Hybrid thin film/thick film solid oxide fuel cell and method of manufacturing the same
First Claim
1. A fuel cell comprising:
- a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface;
a thick film anode layer disposed on the first surface; and
a thick film cathode layer disposed on the second surface;
wherein at least one of the anode layer or the cathode layer has a thickness of about 30 microns; and
wherein the electrolyte layer consists essentially of Ta2O5.
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Accused Products
Abstract
A SOFC providing higher power densities than PEM-based cells; the possibility of direct oxidation and/or internal reforming of fuel; and reduced SOFC operating temperatures. The SOFC comprises a thin film electrolyte layer. A thick film anode layer is disposed on one surface of the electrolyte layer; and a thick film cathode layer is disposed on the opposite surface of the electrolyte layer. A method of making the SOFC comprises the steps of: creating a well in one side of a dielectric or semiconductor substrate; depositing a thin film solid oxide electrolyte layer on the surface of the well; applying a thick film electrode layer in the electrolyte coated well; creating a counter well in the opposite side of the substrate, the counter well abutting the electrolyte layer; and applying a thick film counter electrode layer in the counter well.
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Citations
41 Claims
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1. A fuel cell comprising:
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a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface;
a thick film anode layer disposed on the first surface; and
a thick film cathode layer disposed on the second surface;
wherein at least one of the anode layer or the cathode layer has a thickness of about 30 microns; and
wherein the electrolyte layer consists essentially of Ta2O5. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15, 16, 17, 23, 24, 25, 26, 27, 28, 29, 30, 31)
a first interfacial layer, positioned between the anode and the electrolyte; and
a second interfacial layer positioned between the cathode and the electrolyte.
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15. The fuel cell as defined in claim 14 wherein the first interfacial layer comprises yttria doped ceria (YDC).
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16. The fuel cell as defined in claim 14 wherein the second interfacial layer comprises yttria stabilized bismuthsesquioxide (YSB).
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17. The fuel cell as defined in claim 1, further comprising a material for connecting the fuel cell to at least one of an electrical load or an electrical storage device, the connecting material deposited on at least one of the anode layer or the cathode layer.
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23. The fuel cell as defined in claim 1, further comprising:
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a plurality of the fuel cells arrayed within a substrate;
an electrical connection between the plurality of anode layers; and
an electrical connection between the plurality of cathode layers.
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24. The fuel cell as defined in claim 23 wherein the plurality of fuel cells are connected within a planar array, the planar array having a first plane adapted to contact a source of oxygen, the first plane having a plurality of cathode layers therein, the planar array further having a second plane opposed to the first plane, the second plane adapted to contact a fuel, the second plane having a plurality of anode layers therein.
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25. The fuel cell as defined in claim 24 wherein the source of oxygen is air.
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26. The fuel cell as defined in claim 24 wherein the fuel is selected from the group consisting of methane, butane, propane, pentane, methanol, ethanol, higher straight chain or mixed hydrocarbons, and mixtures thereof.
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27. The fuel cell as defined in claim 1 wherein the fuel cell has a power density of between about 100 mW/cm2 and about 2000 mW/cm2.
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28. The fuel cell as defined in claim 27 wherein the fuel cell has a power density of between about 1000 mW/cm2 and about 2000 mW/cm2.
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29. The fuel cell as defined in claim 28 wherein the fuel cell has an operating temperature of between about 400°
- C. and about 800°
C.
- C. and about 800°
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30. The fuel cell as defined in claim 29 wherein the fuel cell has an operating temperature of between about 400°
- C. and about 600°
C.
- C. and about 600°
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31. The fuel cell as defined in claim 30 wherein the fuel cell has an operating temperature of between about 400°
- C. and about 500°
C.
- C. and about 500°
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9. A fuel cell, comprising:
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a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface;
a thick film anode layer disposed on the first surface; and
a thick film cathode layer disposed on the second surface;
wherein the electrolyte layer consists essentially of Ta2O5.
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18. A fuel cell comprising:
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a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface;
a thick film anode layer disposed on the first surface; and
a thick film cathode layer disposed on the second surface; and
a material for connecting the fuel cell to at least one of an electrical load or an electrical storage device, the connecting material deposited on at least one of the anode layer or the cathode layer;
wherein at least one of the anode layer or the cathode layer has a thickness of about 30 microns;
wherein the electrical load comprises at least one of computers, portable electronic appliances or communication devices; and
wherein the electrolyte layer consists essentially of Ta2O5.
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19. A fuel cell comprising:
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a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface;
a thick film anode layer disposed on the first surface; and
a thick film cathode layer disposed on the second surface; and
a material for connecting the fuel cell to at least one of an electrical load or an electrical storage device, the connecting material deposited on at least one of the anode layer or the cathode layer;
wherein at least one of the anode layer or the cathode layer has a thickness of about 30 microns;
wherein the electrical storage device comprises at least one of capacitors, batteries or power conditioning devices; and
wherein the electrolyte layer consists essentially of Ta2O5.
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20. A fuel cell comprising:
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a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface;
a thick film anode layer disposed on the first surface; and
a thick film cathode layer disposed on the second surface; and
a material for connecting the fuel cell to at least one of an electrical load or an electrical storage device, the connecting material deposited on at least one of the anode layer or the cathode layer;
wherein at least one of the anode layer or the cathode layer has a thickness of about 30 microns;
wherein the connecting material has as a main component thereof a material selected from the group consisting of silver, palladium, platinum, gold, titanium, tantalum, chromium, iron, nickel, carbon, stainless steels, high temperature nickel alloys, tungsten, and mixtures thereof; and
wherein the electrolyte layer consists essentially of Ta2O5.
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- 21. The fuel cell as defined in claim 21, further comprising a material for interconnecting at least two of the fuel cells, the interconnecting material deposited on at least one of the anode layer or the cathode layer.
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32. A fuel cell comprising:
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a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface;
wherein the electrolyte layer has a thickness greater than 0 microns to about 10 microns;
a thick film anode layer disposed on the first surface, wherein the anode layer has an interconnected porosity ranging between about 19% and about 55%; and
a thick film cathode layer disposed on the second surface, wherein the cathode layer has an interconnected porosity ranging between about 19% and about 55%, wherein at least one of the anode or cathode layers has a thickness of about 30 microns; and
wherein the electrolyte layer consists essentially of Ta2O5. - View Dependent Claims (33, 34, 35, 36, 37, 38)
a first interfacial layer, positioned between the anode and the electrolyte; and
a second interfacial layer positioned between the cathode and the electrolyte.
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36. The fuel cell as defined in claim 35, further comprising a material for connecting the fuel cell to at least one of an electrical load or an electrical storage device, the connecting material deposited on at least one of the anode layer or the cathode layer, wherein the electrical load comprises at least one of computers, portable electronic appliances, or communication devices, and wherein the electrical storage device comprises at least one of capacitors, batteries, or power conditioning devices.
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37. The fuel cell as defined in claim 36, further comprising a material for interconnecting at least two of the fuel cells, the interconnecting material deposited on at least one of the anode layer or the cathode layer.
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38. The fuel cell as defined in claim 37, further comprising;
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a plurality of the fuel cells arrayed within a substrate;
an electrical connection between the plurality of anode layers; and
an electrical connection between the plurality of cathode layers.
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39. A fuel cell, comprising:
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a thin film electrolyte layer consisting essentially of Ta2O5 having a first surface and a second surface, the first surface being opposed to the second surface, wherein the electrolyte layer has a thickness greater than 0 microns to about 10 microns;
a thick film anode layer disposed on the first surface, wherein the anode layer has an interconnected porosity ranging between about 19% and about 55%;
a thick film cathode layer disposed on the second surface, wherein the cathode layer has an interconnected porosity ranging between about 19% and about 55%, and wherein each of the anode and cathode layers has a thickness greater than or equal to 30 microns, wherein each of the anode layer, cathode layer and electrolyte layer are formed substantially within a substrate;
a first interfacial layer, positioned between the anode and the electrolyte;
a second interfacial layer positioned between the cathode and the electrolyte;
a material for connecting the fuel cell to at least one of an electrical load or an electrical storage device, the connecting material deposited on at least one of the anode layer or the cathode layer, wherein the electrical load comprises at least one of computers, portable electronic appliances, or communication devices, and wherein the electrical storage device comprises at least one of capacitors, batteries, or power conditioning devices;
a material for interconnecting at least two of the fuel cells, the interconnecting material deposited on at least one of the anode layer or the cathode layer;
a plurality of the fuel cells arrayed within a substrate;
an electrical connection between the plurality of anode layers; and
an electrical connection between the plurality of cathode layers;
wherein the plurality of fuel cells are connected within a planar array, the planar array having a first plane adapted to contact a source of oxygen, the first plane having a plurality of cathode layers therein, the planar array further having a second plane opposed to the first plane, the second plane adapted to contact a fuel, the second plane having a plurality of anode layers.
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40. A fuel cell system including a plurality of fuel cells, each of the fuel cells comprising:
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a thin film electrolyte layer consisting essenitially of Ta2O5 having a first surface and a second surface, the first surface being opposed to the second surface;
a thick film anode layer disposed on the first surface; and
a thick film cathode layer disposed on the second surface;
wherein the fuel cell system comprises;
a planar array of the plurality of the fuel cells within a substrate;
an electrical connection between the plurality of anode layers; and
an electrical connection between the plurality of cathode layers. - View Dependent Claims (41)
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Specification