Perimeter electrolyte reinforcement layer composition for solid oxide fuel cell electrolytes

• US 10,347,930 B2
• Filed: 03/22/2016
• Issued: 07/09/2019
• Est. Priority Date: 03/24/2015
• Status: Active Grant

• Current Assignee: Bloom Energy Corporation
• Original Assignee: Bloom Energy Corporation
• Inventors: El Batawi, Emad, Touma, Mina, Gasda, Michael, Palety, Vijay
• Primary Examiner(s): Fraser, Stewart A
• Application Number:
  US15/077,030
• Publication Number:
  US 20160285122A1
• Time in Patent Office: 1,204 Days
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 2300/0074 Ion conductive at high temperature
• CPC Class Codes: H01M 2300/0077 based on zirconium oxide
• CPC Class Codes: H01M 2300/0094 in the form of layered products, e.g. coatings
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 4/881 Electrolytic membranes
• CPC Class Codes: H01M 4/8828 Coating with slurry or ink
• CPC Class Codes: H01M 4/8889 Cosintering or cofiring of a catalytic active layer with another type of layer
• CPC Class Codes: H01M 8/006 Flat
• CPC Class Codes: H01M 8/0282 Inorganic material
• CPC Class Codes: H01M 8/0286 Processes for forming seals
• CPC Class Codes: H01M 8/1246 the electrolyte consisting of oxides
• CPC Class Codes: H01M 8/1253 the electrolyte containing zirconium oxide
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Solid oxide fuel cells and methods for fabricating solid oxide fuel cells include an electrolyte reinforcement (ERI) layer. An ink composition including a ceramic material and a sintering aid, such as a metal or metal oxide material, is applied to select portions of a solid oxide electrolyte and sintered to form an ERI layer. The ERI layer may improve the strength and durability of the electrolyte and may facilitate bonding to a high-temperature seal.

Claims

1. A solid oxide fuel cell, comprising:

a solid oxide electrolyte;

a cathode electrode over a first major surface of the solid oxide electrolyte;

an anode electrode over a second major surface of the solid oxide electrolyte opposite the first major surface; and

an electrolyte reinforcement layer over a portion of at least one of the first major surface and the second major surface of the solid oxide electrolyte, the electrolyte reinforcement layer comprising a ceramic material and at least one of a metal and a metal oxide sintering aid;

wherein the electrolyte reinforcement layer comprises yttria-stabilized zirconia (YSZ), alumina and the sintering aid selected from Ti, Mo, W, Mg, Hf, Rh, Co, Ni, Fe, Mn, Cu or Sn metal or an oxide of Ti, Mo, W, Mg, Hf, Rh, Co, Ni, Fe, Mn, Cu or Sn.

2. The solid oxide fuel cell of claim 1, wherein the electrolyte reinforcement layer is located over the first major surfaces of the electrolyte and a second electrolyte reinforcement layer is located over the second major surface of the electrolyte.

3. The solid oxide fuel cell of claim 1, wherein the sintering aid comprises cobalt (II) oxide, or copper (II) oxide and tin (II) oxide.

4. The solid oxide fuel cell of claim 1, wherein the electrolyte reinforcement layer extends around a periphery of at least one of the first major surface and the second major surface of the solid oxide electrolyte.

5. The solid oxide fuel cell of claim 1, wherein the solid oxide electrolyte includes a fuel inlet riser opening and a fuel outlet riser opening, and the electrolyte reinforcement layer extends at least partially around a perimeter of the fuel inlet riser opening and at least partially around a perimeter of the fuel outlet riser opening on at least one of the first major surface and the second major surface of the electrolyte.

6. The solid oxide fuel cell of claim 1, further comprising a glass or glass-ceramic seal on the electrolyte reinforcement layer, wherein the electrolyte reinforcement layer comprises at least one component of the glass or glass-ceramic seal and wherein the at least one component of the glass or glass-ceramic seal comprises silicon.

7. The solid oxide fuel cell of claim 1, wherein the electrolyte reinforcement layer increases a bend strength of the solid oxide fuel cell compared to an identical fuel cell that does not include the electrolyte reinforcement layer;

wherein the electrolyte reinforcement layer comprises 50-75 wt % of stabilized zirconia, 20-45 wt % of alumina, and 1-5 wt % of the sintering aid; and

wherein the electrolyte reinforcement layer is located around the periphery of the electrolyte and at least partially around perimeters of fuel inlet and fuel outlet riser openings in the electrolyte.

8. The solid oxide fuel cell of claim 1, wherein the electrolyte reinforcement layer is located around an entire perimeter of the electrolyte and around a perimeter of fuel inlet and fuel outlet riser openings in the electrolyte, and wherein the electrolyte reinforcement layer is about 6-10 mm wide.

9. A solid oxide fuel cell, comprising:

a solid oxide electrolyte;

a cathode electrode over a first major surface of the solid oxide electrolyte;

an anode electrode over a second major surface of the solid oxide electrolyte opposite the first major surface; and

an electrolyte reinforcement layer over a portion of at least one of the first major surface and the second major surface of the solid oxide electrolyte, the electrolyte reinforcement layer comprising a ceramic material and at least one of a metal and a metal oxide sintering aid;

wherein the electrolyte reinforcement layer increases a bend strength of the solid oxide fuel cell compared to an identical fuel cell that does not include the electrolyte reinforcement layer;

wherein the electrolyte reinforcement layer comprises 50-75 wt % of stabilized zirconia, 20-45 wt % of alumina, and 1-5 wt % of the sintering aid; and

wherein the electrolyte reinforcement layer is located around the periphery of the electrolyte and at least partially around perimeters of fuel inlet and fuel outlet riser openings in the electrolyte.

10. A solid oxide fuel cell, comprising:

a solid oxide electrolyte;

a cathode electrode over a first major surface of the solid oxide electrolyte;

an anode electrode over a second major surface of the solid oxide electrolyte opposite the first major surface; and

an electrolyte reinforcement layer over a portion of at least one of the first major surface and the second major surface of the solid oxide electrolyte, the electrolyte reinforcement layer comprising a ceramic material and at least one of a metal and a metal oxide sintering aid;

wherein the electrolyte reinforcement layer is located around an entire perimeter of the electrolyte and around a perimeter of fuel inlet and fuel outlet riser openings in the electrolyte; and

wherein the electrolyte reinforcement layer is about 6-10 mm wide.