Fuel Gas Electrode and Method for Producing a Fuel Gas Electrode

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This patent discloses a fuel gas electrode suitable for applications like solid oxide fuel cells (SOFC) and electrolysis cells. The core innovation is the incorporation of copper oxide (CuO) into the electrode layer containing nickel oxide (NiO) and an ion conductor, so that the copper oxide is present as a gradient in the electrode. The manufacturing process involves adding a copper-containing layer onto the nickel-based electrode layer, followed by high-temperature treatment, allowing copper to diffuse into the nickel. This approach enhances resistance to poisoning by sulfur and hydrocarbons, improves redox stability, and simplifies manufacturing compared to traditional infiltration techniques.

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• Solid oxide fuel cells (SOFCs) for clean energy generation from fuels like hydrogen or methane
• High-temperature electrolysis cells (SOECs) for efficient hydrogen production
• Intermediate-temperature fuel cells (IT-SOFC) for distributed power generation
• Fuel gas sensors in harsh environments with sulfur or hydrocarbon contaminants
• Industrial applications requiring long-life fuel gas electrodes
• Portable or stationary power sources using fuel cells with exposure to impure fuels

BenefitsContent extracted from patent full text and abstract with AI.

• Improved resistance to poisoning from sulfur compounds and hydrocarbons, increasing electrode lifetime
• Enhanced redox stability due to copper addition, reducing degradation from oxidation-reduction cycles
• Cost reduction by partially substituting nickel with less expensive copper
• Simplified manufacturing process avoiding multiple infiltration and calcination steps
• Compatibility with existing electrode fabrication techniques and materials
• Gradient distribution of copper oxide provides targeted performance improvement at the electrode/electrolyte interface
• Broader applicability across temperature ranges (medium and high-temperature fuel cell/electrolysis operation)

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Patent Abstract

The invention relates to a substrate-supported fuel gas electrode, comprising an electrode substrate and an electrode layer arranged thereon, the electrode layer comprising an ion conductor and nickel oxide. The invention is characterized in that at least the electrode layer additionally comprises copper oxide with a content of at least 2 % by weight, and in that the copper oxide is present as a gradient in the electrode layer. In the method according to the invention for producing a fuel gas electrode a copper-containing layer is applied to the nickel-comprising electrode layer arranged on the electrode carrier. The layer composite is then subjected to heat treatment at more than 900°C, wherein copper diffuses at least partially from the copper-containing layer into the nickel of the electrode layer. The copper-containing layer used may comprise elemental copper, monovalent or divalent copper oxide, and also additionally an ion conductor having a mass fraction of at most 95 % by weight, preferably between 5 and 50 % by weight.