Electrolyte supported cell designed for longer life and higher power

• US 8,067,129 B2
• Filed: 11/12/2008
• Issued: 11/29/2011
• Est. Priority Date: 11/13/2007
• Status: Active Grant

• Current Assignee: Bloom Energy Corporation
• Original Assignee: Bloom Energy Corporation
• Inventors: Couse, Stephen
• Primary Examiner(s): Maples; John S
• Application Number:
  US12/292,151
• Publication Number:
  US 20090136821A1
• Time in Patent Office: 1,112 Days
• Field of Search: None
• US Class Current: 429/495
• CPC Class Codes: H01M 4/8885 Sintering or firing
• CPC Class Codes: H01M 4/9025 Oxides specially used in fuel cell operating at high temperature, e.g. SOFC
• CPC Class Codes: H01M 4/9066 of metal-ceramic composites or mixtures, e.g. cermets
• CPC Class Codes: H01M 8/1253 the electrolyte containing zirconium oxide
• CPC Class Codes: H01M 8/126 the electrolyte containing cerium 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
• CPC Class Codes: Y10T 156/1051 by folding

Abstract

A solid oxide fuel cell (SOFC) includes a cathode electrode, an anode electrode, and a solid oxide electrolyte located between the anode electrode and the cathode electrode. The cathode electrode is a porous ceramic layer infiltrated with a cathode catalyst material, and the anode electrode is a porous ceramic layer infiltrated with an anode catalyst material, and the electrolyte is a ceramic layer having a lower porosity than the anode and the cathode electrodes. A ceramic reinforcing region may be located adjacent to the riser opening in the electrolyte.

Claims

1. A solid oxide fuel cell, comprising:

a ceramic electrolyte having at least one fuel inlet or outlet riser opening;

an anode contacting the electrolyte on a first side of the electrolyte;

a cathode contacting the electrolyte on a second side opposite the first side; and

a ceramic reinforcing region that is located adjacent to the riser opening;

wherein;

the ceramic reinforcing region is located at least partially around a circumference of the riser opening;

the electrolyte comprises an active region and an inactive region;

the anode and cathode contact the electrolyte at least partially on the active region of the electrolyte;

the ceramic reinforcing region is located on the inactive region of the electrolyte; and

a combined thickness of the electrolyte and the ceramic reinforcing region is thicker than a thickness of the active region and thicker than a thickness of the inactive region that does not contain the ceramic reinforcing region.

2. The fuel cell of claim 1, wherein the combined thickness of the electrolyte and the ceramic reinforcing region is about 25 μ

m to about 150 μ

m thicker than the thickness of the active region and about 25 μ

m to about 150 μ

m thicker than the thickness of the inactive region that does not contain the ceramic reinforcing region.

3. The fuel cell of claim 1, wherein the reinforcing region comprises at least one of a semicircle, horseshoe, crescent, or U shape.

4. The fuel cell of claim 1, further comprising a seal, wherein:

the reinforcing region is located on the first side; and

the seal is located on the second side entirely around the circumference of the riser opening.

5. The fuel cell of claim 1, wherein the reinforcing region comprises a laminate of electrolyte material comprising yttria or scandia.

6. The fuel cell of claim 1, wherein the reinforcing region comprises a screen printed ceramic.

7. The fuel cell of claim 6, wherein the screen printed ceramic contains reinforcing fibers or particles.