ELECTRODE HAVING COLUMNAR STRUCTURE PROVIDED WITH MULTILAYER PART

Abstract

This electrode comprises: an electrode component containing a columnar structure; and a porous collector layer that is prepared on the electrode component. The columnar structure comprises a multiple columnar sections, the lateral surfaces of which are at least partially in contact with each other. Each columnar part section is provided with a multilayer part wherein different inorganic compound layers are stacked. In addition, the columnar structure comprises two or more adjacent columnar sections, which are different from each other in the stacking direction of the multilayer part. For example, each columnar section has a width of 10 nm to 100 nm, and each inorganic compound layer has a thickness of 1 nm to 10 nm.

Claims

1. A columnar structure comprising: multiple columnar sections with lateral surfaces at least partially contacting each other, wherein each columnar section includes a multilayer part in which different inorganic compound layers are stacked on each other.

2. The columnar structure according to claim 1, wherein the inorganic compound layers are one or more types of layers including a metal oxide layer, a metal nitride layer, and a metal carbide layer.

3. The columnar structure according to claim 1, wherein the columnar sections include two or more adjacent columnar sections different from each other in a layer stacking direction of the multilayer part.

4. The columnar structure according to claim 1, wherein a width of each columnar section is 10 nm to 100 nm.

5. The columnar structure according to claim 1, wherein a thickness of each inorganic compound layer is 1 nm to 10 nm.

6. The columnar structure according to claim 1, wherein the layer stacking direction of the multilayer part is different from the height direction of each columnar section.

7. The columnar structure according to claim 1, wherein the multilayer part includes two or more types of metal oxide layers.

8. The columnar structure according to claim 7, wherein one of the two or more types of metal oxide layers is a (Ce,Gd)O.sub.2 layer, a (La,Sr)CoO.sub.3 layer, or a (La,Sr)(Co,Fe)O.sub.3 layer.

9. The columnar structure according to claim 7, wherein one of two types of metal oxide layers among the two or more types of metal oxide layers is a (Ce,Gd)O.sub.2 layer, and the other one of the two types of metal oxide layers among the two or more types of metal oxide layers is a (La,Sr)CoO.sub.3 layer or a (La,Sr)(Co,Fe)O.sub.3 layer.

10. A composite structure comprising: a polycrystalline base material; and the columnar structure according to claim 1, the columnar structure being provided on the polycrystalline base material.

11. An electrode comprising: an electrode component including the columnar structure according to claim 1; and a porous current collector layer provided on the electrode component.

12. The electrode according to claim 11, wherein the current collector layer includes multiple columnar bodies prepared on some of the columnar sections of the columnar structure and voids formed in-between the columnar bodies.

13. A method for manufacturing the composite structure according to claim 10, comprising: a step of simultaneously forming the different metal oxide layers on the polycrystalline base material by a pulsed laser deposition method.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 shows a schematic perspective view of a composite structure of the embodiment;

[0010] FIG. 2 shows a schematic perspective view of a composite structure of Example 1, a cross-sectional TEM image for the rectangle at the upper part of the schematic perspective view, and an HAADF-STEM image for the rectangle at the lower part of the schematic perspective view;

[0011] FIG. 3 shows a surface SEM image of the composite structure of Example 1;

[0012] FIG. 4 shows images of the composite structure of Example 1, (a) HAADF-STEM image, (b) Ce mapping data, (c) Fe mapping data, and (d) overlay of the Ce mapping data and the Fe mapping data;

[0013] FIG. 5 shows a cross-sectional SEM image of an electrode component of Example 2;

[0014] FIG. 6 shows a graph of a change in the electrode reaction resistance component of a cell of Example 3 over time;

[0015] FIG. 7 shows a graph of a change in the electrical conductivity of the cell of Example 3 over time; and

[0016] FIG. 8 shows a cross-sectional SEM image after the cell of Example 3 has been held for 270 hours at 700° C.

PREFERRED MODE FOR CARRYING OUT THE INVENTION

[0017] FIG. 1 schematically shows a composite structure of an embodiment of the present application. Unless otherwise provided, an upper-lower direction is, in the present application, defined with reference to the orientation of the composite structure shown in FIG. 1. Thus, e.g., a height direction of a columnar section is coincident with the upper-lower direction. The composite structure of the present embodiment includes a polycrystalline base material and a columnar structure of the embodiment of the present application provided on the polycrystalline base material. The columnar structure of the present embodiment includes multiple columnar sections with lateral surfaces which are at least partially in contact with each other. These columnar sections preferably should be in contact with each other over their entire lateral surfaces.

[0018] The columnar section includes a multilayer part in which different inorganic compound layers are stacked on each other. The inorganic compound layers are preferably one or more types of layers including a metal oxide layer, a metal nitride layer, and a metal carbide layer. Since metal oxide is used for, e.g., an electrode of an SOFC, a case where the inorganic compound layer is the metal oxide layer will be hereinafter described as an example.

[0019] The columnar structure of the present embodiment includes the multilayer parts in which different metal oxide layers are stacked on each other and has a large area of dissimilar material interfaces. Normally, in a case where two types of metal oxides form the electrode of the SOFC, an oxide ion conductor is used for one metal oxide, and an electron conductor or a mixed electron-oxide ion conductor is used for the other metal oxide. It is known that electrode activity is high at such dissimilar metal oxide interfaces. The same also applies not only to metal oxide, but also to other inorganic compounds. Thus, in a case where the columnar structure of the present embodiment is used as an electrode catalyst for, e.g., the SOFC, dissimilar material interfaces are present in high densities, and therefore, catalytic activity is high.

[0020] An electrode of the present embodiment includes an electrode component having the columnar structure of the present embodiment and a porous current collector layer provided on the electrode component. The current collector layer preferably includes multiple columnar bodies prepared on some columnar sections of the columnar structure and voids formed in-between the columnar bodies. Corresponding to the current collector layer having this structure, an effective electron supply to the electrode component can be achieved, and diffusion of oxygen or fuel essential to electrode reaction is not inhibited.

[0021] The interfaces between the dissimilar metal oxide layers exhibit a low mechanical strength along their planar direction, i.e., a low mechanical strength at the interface between the stacked layers. Thus, if the direction of such an interface is different between adjacent ones of the columnar sections, the direction in which the mechanical strength is low varies according to the columnar sections. In the columnar structure of the present embodiment, one columnar section compensates for the low mechanical strength of the other columnar section, and accordingly, the mechanical strength of the columnar structure increases. Thus, even if a thin columnar structure with reduced electrical resistance is used as an electrode catalyst for improving the performance of, e.g., the SOFC the necessary mechanical strength is obtained.

[0022] Note that in a case where an electrode catalyst having small metal oxide particles of the same type and having a large surface area is used for, e.g., the SOFC, the surface energy, i.e., the surface area, of the electrode catalyst decreases, and therefore, the metal oxide particles are easily sintered. When the metal oxide particles are sintered, the surface area further decreases, and therefore, the performance of the electrode catalyst is degraded. However, the columnar structure of the present embodiment includes the columnar sections, each of which is configured such that the different metal oxide layers are stacked on each other. Moreover, in the columnar structure of the present embodiment, a layer stacking direction is different between adjacent ones of the columnar sections. That is, the columnar structure of the present embodiment includes two or more adjacent columnar sections different from each other in the layer stacking direction.

[0023] The columnar structure of the present embodiment includes the columnar sections, each of which is configured such that the different metal oxide layers are stacked on each other. Moreover, the layer stacking direction is different between adjacent ones of the columnar sections. Thus, mass transfer at the contact interface between the columnar sections is inhibited, and the regions where the metal oxide particles of the same type exist together is small. Thus, even if the columnar structure of the present embodiment is used as the electrode catalyst of, e.g., the SOFC, sintering of the metal oxide is reduced. That is, if the columnar structure of the present embodiment is used as the electrode catalyst, the performance of the catalyst is sustained for a long period.

[0024] For improvement of the electrode catalytic activity and improvement of the material strength, the width of the columnar section is preferably 10 nm to 100 nm, and the thickness of the metal oxide layer is preferably 1 nm to 10 nm. This is because the substance forming each metal oxide layer retains such a size that it exhibits its physical properties as a crystal (substance) while a sufficient multilayer structure is formed in the columnar structure. Furthermore, this is because adjacent parts of the columnar sections, which contribute to relieving stress and catalytic activity improvement, can be sufficiently formed.

[0025] In the columnar structure of the present embodiment, the layer stacking direction of the multilayer part is different from the height direction of the columnar section. That is, the planar direction of the multilayer part and the height direction of the columnar section are not perpendicular to each other. Thus, when fuel or oxygen moves along the height direction of the columnar sections, inhibition of the movement of fuel or oxygen by layer interfaces in the multilayer structure is limited. Assuming that the planar direction of the multilayer part and the height direction of the columnar section is defined as 90° when the planar direction of the multilayer part and the height direction of the columnar section are orthogonal, the angle between the planar direction of the multilayer part and the height direction of the columnar section should preferably be between 5° and 85°.

[0026] The multilayer part may include two types of metal oxide layers as in the columnar structure of the present embodiment, or may include three or more different types of metal oxide layers as stacked layers. One of two or more types of metal oxide layers is preferably a (Ce,Gd)O.sub.2 layer, a (La,Sr)CoO.sub.3 layer, or a (La,Sr)(Co,Fe)O.sub.3 layer. Note that (Ce,Gd)O.sub.2 indicates a compound in which part of Ce of CeO.sub.2 is substituted with Gd, (La,Sr)CoO.sub.3 indicates a compound in which part of La of LaCoO.sub.3 is substituted with Sr, and (La,Sr)(Co,Fe)O.sub.3 indicates a compound in which part of La of LaCoO.sub.3 is substituted with Sr and part of Co of LaCoO.sub.3 is substituted with Fe.

[0027] For example, in a case where the multilayer part includes two types of metal oxide layers as in the columnar structure of the present embodiment, one metal oxide layer is the (Ce,Gd)O.sub.2 layer, and the other metal oxide layer is the (La,Sr)CoO.sub.3 layer or the (La,Sr)(Co,Fe)O.sub.3 layer. It is assumed that the columnar structure of the present embodiment can be used not only for the electrode catalyst but also for, e.g., a catalyst for chemical synthesis.

[0028] The columnar structure of the present embodiment including the multilayer parts, each of which is configured such that the different metal oxide layers are stacked on each other, and configured such that at least a part of the lateral surfaces of the columnar sections are in contact with each other is obtained in such a manner that the films of the different types of metal oxides are simultaneously formed on the polycrystalline base material by a PLD method. That is, the method for fabricating the composite structure of the embodiment of the present application has the step of simultaneously forming the different metal oxide layers on the polycrystalline base material by the pulsed laser deposition method.

EXAMPLES

Example 1

[0029] Using a PLD apparatus (PVD Products Inc., NanoPLD), films of (Ce,Gd)O.sub.2 (hereinafter “(Ce,Gd)O.sub.2” will be sometimes referred to as “GDC”) and (La,Sr)(Co,Fe)O.sub.3 (hereinafter, “(La,Sr)(Co,Fe)O.sub.3” will be sometimes referred to as “LSCF”) were simultaneously formed on a polycrystalline (Ce,Gd)O.sub.2 substrate. In this manner, a composite structure was produced. Note that the films were formed under such conditions in which an oxygen partial pressure is 35 mTorr, a substrate temperature is 750° C., film deposition time is 100 minutes, a distance between a target and the substrate is 75 mm, a substrate rotation speed is 10 rpm, the incident angle of laser light (Coherent Inc., Compex Pro 102F, KrF, a wavelength of 248 nm) is 60°, a laser energy is 200 mJ, and a laser repetition rate is 10 Hz. A TEM image and an HAADF-STEM image of the composite structure of the present example are shown in FIG. 2, and a surface SEM image is shown in FIG. 3.

[0030] FIG. 2 shows the cross-sectional TEM image (a scale bar is 2 nm) for the rectangle at the upper part of the schematic perspective view of the composite structure and the HAADF-STEM image (a scale bar is 10 nm) for the rectangle at the lower part of the schematic perspective view. As shown in the sectional TEM image of FIG. 2, a columnar section comprises a multilayer part in which GDC layers and LSCF layers with thicknesses of 1 nm to 5 nm are alternately stacked on each other. Moreover, as shown in the HAADF-STEM image of FIG. 2, in a columnar structure, lateral surfaces of the columnar sections are in contact with each other, and the layer stacking direction of the multilayer parts is different among these columnar sections. It is assumed that the lateral surfaces of the columnar sections are in contact with each other, the layer stacking direction of the multilayer part is different among the columnar sections, and the GDC layers the LSCF layers are alternately stacked on each other in the multilayer part resulting from the use of the polycrystalline GDC substrate. That is, in the PLD method, the deposited film is easily grown epitaxially along the orientation matching that of the substrate material.

[0031] In the present example, the films of the different types of metal oxides were simultaneously formed on the polycrystalline substrate by the PLD method. Accordingly, the different metal oxide layers simultaneously nucleated in a several-nm region and were epitaxially grown, thereby forming the columnar section. In addition, the crystal orientation of the substrate material is not constant. Thus, the growth direction was different for each metal oxide particle, resulting in a stripe-like multilayer structure with different inclinations in adjacent columnar sections. FIG. 3 shows that the composite structure of the present example includes the columnar structure having the columnar sections contacting each other at the lateral surfaces. The width of the columnar section was 20 nm to 30 nm.

[0032] An HAADF-STEM image of this composite structure is shown in (a) of FIG. 4. Ce mapping data measured in the same field of view as that of (a) of FIG. 4 is shown in (b) of FIG. 4. Fe mapping data measured in the same field of view as that of (a) of FIG. 4 is shown in (c) of FIG. 4. Data showing the overlay of the mapping data of (b) of FIG. 4 and the mapping data of (c) of FIG. 4 is shown in (d) of FIG. 4. As shown in (a) to (d) of FIG. 4, the columnar section of the composite structure of the present example included the multilayer part in which the layers containing Ce and the layers containing Fe are alternately stacked on each other.

Example 2

[0033] As in Example 1, films of GDC and LSCF were simultaneously formed on a polycrystalline (Ce,Gd)O.sub.2 substrate, and a columnar structure was produced on the substrate. Under such conditions in which an oxygen partial pressure is 100 mTorr, film deposition time is 90 minutes, a laser energy is 275 mJ, and a laser repetition rate is 20 Hz, a current collector layer of a porous layer of LSCF was, without heating the substrate, formed on the columnar structure by a PLD method, and an electrode was fabricated on a polycrystalline GDC substrate. A cross-sectional SEM image of the electrode of the present example is shown in FIG. 5.

[0034] As shown in FIG. 5, the electrode was obtained, which includes the columnar structure (in the figure, “LSCF-GDC”) made of LSCF and GDC and the LSCF nano current collector layer formed on the columnar structure and having nanosized columnar particles of LSCF. As shown in FIG. 5, the columnar structure of the present example was configured such that columnar sections with a width of 20 nm to 30 nm and a height of about 400 nm are densely formed. Moreover, the current collector layer of the present example included multiple columnar bodies with a width of 20 nm to 30 nm. These columnar bodies were prepared on some columnar sections of the columnar structure. Voids were formed in-between these columnar bodies. For efficiently utilizing the nanosized columnar structure as an electrode catalyst, as shown in this example, an electrode wherein the current collector layer has voids for gas diffusion and with columnar bodies having nanosized particles connected to the columnar structure and capable of uniform current collection across the entirety of the electrode is preferable.

Example 3

[0035] As in Example 1, films of GDC and (La,Sr)CoO.sub.3 (hereinafter “(La,Sr)CoO.sub.3” will be sometimes referred to as “LSC”) were simultaneously formed on a polycrystalline GDC substrate, and a columnar structure was produced on the substrate. Under such conditions in which an oxygen partial pressure is 100 mTorr, film deposition time is 45 minutes, a laser energy is 275 mJ, and a laser repetition rate is 20 Hz, a current collector layer of a porous layer of LSC was, without heating the substrate, formed on the columnar structure by a PLD method, and an electrode component was manufactured. Similarly, a columnar structure and a current collector layer were also formed on the back surface of the substrate, forming a symmetric cell for electrode performance test.

[0036] Using the cell of Example 3, the electrode reaction resistance (ASR) of the electrode and the ohmic resistance of the cell were calculated by the following method. First, LSC paste was applied to the current collector layer of the cell of Example 3, and a metal mesh was pressed against such paste. Next, using an electrochemical measurement apparatus (Princeton Applied Research, VersaSTAT4) including a frequency response analyzer (FRA), the impedance spectrum of the cell was measured in every predetermined time under such conditions in which a swept frequency range is 1 MHz to 0.1 Hz and an applied voltage amplitude is 10 mV.

[0037] From the obtained spectrum, the reaction resistance component and ohmic resistance component of the cell were calculated. A value obtained in such a manner in which the half value of the reaction resistance component is multiplied by the surface area of the current collector layer was taken as the ASR of the electrode component. The intersection of the obtained spectrum with the real axis of a high-frequency resistance component in a Nyquist plot was read as the ohmic resistance (R). From the thickness (L) of the polycrystalline substrate and the surface area (S) of the current collector layer, an electrical conductivity (σ) was calculated according to σ=L/R.Math.S.

[0038] FIG. 6 shows a change in the electrode reaction resistance component of the cell of the present example over time. As shown in FIG. 6, the initial ASR of the cell of the present example was a small value of about 0.021 Ω.Math.cm.sup.2. The electrode reaction resistance of the cell after a lapse of 50 hours was about 0.037 Ω.Math.cm.sup.2, which increased to about 1.5 times as high as the initial value. However, the electrode reaction resistance was stable thereafter, and was maintained low until after a lapse of about 270 hours. FIG. 7 shows a change in a of the cell of the present example over time. As shown in FIG. 7, σ, i.e., the ohmic resistance component, of the cell of the present example did not change. FIG. 8 is a cross-sectional SEM image of the cell of the present example which had been held in air for 270 hours at 700° C. As shown in FIG. 8, the cell structure having been held as described above showed little change from its cell structure before being held.

[0039] According to the present example, no great change in the electrode component structure, the electrode reaction resistance, and the ohmic resistance component was shown. As described above, the electrode of the present application includes the dense multilayer structure of the different types of metal oxides, and therefore, the catalytic activity is improved. Moreover, the electrode of the present application includes the dense multilayer structure of the different types of metal oxides, and therefore, the area of direct contact among the nanosized metal oxide particles of the same type can be decreased and sintering upon use for, e.g., the SOFC can be reduced. By suppressing sintering, the electrode of the present application can extend the performance lifetime, i.e., its performance as catalyst can be sustained for a long period.