Hybrid thin film/thick film solid oxide fuel cell and method of manufacturing the same
First Claim
1. A fuel cell, comprising:
- a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface, wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well; and
the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well.
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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.
84 Citations
39 Claims
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1. A fuel cell, comprising:
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a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface, wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well; and
the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 29, 30, 31, 32, 33)
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20. A fuel cell, comprising:
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a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface, wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well;
the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well; and
a connecting 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.
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21. A fuel cell, comprising:
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a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface, wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well;
the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well; and
a connecting 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 storage device comprises at least one of capacitors, batteries, or power conditioning devices.
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22. A fuel cell, comprising:
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a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface, wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well;
the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well; and
a connecting 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 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.
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23. A fuel cell system including a plurality of fuel cells, each of the plurality of fuel cells comprising:
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a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface, wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well; and
,the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well;
a wherein the fuel cell system further comprises an interconnecting material for interconnecting at least two of the plurality of fuel cells, the interconnecting material deposited on at least one of the thick film anode layer or the thick film cathode layer. - View Dependent Claims (24, 25, 26, 27, 28)
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34. A fuel cell, comprising:
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a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
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, and wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well; and
the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well;
wherein each of the anode layer and the cathode layer has an interconnected porosity ranging between about 19% and about 55%, and wherein at least one of the anode or cathode layers has a thickness of about 30 microns or more. - View Dependent Claims (35, 36, 37)
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38. A fuel cell system including a plurality of fuel cells, each of the plurality of fuel cells comprising:
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a well in a dielectric or semiconductor substrate, the substrate having a first side and a second side, the second side opposed to the first side, the well being defined in the first side;
a counter well defined in the second side, wherein an opening is defined in the substrate between the well and the counter well;
a thin film electrolyte layer having a first surface and a second surface, the first surface being opposed to the second surface, wherein the second surface contacts the well and covers the opening;
one of a thick film anode layer or a thick film cathode layer disposed on the electrolyte first surface and within the well; and
the other of the thick film cathode layer or the thick film anode layer disposed on the electrolyte second surface and within the counter well;
wherein the fuel cell system comprises;
a planar array of the plurality of fuel cells within the substrate;
an electrical connection between a plurality of the thick film anode layers; and
an electrical connection between a plurality of the thick film cathode layers. - View Dependent Claims (39)
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Specification