中文核心期刊
中国科技核心期刊
中国化学与物理电源行业协会会刊
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20 June 2026, Volume 50 Issue 6
    

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  • LI Linmin, LI Cancan, CHEN Lanhua, LI Zhizai, LI Kai, CHAI Zhifang, WANG Shuao, WANG Yaxing
    Chinese Journal of Power Sources. 2026, 50(6): 990-1013. https://doi.org/10.3969/j.issn.1002-087X.2026.06.001
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    Radiation-voltaic batteries (RVBs) recently have been regarded as highly promising batteries for micro energy owing to their high output stability, small size, high energy density and long life. Since its first discovery in 1913, the RVBs have evolved into a variety of forms, and the corresponding device structure and performance studied more extensively. Notably, the semiconductors play a key role in converting decaying particles into electrical signals and are the core component of the entire RVBs. The physical properties of the semiconductor affect the depth of penetration of decay particles in the semiconductor and the separation of electron-hole pairs. Besides, the design of the transducer unit is limited by the operational feasibility of the semiconductors. Therefore, understanding the relationship between the semiconductors and decay sources and transducer unit is essential for the development of high-quality RVBs. The review starts with a description of the role of each component in the RVBs and its effect on the device performance. Subsequently, the latest advances in the different types of RVBs are systematically reviewed by using semiconductors as the main line of discussion. Finally, we highlight the current problems and challenges that still exist in RVBs and propose feasible ideas for conquering them.
  • WEI Junfeng, SONG Qingzhi, JIANG Bingxu, YU Zhihang, ZHANG Chao
    Chinese Journal of Power Sources. 2026, 50(6): 1014-1023. https://doi.org/10.3969/j.issn.1002-087X.2026.06.002
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    Radioisotope batteries can achieve long-term stable power supply by utilizing the energy continuously released during the decay of radioactive nuclides, showing important application prospects in fields such as deep-space exploration, implantable medical devices, extreme-environment sensing, and microelectronic systems. In recent years, with the rapid development of wide-bandgap semiconductor epitaxial growth, radiation transport simulation, and micro-nano device fabrication technologies, materials including silicon carbide, gallium nitride, and diamond have become promising candidates for high-performance radiovoltaic devices owing to their excellent thermal stability and strong radiation resistance. Meanwhile, perovskite-based materials and radiophotovoltaic coupling strategies have provided new ideas for material and structural design of novel nuclear micro-power sources. This paper systematically reviews the basic working principles of wide-bandgap radiovoltaic radioisotope batteries, the selection principles of radioactive sources, typical wide-bandgap material systems, and representative device structures. Future research trends are discussed focusing on the innovation of material systems, optimization of energy spectrum matching, and optimal structural design.
  • LIU Huan, JIA Nannan, WEI Xubo, ZHOU Jian, KE Bingzheng, KANG Ning, YU Xiang, YANG Linqing, LI Xingjie
    Chinese Journal of Power Sources. 2026, 50(6): 1024-1032. https://doi.org/10.3969/j.issn.1002-087X.2026.06.003
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    Radioisotope batteries possess irreplaceable application value in extreme environment power supply due to their long-term stability and strong environmental adaptability. This paper systematically reviews the current research status, technical routes and latest progress of 85Kr isotope batteries both domestically and internationally. It is found that the current Kr radioisotope battery is still in the stage of theoretical verification and prototype development. The core bottlenecks lie in the contradiction between gaseous source encapsulation and structural lightweight, low energy conversion efficiency, and imperfect life cycle safety management system. In the future, with the growth of the demand for nuclear waste resource utilization and the innovation of materials and encapsulation technologies, 85Kr isotope batteries are expected to achieve engineering applications in micro-power civilian scenarios, providing theoretical references and direction guidance for related research and promotion.
  • LIU Youhong, LI Tailin, CHEN Haodong, ZHANG Yingzeng, XIANG Qingpei
    Chinese Journal of Power Sources. 2026, 50(6): 1033-1045. https://doi.org/10.3969/j.issn.1002-087X.2026.06.004
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    With lunar exploration intensifying in both China and the United States, long-duration surface presence, in-situ scientific investigation, and lunar infrastructure development are creating an urgent demand for continuous, hundred-watt-class, and long-lifetime power systems. This study investigates the lunar application feasibility of the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) under complex lunar conditions including prolonged night, large temperature swings, radiation-dominated heat transfer, and dust deposition. Based on an established full-scale three-dimensional finite-element thermoelectric model of the MMRTG, a three-dimensional finite-element lunar thermal environment model is further developed, explicitly accounting for direct solar irradiation, lunar surface albedo, lunar thermal radiation, deep-space sink, and dust coverage. The results show that dust coverage significantly deteriorates the thermal safety margin, and the most adverse thermal condition does not occur exactly at geometric noon. Latitude significantly affects thermal safety: the equatorial region presents the most severe thermal risk, while mid-to-high latitude and polar regions show substantially improved thermal margins. Under the most adverse equatorial case, a standard MMRTG cannot simultaneously satisfy thermal safety and output requirements within its normal operating voltage range. These results provide support for scheme evaluation and thermal safety design of lunar radioisotope power systems.
  • WU Yingjie, YU Yonglong, ZHANG Lixin, ZHU Yingxi, YANG Chunhui
    Chinese Journal of Power Sources. 2026, 50(6): 1046-1051. https://doi.org/10.3969/j.issn.1002-087X.2026.06.005
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    Radioisotope thermoelectric generators (RTGs) are static energy conversion devices that directly convert the decay heat of radioactive isotopes into electrical energy using thermoelectric materials. They offer advantages such as a simple structure, stable and reliable operation, no moving parts, and light weight, leading to their wide application in deep space exploration and aerospace fields. A heat transfer model of an RTG was established, and a numerical simulation analysis of its internal temperature field was conducted. The simulation results show good agreement with experimental data, validating the accuracy and reliability of the developed simulation model. The temperatures of all internal components were found to be significantly lower than the material tolerance thresholds, satisfying the thermal safety requirements under actual operating conditions and effectively ensuring stable operation within a safe temperature range. The analysis results, combining the thermal expansion behavior of the heat source with the temperature field distribution characteristics, provide data support for optimizing the structural design of RTGs.
  • YUAN Chengyang, HOU Xufeng, GAO Ben
    Chinese Journal of Power Sources. 2026, 50(6): 1052-1056. https://doi.org/10.3969/j.issn.1002-087X.2026.06.006
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    Radioisotope Thermoelectric Generator (RTG) is an ideal power source for deep space, deep sea, and other scenarios with extremely low temperature, weak or no light. The performance and lifetime of thermoelectric devices directly determine mission success. Accurate evaluation under simulated conditions is fundamental for RTG technology. To address low efficiency, unstable control, and inconvenient maintenance of existing test apparatus, a novel system is developed. It features a split vacuum chamber for three‑station parallel testing, a pneumatic preload for precise clamping force, and independently adjustable hot/cold side temperatures achieving a 450 ℃ maximum temperature difference. Experiments show vacuum better than 10-3 Pa, temperature accuracy ±1 ℃, pressure accuracy ±1% F.S., good multi‑zone consistency, and a repeatability coefficient of variation below 2%. Parallel testing improves efficiency by over 60% compared with conventional single‑device testing, and continuous operation (120 h) verifies long‑term stability.
  • ZHANG Kang, SONG Qingfeng, WU Zihua, BAI Shengqiang
    Chinese Journal of Power Sources. 2026, 50(6): 1057-1065. https://doi.org/10.3969/j.issn.1002-087X.2026.06.007
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    In response to the lack of highly reliable interfacial diffusion barrier layers for n-type Bi2Te3-based thermoelectric materials, an orthogonal experimental design is employed to investigate the effects of Fe (FeSO4·7 H2O) concentration, P (NaH2PO2·H2O) concentration, and current density on the composition and microstructure of the interfacial diffusion barrier layers Ni-Fe-P. The results of XRD and SEM indicate that the combined contents of Fe and P in the Ni-Fe-P influence its microstructure. The results of isothermal aging experiment demonstrate that Ni-Fe-P with a crystalline structure exhibit high interfacial bonding strength and low room-temperature interfacial resistivity. A crystalline Ni-Fe-P with a composition of 79.3% Ni-17.8% Fe-2.9% P (weight fraction) maintained an interfacial bonding strength above 16 MPa and an interfacial resistivity below 8 μΩ·cm² after aging at 200 °C for 144 h, proving to be a suitable diffusion barrier layer for n-type Bi2Te3-based thermoelectric material.
  • LI Xuan, HOU Xufeng
    Chinese Journal of Power Sources. 2026, 50(6): 1066-1070. https://doi.org/10.3969/j.issn.1002-087X.2026.06.008
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    The amount of centimetre-sized thermoelectric elements used in radioisotope thermo-electric generator are many for deep space exploration. The mass production technique is necessary. Hectogram-scale N-type skutterudites were fabricated by induction melting- annealing- sintering method. The ZT was 1.35 at 600 ℃. Laying powder auxiliary device was used for large sample to avoid uneven interface between skutterudite and barrier layer. The sample was fabricated by integrated hot-pressing. The contact resistivity was small and the bonding strength was high. The breakage occurred near skutterudite when the sample was applied shear force.
  • LI Tailin, ZHANG Yingzeng, CHEN Haodong, LIU Youhong, XIANG Qingpei
    Chinese Journal of Power Sources. 2026, 50(6): 1071-1083. https://doi.org/10.3969/j.issn.1002-087X.2026.06.009
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    The Radioisotope Power System (RPS) is one of the indispensable energy systems for future deep space exploration missions. There are significant differences in the geometric dimensions, structural design, and power ranges of in-service RPSs, leading to low modeling efficiency and difficulties in modeling. Therefore, a digital mock-up modeling and simulation technology for RPS is proposed. Its functions and research methodology were summarized and synthesized. Then, the process, methods, and instructions for thermoelectric coupling analysis and radiation dose analysis in reverse engineering of in-service RPS were explained in detail. This technology were applied to the reverse engineering of typical RPSs such as the GPHS-RTG, “Chang'e-4” RTG, and MMRTG. Important results were obtained, including the thermoelectric performance, application schemes, and radiation dose distributions of these RPSs under deep-space and planetary-surface environments. The findings demonstrate the feasibility and general applicability of the technology, which can provide technical support for future deep-space exploration missions.
  • TIAN Jibin, SUN Shuze, ZHANG An, XU Faduo, LI Shenghua, LUO Xinkui
    Chinese Journal of Power Sources. 2026, 50(6): 1084-1091. https://doi.org/10.3969/j.issn.1002-087X.2026.06.010
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    The free-piston Stirling generator is composed of a Stirling engine and a linear motor. It describes a single-gap motional magnetic structure linear motor. During operation, the electromotor components oscillate back and forth under the drive of the piston. During operation, the motor's moving component oscillates under the drive of the piston. Finite element simulation analysis of the electromagnetic performance of the linear motor was conducted. By comprehensively evaluating parameters such as no-load output characteristics, and load output characteristics, the magnetic circuit structure parameters were determined. Through the analysis of the dynamic characteristics of the linear motor, the resonant operating characteristics of the linear motor were clarified. Based on the optimized structural parameters, a prototype was designed and manufactured for experimental testing, verifying the motor's operational performance.
  • LIU Huan, ZHOU Jian, JIA Nannan, KE Bingzheng, KANG Ning
    Chinese Journal of Power Sources. 2026, 50(6): 1092-1101. https://doi.org/10.3969/j.issn.1002-087X.2026.06.011
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    A principle prototype of an mW-level 90Sr radioisotope thermoelectric generator (RTG) was constructed with a customized thermoelectric conversion module. The output performance of the RTG was tested under series and parallel connections of multilayer thermoelectric devices. The results indicate that for the study of multi-layer thermoelectric devices in series and parallel configurations, the conversion efficiency reaches its maximum when three layers of thermoelectric conversion devices are connected in series, at which point energy utilization is optimized. The measured maximum conversion efficiency is 1.29%, while the simulated maximum conversion efficiency is 1.54%. The findings are of great significance for the subsequent design of thermoelectric conversion modules and the structural improvement of isotope batteries.
  • LI Jiangchuan, YU Yonglong, MU Zhou, SUN Shudong, MAO Xiaomei, MA Hongjun, YU Zhenhua
    Chinese Journal of Power Sources. 2026, 50(6): 1102-1109. https://doi.org/10.3969/j.issn.1002-087X.2026.06.012
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    The small isotope thermoelectric battery is a promising new type of battery, but it suffers from defects such as high internal resistance and weak output power. Conventional buck-boost circuits fail to realize efficient energy harvesting and optimal utilization of isotopic materials. This study develops an energy harvesting system based on the BQ25570 micropower management IC for small-scale isotope thermoelectric batteries, incorporating maximum power point tracking functionality to achieve high-efficiency collection of output energy from isotope batteries, with a peak energy conversion efficiency reaching 87.3%. The system integrates energy harvesting, main control, and wireless charging modules, significantly expanding the application scope of isotope batteries.
  • WU Weiming, LI Xin, SANG Yurou
    Chinese Journal of Power Sources. 2026, 50(6): 1110-1118. https://doi.org/10.3969/j.issn.1002-087X.2026.06.013
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    Addressing the nonlinear degradation characteristics of space radioisotope thermoelectric generator (RTG) during long-term service, a Lifetime prediction method based on the inverse Gaussian process (IGP) was proposed. First, the degradation mechanisms of the RTG were analyzed, identifying two distinct stages: rapid degradation and stable degradation. Subsequently, a two-stage IGP degradation model incorporating random effects was constructed, and an adaptive algorithm based on differential features was introduced to accurately identify the degradation turning point. The analytical distribution of the RUL was derived based on the first passage time (FPT) theory, and the expectation-maximization (EM) algorithm was employed for model parameter estimation. Finally, the proposed method was validated using on-orbit monitoring data from the Pioneer and Cassini RTGs. Experimental results demonstrate that the method effectively predicts the physical degradation trends of RTG. Specifically, in long-term mission predictions, the two-stage model maintains the final relative error within 0.5%, yielding a prediction error significantly lower than that of traditional single-stage model methods.
  • ZHAI Fanshun, LI Xin, LUO Hongyi, TANG Xian, HE Hu, WU Weiming, NIU Changlei
    Chinese Journal of Power Sources. 2026, 50(6): 1119-1126. https://doi.org/10.3969/j.issn.1002-087X.2026.06.014
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    In deep space exploration missions, the supply of energy presents a critical challenge. Due to the significant attenuation of sunlight intensity in the deep-space environment, the application of solar cells is limited. Consequently, radioisotope heat sources have emerged as a commonly used energy source. To improve the utilization efficiency of radioisotopes, this paper proposes a power supply system for deep-space probes that combines a radioisotope with a Stirling engine, aiming to investigate the overall efficiency optimization of the radioisotope heat source-Stirling engine system. Initially, three-dimensional models of the radioisotope heat source and the heat collector were created using 3D modeling software, and assembled to form the Stirling engine hot end. Thermal analysis was subsequently performed using finite element analysis software to ensure temperature matching between the thermally coupled components. Following this, a thermodynamic model of a free-piston Stirling engine was established based on the one-dimensional Stirling optimization software, Sage. The study systematically explored the influence of key parameters on system efficiency, including charge pressure, hot-end temperature, cold-end temperature, as well as the number and diameter of heater channels. The results indicate that increasing the charge pressure, raising the hot-end temperature, lowering the cold-end temperature, increasing the number of heater channels, and reducing their diameter contribute to enhancing both the efficiency and output power of the Stirling engine. These findings provide guidance for the design of efficient and reliable radioisotope Stirling engines.
  • MENG Zhankun, ZHAO Yicong, GAO Peng, WANG He, LIU Yufei, DING Jian, ZHANG Lili
    Chinese Journal of Power Sources. 2026, 50(6): 1127-1134. https://doi.org/10.3969/j.issn.1002-087X.2026.06.015
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    To address the long-endurance and low-maintenance demand of Internet of Things (IoT) nodes and the inherent limitations of traditional chemical batteries, this paper designs a thermoelectric generation-based self-powered sensor tag. It integrates full-link functional modules, realizes accurate temperature and humidity monitoring, and transmits data via Bluetooth Low Energy (BLE) protocol. Tests show it has a static power of 4.87 μW and dynamic power of 0.033 5 mW. Under 1.8 ℃ human body temperature difference, it outputs 0.039 6 mW power with 96.8% endurance improvement, realizing self-sustained operation and providing a green autonomous power supply scheme for IoT scenarios.
  • YI Weiliang, ZHANG Chuangye, CHEN Liang, LIU Zhaoping
    Chinese Journal of Power Sources. 2026, 50(6): 1135-1144. https://doi.org/10.3969/j.issn.1002-087X.2026.06.016
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    Lithium metal anodes paired with lithium-rich manganese-based(LLOs) cathodes are ideal for high-energy-density batteries exceeding 600 Wh/kg. To address high reactivity and high voltage characteristics, a molecular synergistic regulation strategy was employed, a fully fluorinated localized high-concentration electrolyte(DFD) composed of 2,2-difluoroethyl acetate(DFEA), fluoroethylene carbonate(FEC), fluoromethyl hexafluoroisopropyl ether(D3), and lithium bis(fluorosulfonyl) imide (LiFSI). Theoretical and experimental results demonstrate that weakly solvating and oxidation-resistant DFEA promoted FSI incorporation into the primary solvation sheath of Li+, forming contact ion pairs(CIPs) and aggregates(AGGs). FEC was preferentially reduced to build a LiF-rich and dense solid electrolyte interphase(SEI), D3 reduces viscosity and improves wettability. The DFD electrolyte exhibits a wide electrochemical window, enabling Li||LLO cells cycled stably for 150 cycles at 4.6 V. A 12.8 Ah pouch cell delivering 608 Wh/kg retains 64.5% capacity after 100 cycles under high loading, lean electrolyte, and low N/P ratio, highlighting significant application potential.
  • WEI Haitao, ZHU Weihua, REN Xueyan
    Chinese Journal of Power Sources. 2026, 50(6): 1145-1152. https://doi.org/10.3969/j.issn.1002-087X.2026.06.017
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    This study investigated the impact of tris(trimethylsilyl) phosphate (TMSP) as an electrolyte additive on the high-voltage cycling performance of LiMn0.6Fe0.4PO4-LiNi0.8Co0.1Mn0.1O2(LMFP-NCM)/graphite full cells. Through a combination of theoretical calculations, electrochemical characterization, scanning electron microscopy (SEM), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS). It was found that under high voltage (4.2 V), TMSP preferentially oxidizes and decomposes on the surface of the LMFP-NCM cathode. This process generates a cathode electrolyte interphase (CEI) film rich in inorganic salts. Analyses indicate that this robust and uniform CEI film effectively reduces the polarization voltage during cycles, isolates the direct contact between the electrolyte and the cathode, thereby suppressing continuous electrolyte decomposition, mitigates the dissolution of transition metal ions, and stabilizes the cathode crystal structure. Consequently, the LMFP-NCM/graphite full cell maintains excellent electrochemical performance even under the 4.2 V. Electrochemical performance tests demonstrated that cells with 1% TMSP additive exhibit outstanding cycling stability and rate capability under the 4.2 V. Specifically, the capacity retention rate exceeded 94% after 500 cycles, and the discharge capacity of 127.51 mAh/g was achieved at 3 C rate. These results are significantly superior to those of the baseline electrolyte system without TMSP.
  • ZHANG Hong, WANG Yumin, FU Rong, LI Xiang, ZHANG Lijuan
    Chinese Journal of Power Sources. 2026, 50(6): 1153-1162. https://doi.org/10.3969/j.issn.1002-087X.2026.06.018
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    The strategically critical metals—lithium, nickel, and cobalt—in ternary cathode materials for lithium-ion batteries are geochemically scarce and economically costly. As vast volumes of these batteries enter their decommissioning phase, sustainable repair has emerged as a pivotal industrial focus. Unlike conventional repair processes, direct regeneration technology eliminates energy-intensive pyrometallurgical smelting and complex hydrometallurgical leaching, restoring spent lithium-ion batteries to electrochemical performance levels comparable to pristine materials through targeted interventions. As a pivotal technique for direct regeneration, molten salt methods fundamentally enable concurrent structural reconstruction and lithium replenishment of degraded cathodes through specifically designed molten salt systems under optimized conditions. This study implements a ternary LiOH-LiNO₃-KCl molten salt system to achieve direct regeneration of degraded NCM613 cathode materials. Experimental results demonstrate that the microstructure of the repaired material was restored, as evidenced by the elimination of microcracks and the reconstruction of the surface rock-salt phase into a layered phase, and its electrochemical performance was significantly enhanced. The regenerated cathode achieves a 91.7% capacity recovery rate at 1 C, demonstrating 86.6% capacity retention after 200 cycles at 1 C-surpassing industry-standard new cathodes by 30.0 percentage points (56.6% vs. 86.6%). Remarkably, it maintains 81.6% retention after 200 cycles at high rate 5 C, outperforming commercial counterparts by 52.7 percentage points (28.9% vs. 81.6%). These results conclusively validate the industrial viability of the molten salt regeneration protocol for spent NCM613 cathodes.
  • TIAN Yu, WANG Gang
    Chinese Journal of Power Sources. 2026, 50(6): 1163-1166. https://doi.org/10.3969/j.issn.1002-087X.2026.06.019
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    By compositing chromium-based metal oxide materials with vanadium pentoxide to form a novel composite system for lithium primary batteries, this work aims to achieve high power and enhanced safety after battery grouping. Chromium-based metal oxide materials and vanadium pentoxide were composited at a ratio of 7∶3 and fabricated into soft-packaged lithium primary batteries. The initial minimum voltage during 2 C discharge was increased by 0.18 V, significantly alleviating voltage lag at high-rate discharge in the early stage. In the final stage of discharge(<2 V), V2O5 forms a gentle discharge plateau in the low-voltage region, creating a low-voltage buffer segment for the single cell. This prevents over-discharge caused by capacity imbalance and improves the safety of the system.
  • CHENG Zhe, ZHOU Yingke, TIAN Xiaohui
    Chinese Journal of Power Sources. 2026, 50(6): 1167-1173. https://doi.org/10.3969/j.issn.1002-087X.2026.06.020
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    Fluorinated carbon (CF) is one of the most promising high energy density cathode materials for lithium primary batteries. However, its strong covalent C-F bonds result in a wide bandgap and low electronic conductivity, while sluggish ion diffusion kinetics severely limit the rate capability. To address these bottlenecks in conductivity and ion transport, this work employs an elemental doping strategy to tune the electronic structure and lithium migration pathways in CF, aiming to enhance its overall electrochemical performance. Based on first-principles calculations, the effects of B, N, P, and S doping on the structural stability, electronic properties, lithium adsorption, and diffusion in CF are systematically investigated. In summary, 2% N-doped CF achieves an optimal balance among structural stability, moderate adsorption strength, and excellent ion diffusion capability, offering a theoretical basis for designing high-rate Li-CF cathode materials.
  • ZHANG Molei, SUN Yaoning, MENG Acong, WEI Ning, CHEN Si
    Chinese Journal of Power Sources. 2026, 50(6): 1174-1184. https://doi.org/10.3969/j.issn.1002-087X.2026.06.021
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    The development of solid oxide fuel cells (SOFCs) toward intermediate- to low-temperature operation is essential for their commercialization. Samarium/gadolinium co-doped ceria (SGDC) is a promising electrolyte for such SOFCs due to its high ionic conductivity; however, its high sintering temperature limits practical application. Ce0.9-xGd0.05Sm0.05CuxO1.95(x=0~0.02) electrolytes were synthesized by the sol-gel method, and the effects of Cu doping on sintering behavior and electrochemical performance were investigated. The results show that 1% Cu doping effectively reduces the densification sintering temperature of SGDC to 1 050 ℃, achieving a relative density above 95%. The Ce0.89Gd0.05Sm0.05Cu0.01O1.95 sample exhibits a high total ionic conductivity of 0.024 3 S/cm at 600 ℃ and the lowest activation energy, corresponding to an improvement of about 38% compared with undoped SGDC. These results indicate that Cu doping is an effective sintering aid for enhancing SGDC electrolytes prepared at low temperatures.
  • WU Wei, ZHANG Yan, LV Lin, FU Chenggang, DENG Xin, WANG Jingjing, HONG Yudan, AN Chao
    Chinese Journal of Power Sources. 2026, 50(6): 1185-1191. https://doi.org/10.3969/j.issn.1002-087X.2026.06.022
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    Tunnel-oxidation passivated contact (TOPCon) solar modules are prone to degradation through corrosion when exposed to water vapor and acidic environments. This study systematically analyzed the impact of backsheets, encapsulation films, and metallization pastes on the damp-heat (DH) resistance of glass-backsheet modules. The relative influence of these factors on DH durability was ranked as follows: cell paste>backsheet>encapsulation film. Notably, glass-backsheet modules with Al composite backsheets exhibiting ultra-low water vapor transmission rates demonstrated DH durability comparable to glass-glass modules. Lower acid concentrations in encapsulation films correlate with reduced corrosion. Bifacial acetic acid-resistant film encapsulation effectively suppresses acetic acid-moisture synergistic corrosion, thereby enhancing DH durability. Microscopic and elemental analyses indicate that, compared to lead/boron-rich formulations, the enrichment of metal modifiers such as bismuth, barium, zinc, and hafnium in cell pastes significantly improves interface stability. Furthermore, module-level damp heat testing further confirms the outstanding reliability of optimized low-aluminum silver paste: the findings indicate that high-water-barrier backsheets, acid-resistant solar cells, and encapsulants with lower acid concentrations critically influence the damp-heat resistance of glass-backsheet TOPCon modules. They also underscore that optimizing cell pastes is essential for achieving durable metallization layers and module reliability.