Three-Dimensionally Micro-Architected Protonic Ceramic Fuel Cells
Authors: Lee Channyung , Kim Jinhyeon , Choi Mansoo , Shin Hyunho 
Published: May 2020

The solid oxide fuel cells (SOFCs) have been considered as important alternative energy technology, due to a variety of advantages, such as their high energy conversion efficiency, free noxious emissions, and direct use of a wide range of hydrocarbon fuels. Especially, the reverse operation of SOFCs, which is called solid oxide electrolysis cell (SOEC), is currently one of the most promising technologies for fuel production. However, their high-temperature operation (typically >700°C) leads to the rapid degradation of electrodes and necessitates a high balance of plant costs. To make SOFCs more economically feasible and viable, further reduction of operating temperature is inevitable. To this end, the utilization of proton-conducting oxides, which exhibit relatively high ionic conductivity with the low activation energy (<0.5eV), enables protonic ceramic fuel cells (PCFCs) to operate at an intermediate temperature regime (IT, 400–600°C), where the aforementioned benefits of SOFCs can also be accomplished. Moreover, PCFCs prevents the dilution of the fuel during the operation and provides higher resistance of carbon cocking on hydrocarbon fuels.

Although the PCFCs have distinct advantages against traditional oxygen conducting SOFCs, the lower-than-predicted performance of PCFCs and scalability issues caused the considerable skepticism of the successful applicability of PCFCs. Most importantly, unlike traditional SOFCs, the development of mixed oxide ion and electron conductors (MIECs) for oxygen reduction reaction (ORR) at the cathode of PCFCs has shown marginal success due to the absence of protonic conduction and still needs to be improved. At the cathode, the ORR is limited to triple phase boundary (TPB), where the electrolyte, gas, and cathode mutually contact, and its geometrical enhancement at the interface area between cathode and electrolyte layers is crucial to improve the performance of PCFCs. Therefore, electrode-electrolyte interface architecting via micro-patterning is one of the most attractive approaches, since it significantly expands the catalytic active sites of TPB near the interface, where ORR preferentially occur. Moreover, this architecting approach also facilitates the use of currently viable state-of-art cathode materials of SOFCs; Lanthanum Strontium Cobalt Ferrite (LSCF), Barium Strontium Cobalt Ferrite (BSCF). Therefore, patterns with a high aspect ratio, which maximize the interface area, are required for significant enhancement of electrochemical performance.

Here, for the first time, we describe a three-dimensionally micro-architecting process for anode-supported PCFCs, demonstrating dramatic performance enhancement from the expanded interface area between cathode and electrolyte. The various patterns with high ratios were exactly transferred from the original PUA (polyurethane acrylate) molds to the thin and dense protonic conducting electrolyte layer. The patterns maintained the same aspect ratios during the sintering process and finally increased the interface area of more than 30%. The morphology of the patterned surface was characterized by scanning electron microscope (SEM) and atomic force microscopy (AFM). The AC electrochemical impedance spectroscopy was utilized to examine the electrochemical performances of patterned cells. Our unique patterning method opens the new pathway for further performance enhancement of PCFCs.

Figure 1