Back to results
US 2006/0234100 A1Published application
Self-supporting ceramic membranes and electrochemical cells and cell stacks including the same
AssigneeNexTech Materials, Ltd.
InventorsMichael Day, Katarzyna Sabolsky, Todd Lesousky, Matthew Seabaugh
Life of this patent
Estimating the term…
Abstract
Self-supporting thin film membranes of ceramic materials and related electrochemical cells and cell stacks. The membrane structure is divided into a plurality of self-supporting thin membrane regions by a network of thicker integrated support ribs. The membrane structure may be prepared by laminating a thin electrolyte layer with a thicker ceramic layer that forms a network of support ribs.
Claims31
A self-supporting thin-film ceramic membrane, comprising:
- a thin electrolyte layer comprising at least one sheet of a ceramic electrolyte material in the green state;
- and
- a thicker support layer comprising at least one sheet of a ceramic electrolyte material in the green state, the thicker support layer defining a plurality of voids separated by a network of support ribs;
- the thin electrolyte layer being laminated to the thicker support layer and then sintered to form a composite structure, the composite structure having a textured surface at least on the support layer side.
1 more element
A self-supporting thin-film ceramic membrane, comprising:
- a thin electrolyte layer comprising at least one sheet of a ceramic electrolyte material in the green state;
- and
- a thicker support layer comprising at least one sheet of a ceramic electrolyte material in the green state, the thicker support layer defining an integral central mesh portion;
- the thin electrolyte layer being laminated to the thicker support layer and then sintered to form a composite structure.
1 more element
A self-supporting thin-film ceramic membrane, comprising:
- a thin electrolyte layer comprising a stack of at least two sheets of a scandia-stabilized zirconia composition in the green state;
- and
- a thicker support layer comprising a laminate of at least two sheets of a partially stabilized zirconia composition in the green state, the sheets including a polymeric component and defining a plurality of voids separated by a network of support ribs;
- the thin electrolyte layer being laminated to the thicker support layer by heating the layers to a temperature greater than the glass transition temperature of the polymeric component and the laminated layers being sintered to form a composite structure having a textured surface at least on the support layer side, the sintered thin electrolyte layer having a thickness less than 100 microns.
1 more element
An electrochemical cell, comprising:
- a self-supporting thin-film ceramic membrane, comprising:
- a thin electrolyte layer comprising at least one sheet of a ceramic electrolyte material in the green state;
- and
- a thicker support layer comprising at least one sheet of a ceramic electrolyte material in the green state, the support layer defining a plurality of voids separated by a network of support ribs;
- the thin electrolyte layer being laminated to the thicker support layer and then sintered to form a composite structure having a textured surface at least on the support layer side;
- an anode material applied to a textured surface of the composite structure;
- and
- a cathode material applied to the opposing surface of the composite structure.
5 more elements
An electrochemical cell, comprising:
- a self-supporting thin film membrane, comprising:
- a thin electrolyte layer comprising at least one sheet of a scandia-stabilized zirconia composition in the green state;
- and
- a thicker support layer comprising at least one sheet of a partially stabilized zirconia composition in the green state, the thicker support layer including a polymeric component and defining a plurality of voids separated by a network of support ribs;
- the thin electrolyte layer being laminated to the thicker support layer by heating the layers to a temperature greater than the glass transition temperature of the polymeric component and then sintered to form a composite structure having a textured surface at least on the support layer side;
- an anode material applied to a textured surface of the composite structure;
- and
- a cathode material applied to the opposing surface of the composite structure.
5 more elements
An electrochemical cell stack, comprising:
- a first dense electronically conductive ceramic plate;
- a first bi-layer assembly comprising:
- a thin electrolyte layer comprising at least one sheet of a ceramic electrolyte material in the green state;
- and
- a thicker support layer comprising at least one sheet of a ceramic electrolyte material in the green state, the support layer defining a plurality of voids separated by a network of support ribs;
- the support layer positioned adjacent to the first conductive plate;
- a second dense electronically conductive ceramic plate adjacent to the thin electrolyte layer of the first bi-layer assembly;
- a second bi-layer assembly comprising:
- a thin electrolyte layer comprising at least one sheet of a ceramic electrolyte material in the green state;
- and
- a thicker support layer comprising at least one sheet of a ceramic electrolyte material in the green state, the support layer defining a plurality of voids separated by a network of support ribs, the support layer positioned adjacent to the opposing surface of the second conductive plate;
- a third dense electronically conductive ceramic plate adjacent to the thin electrolyte layer of the second bi-layer assembly;
- the layered assembly being laminated and then sintered to form a composite structure;
- an anode material being applied to the support layers of the composite structure;
- and
- a cathode material being applied to the thin electrolyte layers of the composite structure.
13 more elements
An electrochemical cell stack, comprising:
- n bi-layer assemblies wherein n≧2;
- each of the bi-layer assemblies comprising
- a thin electrolyte layer each comprising at least one sheet of a ceramic electrolyte material in the green state;
- and
- a thicker support layer each comprising at least one sheet of a ceramic electrolyte material in the green state, the support layer defining a plurality of voids separated by a network of support ribs;
- and
- n+1 dense electronically conductive ceramic plates;
- wherein each of n−1 plates is secured between the support layer of one of the n bi-layer assemblies and the thin electrolyte layer of another one of the n bi-layer assemblies and each of the remaining 2 plates is secured to an outer surface of one of the outermost of the n bi-layer assemblies;
- the layered assembly being laminated and then sintered to form a composite structure;
- an anode material being applied to the support layers of the composite structure;
- and
- a cathode material being applied to the thin electrolyte layers of the composite structure.
9 more elements
A method of making a supporting thin-film ceramic membrane, the method comprising the steps of:
- providing a thin electrolyte layer comprising at least one sheet of a ceramic electrolyte material in the green state;
- providing a thicker support layer comprising at least one sheet of a ceramic electrolyte material in the green state, the thicker support layer defining a plurality of voids separated by a network of support ribs;
- laminating the thin electrolyte layer to the thicker support layer;
- and
- sintering the laminated layers to form a composite structure having a textured surface at least on the support layer side.
2 more elements
A method of making an electrochemical cell stack, comprising the steps of:
- providing n bi-layer assemblies wherein n≧2;
- each of the bi-layer assemblies comprising
- a thin electrolyte layer each comprising at least one sheet of a ceramic electrolyte material in the green state;
- and
- a thicker support layer each comprising at least one sheet of a ceramic electrolyte material in the green state, the support layer defining a plurality of voids separated by a network of support ribs;
- and
- providing n+1 dense electronically conductive ceramic plates;
- securing each of n−1 plates between the support layer of one of the n bi-layer assemblies and the thin electrolyte layer of another one of the n bi-layer assemblies;
- securing each of the remaining 2 plates to an outer surface of one of the outermost of the n bi-layer assemblies;
- laminating the layered assembly;
- sintering the laminated assembly to form a composite structure;
- applying an anode material to the support layers of the composite structure;
- and
- applying a cathode material to the thin electrolyte layers of the composite structure.
11 more elements
Dependencies are inferred from the claim text.