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US 7,351,491 B2Granted
Supporting electrodes for solid oxide fuel cells and other electrochemical devices
AssigneeBattelle Memorial Institute
InventorsVincent L. Sprenkle, Nathan L. Canfield, Kerry Meinhardt, Jeffry W. Stevenson
Life of this patent
Estimating the term…
Abstract
An electrode supported electrolyte membrane includes an electrode layer 630 facing an electrolyte layer 620. The opposing side of the electrode layer 630 includes a backing layer 640 of a material with a thermal expansion coefficient approximately equal to the thermal expansion coefficient of the electrolyte layer 620. The backing layer 640 is in a two dimensional pattern that covers only a portion of the electrolyte layer 630. An electrochemical cell such as a SOFC is formed by providing a cathode layer 610 on an opposing side of the electrolyte layer 620.
Claims26
An electrode supported electrolyte membrane for an electrochemical cell comprising:
- a substantially continuous layer of a ceramic ion conducting electrolyte supported on a conductive electrode substrate, wherein the conductive electrode substrate is planar and has a thickness less than about 750 μm and includes an active electrode layer and a bulk electrode layer;
- a backing structure on a face of the bulk electrode layer opposite the electrolyte layer and composed of a material having a thermal expansion coefficient about equal to the terminal expansion coefficient of the ceramic ion conducting electrolyte;
- wherein the backing structure has a thickness cross-section, and includes at least one void extending completely through the thickness cross-section of the backing structures wherein the at least one void is arranged in a two-dimensional pattern such that the backing structure covers less than about 50% of the area of the face of the bulk electrode layer and is effective to prevent deflection of more than about 0.05 mm/cm of length of the bulk electrode layer upon a temperature change from 1000° C. and 100° C. and wherein the pattern includes elongated strips spanning substantially completely across the face of the substrate.
A planar solid oxide fuel cell for electrochemically reacting a fuel gas with an oxidant gas to produce a DC output voltage, said solid oxide fuel cell comprising:
- (a) at least one fuel cell unit comprising:
- a layer of a ceramic ion conducting electrolyte defining first and second opposing surfaces;
- a conductive active anode layer defining first and second opposing surfaces, wherein the first surface of the active anode layer is facing the first surface of the electrolyte layer;
- a conductive bulk anode layer defining first and second opposing surfaces, wherein the first surface of the conductive bulk anode layer is facing the second surface of the active anode layer;
- a conductive cathode layer facing the second surface of the electrolyte layer;
- and
- a backing layer facing the second surface of the conductive bulk anode layer;
- wherein the backing layer is of a material having a thermal expansion coefficient about equal to the thermal expansion coefficient of the ceramic ion conducting electrolyte, wherein the backing layer has a thickness cross-section, and includes at least one void extending completely through the thickness cross-section of the backing layer wherein the at least one void is arranged in a two-dimensional pattern such that the backing layer covers less than about 50% of the area of the second surface of the conductive bulk anode layer and wherein the pattern includes elongated strips spanning substantially completely across the surface of the conductive bulk anode layer;
- and
- (b) at least one interconnect coupled to the fuel cell unit.
7 more elements
An anode supported electrolyte membrane which resists developing thermally induced camber comprising:
- a planar layer of a ceramic ion conducting electrolyte having a length greater than about 3 cm and a thickness less than about 15 μm supported by a planar anode layer having a thickness less than about 750 μm;
- and
- a backing structure on a back face of the anode layer opposite the electrolyte layer and composed of a material having a thermal expansion coefficient about equal to the thermal expansion coefficient of the ceramic ion conducting electrolyte, wherein the backing structure is not an interconnect, wherein the backing structure has a thickness cross-section, and includes at least one void extending completely through the thickness cross-section of the backing structure, wherein the at least one void is arranged in a two-dimensional pattern, and wherein the pattern includes elongated strips spanning substantially completely across the face of the anode layer.
An electrode supported electrolyte membrane for an electrochemical cell comprising:
- a substantially continuous layer of a ceramic ion conducting electrolyte supported on a conductive electrode substrate, wherein the conductive electrode substrate is planar and has a thickness less than about 750 μm and includes an active electrode layer and a bulk electrode layer;
- a backing structure on a face of the bulk electrode layer opposite the electrolyte layer and composed of a material having a thermal expansion coefficient about equal to the terminal expansion coefficient of the ceramic ion conducting electrolyte;
- wherein the backing structure has a thickness cross-section, and includes at least one void extending completely through the thickness cross-section of the backing structure, wherein the at least one void is arranged in a two-dimensional pattern such that the backing structure covers less than about 50% of the area of the face of the bulk electrode layer and is effective to prevent deflection of more than about 0.05 mm/cm of length of the bulk electrode layer upon a temperature change from 1000° C. and 100° C., wherein the pattern includes intersecting thin strips.
An electrode supported electrolyte membrane for an electrochemical cell, wherein the membrane is generally rectangular in outer dimension, comprising:
- a substantially continuous layer of a ceramic ion conducting electrolyte supported on a conductive electrode substrate, wherein the conductive electrode substrate is planar and has a thickness less than about 750 μm and includes an active electrode layer and a bulk electrode layer;
- a backing structure on a face of the bulk electrode layer opposite the electrolyte layer and composed of a material having a thermal expansion coefficient about equal to the terminal expansion coefficient of the ceramic ion conducting electrolyte;
- wherein the backing structure has a thickness cross-section, and includes at least one void extending completely through the thickness cross-section of the backing structure, wherein the at least one void is arranged in a two-dimensional pattern such that the backing structure covers less than about 50% of the area of the face of the bulk electrode layer and is effective to prevent deflection of more than about 0.05 mm/cm of length of the bulk electrode layer upon a temperature change from 1000° C. and 100° C. and wherein the pattern includes a plurality of elongated strips spanning substantially between opposed edges of the rectangular membrane.
Dependencies are inferred from the claim text.