Application of patterned electrodes in solid oxide fuel cell

doi:10.11949/0438-1157.20241401

Abstract

Abstract:

Solid oxide fuel cells (SOFCs) have become the key to sustainable energy with their high efficiency and low emission characteristics, but the complexity of the electrode reaction mechanism restricts their performance improvement. The patterned electrode, as a new type of electrode structure, can precisely control the geometric shape of the electrode, significantly increase the length and reaction surface area of the triple phase boundary (TPB), greatly promote the electrochemical reaction rate of SOFC, and provide an ideal platform for in-depth research on reaction mechanisms. This paper reviews the application and preparation technology of patterned electrodes in the study of SOFC reaction mechanisms. Patterned electrodes realize the precise structural control of the electrode-electrolyte interface through micro-nano processing, significantly increase the length and reaction active area of TPB, thereby enhancing the electrochemical performance and long-term stability of the battery. The unique advantages of patterned electrodes in the study of SOFC reaction mechanisms are discussed in detail, including their application in the study of electrochemical reaction dynamics, material transfer mechanisms, and charge transfer coupling. Through precise control of key processes such as TPB reaction, gas diffusion, and current distribution, patterned electrodes can simplify complex porous electrode structures, providing an ideal platform for in-depth analysis of electrode reaction processes. Finally, the future development direction and challenges faced are looked forward to, especially the potential in large-scale applications and exploration of new materials.

Key words: fuel cells, electrochemistry, microscale, patterned electrodes, triple phase boundary, reaction mechanism

摘要：

固体氧化物燃料电池（SOFC）以其高效、低排放特性成为可持续能源的关键，但电极反应机理的复杂性制约着其性能提升。图形电极作为一种新兴的电极结构，因其可精确调控电极的几何形状，显著提升了三相边界（TPB）的长度和反应表面积，极大促进了SOFC电化学反应速率，并为反应机理的深入研究提供了理想平台。综述了图形电极在SOFC反应机理研究中的应用及其制备技术。图形电极通过微纳加工实现了电极-电解质界面的精确结构控制，显著增加了TPB的长度和反应活性面积，从而提升了电池的电化学性能和长期稳定性。详细探讨了图形电极在SOFC反应机理研究中的独特优势，包括其在电化学反应动力学、物质传输机制以及电荷传输耦合研究中的应用。通过对TPB反应、气体扩散、电流分布等关键过程的精确控制，图形电极能够简化复杂的多孔电极结构，提供了深入分析电极反应过程的理想平台。最后展望了其未来发展方向及面临的挑战，特别是在规模化应用和新型材料探索方面的潜力。

关键词: 燃料电池, 电化学, 微尺度, 图形电极, 三相边界, 反应机理

CLC Number:

TM 911.4

Ziheng WANG, Wenhuai LI, Wei ZHOU. Application of patterned electrodes in solid oxide fuel cell[J]. CIESC Journal, 2025, 76(7): 3153-3171.

王子恒, 李文怀, 周嵬. 图形电极在固体氧化物燃料电池中的应用[J]. 化工学报, 2025, 76(7): 3153-3171.

Figures/Tables 20

Fig.1 Schematic images of the proposed configuration of patterned anode-supported SOFC[30]

Fig.2 Schematic illustration of the laser ablating process and mechanism[32]

Fig.3 Fabrication process of the master mold: (a) SU8 spin coating; (b) pre-baking; (c) UV exposure through the photomask; (d) baking; (e) developing in PGMEA; (f) rinsing; (g) baking to cure SU8 completely; (h) master pillar pattern was obtained[34]

Fig.4 Schematic view of the microextrusion printing process[36]

Fig.5 (a) Schematic of the imprint process for layered material; (b) Two stacked sheets are pressed under heating; (c) Micro patterns are made on both surface and interface between sheets[42]

Fig.6 Schematic outline of the procedure to fabricate patterned Pt thin films using microcontact printing and selective atomic layer deposition[45]

Fig.7 Schematic representations of the cell fabrication process and the experimental setup: (a) first sputtering; (b) second sputtering; (c) Pt cathode fabrication; (d) size adjustment of the cell; (e) experimental set-up with a confocal laser microscope; (f) high temperature chamber; (g) patterned cell configuration; (h) SEM image of the patterned anode[49]

Table 1 Polarisation resistance measured at different temperatures on symmetrical cells sintered with different pressures［31］

温度/℃	极化电阻/(Ω·cm²)
温度/℃	空白无压力	空白 P=4.9 kPa	点阵28 µm 无压力	点阵28 µm P=2.45 kPa	点阵28 µm P=4.90 kPa
700	2.47	2.61	5.05	2.09	1.70
750	1.17	1.27	2.92	1.00	0.91
800	0.54	0.55	1.87	0.43	0.41
850	0.28	0.25	1.31	0.19	0.18
900	0.14	0.13	1.03	0.10	0.10
平均变化	—	-0.36%	+301%	-22.2%	-28.4%

Fig.8 Electrochemical performance of planar- and 3D-cells: Current density-voltage-power density curves for the planar-cell (a) and 3D-cell (b) at different operating temperatures; The Nyquist plots for the planar-cell (c) and 3D-cell (d) under the voltage of 0.75 V and different operating temperatures (The insets are magnified views of the low-resistance region)[52]

Fig.9 Optical microscopy images of Ni morphology on the Y2O3 porous stripe cells (The initial edge of Ni is indicated by the red dashed line, and the migrated Ni front is indicated by the yellow dashed line)[60]

Fig.10 Performance and stability under a nearly dry CH4 atmosphere: (a) Typical impedance spectra of the symmetric model Ni-YSZ (patterned Ni‖YSZ‖patterned Ni) without CELD and with 12% (atom) Ni NP-SDC CELD obtained under a 3%H2O/CH4 atmosphere at 550℃; (b) Temperature dependence of the RLF of bare Ni and 12% (atom) Ni NP-SDC under a 3%H2O/CH4 atmosphere; (c) Degradation rate of the RLF of bare Ni and 12% (atom) Ni NP-SDC under a 3% H2O/CH4 atmosphere at 650℃; (d) SEM image of the 12% (atom) Ni NP-SDC after the EIS test under 3% H2O/CH4 at 650℃ for 90 h[68]

Fig.11 Current-voltage characteristics between the anode and reference electrodes under a 5% humidified hydrogen atmosphere at 800℃: (a) Ni-YSZ by sputtering; (b) Ni-YSZ by screen printing; (c) Ni by sputtering; (d) Ni by screen printing[69]

Fig.12 (a) Combined effect of dimensionless exchange current density (iex/i0) and dimensionless potential (Fϕ0/ RT) on dimensionless average current density (iav/i0); (b) Phase map generated based on Fig.(a) for rational design and operation of patterned anode with semi-cylinder electronic conductor strips embedded in ionic conductor, in which the maximum area, the transition area and the minimum area correspond to the bottom, middle and upper areas of Fig.(a) divided by dash dot line[76]

Fig.13 Schematic of TPB (a) and H-spillover (b) pathways for H2 oxidation on the Cu10/CeO2(111) surface[86]

Fig.14 Comparison of reaction energy profiles for H2 oxidation (The black line and the purple line refer to H2 oxidation on the stoichiometric CeO2(111) and the TPB pathway of the Cu10/CeO2(111), respectively; ΔEx represents the energy difference of structures between two neighboring reaction steps, which is the energy of the xth minus the energy of the (x-1) th; ΔETS represents the energy barrier of the transition state; Rx corresponds to Fig.13)[86]

Fig.15 The schematic of H2 oxidation pathways[85]

Fig.16 SEM images of Ni film electrode cross-sections after (a) 2.5 h, (b) 5 h and (c) 20 h operations at VW-R = 0.7 V; (d) The FIB-SEM reconstruction of the electrode microstructure corresponding to Fig.(c) after 20 h operation[89]

Fig.17 Performances of (a) C1-A—C4-A and (b) C1-C—C4-C and (c) the best cases at 800℃ operating temperature[97]

Fig.18 Operando observation of RSOC cell under anodic polarization (a)—(h) (white line indicates active TPB); (i) Developments of current density and active TPB length over time [Figs.(a)—(h) are the top views at the blue points in Fig.(i)][103]

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