Solid Oxide Cell Oxygen Electrode With Triple-Peak Pore Structure

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Solution Overview

Problem

Existing fuel cells experience a decrease in power output over time due to material deterioration at high operation temperatures, which cannot be sufficiently suppressed by controlling the specific surface area and pore size of the oxygen electrode layer alone.

Innovation Solution

A fuel cell design with a second electrode layer having a pore size distribution with at least three peaks, where small pores enhance air intake, middle-sized pores prevent pore decrease, and large pores adjust porosity, maintaining efficient power generation over long periods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the specific surface area of grains and pore size in the oxygen electrode layer are controlled, then power generation efficiency is improved, but the decrease in output power over time cannot be sufficiently suppressed

Engineering Contradiction:

Improvepower generation efficiencyVSAvoidoutput power stability over time

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention changes the pore size distribution parameter from a single or dual peak to a multi-peak distribution with at least three distinct peaks. This parameter change creates different pore size zones (small, medium, large) that work synergistically to maintain both high power generation efficiency and stable output power over extended operation periods, resolving the contradiction between initial efficiency and long-term reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The oxygen electrode layer is designed as a composite structure with pores of multiple size ranges distributed throughout. This composite pore structure combines the advantages of different pore sizes: small pores for high surface area and reaction sites, medium pores for structural stability, and large pores for gas transport, achieving both high efficiency and long-term reliability

Inventive Principle:

Principle #40Composite materials

2Productivity

If the cell is operated at high temperature (1000°C to 1050°C) for long time, then power generation efficiency is maintained, but material deterioration occurs causing power output to decrease

Engineering Contradiction:

Improvepower generation efficiencyVSAvoidoperational lifespan

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The multi-peak pore distribution is designed in advance to cushion against the harmful effects of high-temperature operation. The medium and large pores provide structural buffer zones that prevent rapid degradation, while the small pores maintain reaction efficiency. This beforehand cushioning structure allows the cell to operate at high temperatures (1000°C to 1050°C) for extended periods without significant power output decrease

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

Different regions of the oxygen electrode layer are assigned different pore size qualities to address local requirements: small pores in reaction-active regions for high efficiency, medium pores in structural regions for stability, and large pores in transport regions for gas flow. This local quality differentiation allows the material to withstand high-temperature operation while maintaining performance

Inventive Principle:

Principle #3Local quality

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 multi-peak pore distribution in the second electrode layer effectively suppresses the decrease in output power, maintaining high power generation efficiency and reliability of the fuel cell over extended operation.

Implementation Method 1

a solid oxide electrolyte layer extending over a main surface of the fuel electrode layer, a first intermediate layer extending over a main surface of the oxygen electrode layer

Methodology Applied

Scientific EffectIon conduction: Conduction (electrical)

Implementation Method 2

the second electrode layer contains a plurality of pores, and the distribution of the pores observed at a section of the second electrode layer has at least three peaks

Methodology Applied

Scientific EffectGas diffusion: Diffusion

Data Source

PatentUS11909051B2Cell, cell stack unit, electrochemical module, and electrochemical apparatus

Publication Date: 2024.02.20 KYOCERA CORP

AI summary

[Object] To provide a cell, a cell stack, an electrochemical module and an electrochemical apparatus that can suppress decrease in output power.[Solution] A cell includes a solid oxide electrolyte layer 9, a first electrode layer 8 on one of the main surfaces of the electrolyte layer 9, and an second electrode layer 10 on the other. The second electrode layer 10 contains a plurality of pores, and the pore size distribution observed at a section of the second electrode layer has at least three peaks (a first peak p1, a second peak p2 and a third peak p3). This structure leads to a cell, a cell stack, an electrochemical module and an electrochemical apparatus that can suppress decrease in output power.