst usage through atomic-level deposition control
2Reliability
If catalysts are used in solid oxide cell electrodes, then catalytic reactivity is achieved, but the high cost of catalysts requires efficient management and reduction of catalyst usage
Solution Approach 1:
The patent deposits catalyst particles in specific regions of the electrode substrate using ALD, creating local catalytic zones that maintain high reactivity while minimizing overall catalyst quantity. The catalyst is strategically placed where it is most needed rather than uniformly distributed
Solution Approach 2:
The patent uses ALD to create precise copies or replicas of catalyst structures at the atomic level, ensuring optimal catalytic activity with minimal material. The controlled deposition creates consistent, reproducible catalyst structures that maximize reactivity per unit mass
3Adaptability or versatility
If the solid oxide cell operates in alternating modes, then adaptability to different operating conditions is improved, but the catalyst form and location must be dynamically maintained
Solution Approach 1:
The patent designs the catalyst system to be dynamic, allowing the catalyst form and location to change in response to different operating modes. The ALD-deposited catalyst can transform between different states (e.g., dispersed particles vs. aggregated structures) to optimize performance in fuel cell mode versus electrolysis mode
Solution Approach 2:
The patent utilizes changes in operational parameters (temperature, pressure, gas composition) to induce controlled transformations in the catalyst structure. These parameter changes enable the catalyst to adapt its form and location dynamically while maintaining stability within each operating mode
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 approach reduces catalyst usage while enhancing catalytic reactivity and maintaining high performance in varying operating conditions, including high temperatures and humidity, by alternately switching catalyst forms and locations.
Implementation Method 1
depositing a catalyst material in the form of particles in each of the first region and the second region using atomic layer deposition (hereinafter, ALD)
Implementation Method 2
the catalyst material of the first catalyst material group is maintained in the form of an alloy with a metallic material of the first region
Implementation Method 3
the catalyst material of the second catalyst material group is inserted into a grain boundary of a material contained in the second region
Implementation Method 4
the catalyst material of the second catalyst material group is precipitated from the grain boundary of the material contained in the second region
Data Source
AI summary
A solid oxide cell comprising: a substrate comprising a first region and a second region; and a catalyst material deposited in the form of particles in each of the first region and the second region, and comprising a first catalyst material group deposited in the first region and a second catalyst material group deposited in the second region, wherein power is applied to an electrode including the substrate, based on operating in a first mode, a first form of a catalyst material of the first catalyst material group and a second form of a catalyst material of the second catalyst material group are different, and based on operating in a second mode, the first form of the first catalyst material group and a third form of a catalyst material of the second catalyst material group are different.