Electrolyte supported cell designed for longer life and higher power

• US 8,333,919 B2
• Filed: 10/07/2011
• Issued: 12/18/2012
• 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): Daniels, Matthew
• Assistant Examiner(s): SNELTING, ERIN LYNN
• Application Number:
  US13/269,006
• Publication Number:
  US 20120024461A1
• Time in Patent Office: 438 Days
• Field of Search: 264/618
• US Class Current: 264/618
• 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 method of making a hole-reinforced electrolyte, comprising:

providing a ceramic reinforcing region adjacent to a riser opening in a ceramic electrolyte; and

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

wherein;

the electrolyte comprises an active region and an inactive region;

an anode and a cathode contact opposite sides of 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 method of claim 1, wherein the step of providing the reinforcing region comprises laminating an additional layer of electrolyte material comprising yttria or scandia onto the electrolyte.

3. The method of claim 1, wherein the step of providing the reinforcing region comprises screen printing a ceramic paste onto the electrolyte.

4. The method of claim 3, wherein the ceramic paste comprises fibers or particles.

5. The method of claim 3, wherein the reinforcing region is screen printed onto a green tape comprising the electrolyte.

6. The method of claim 5, wherein the step of sintering comprises co-sintering the electrolyte, the anode, and the cathode.

7. The method 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.

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

9. The method of claim 1, further comprising:

applying an ink-printed anode and cathode on opposite sides of the electrolyte comprising the sintered ceramic reinforcing region; and

sintering the ink-printed anode and cathode;

wherein the step of providing a ceramic reinforcing region comprises screen printing a ceramic paste onto the electrolyte.