# US 7,410,716 B2 · Electrolyte sheet with protruding features having undercut angles and method of separating such sheet from its carrier

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- Number: US 7,410,716 B2
- Document ID: US7410716B2
- Status: Granted
- Kind: B2
- Application number: 10/699,750
- Filed: 2003-11-03
- Published: 2005-05-05
- Granted: 2008-08-12
- Earliest claimed: 2003-11-03
- Assignees: Corning Incorporated
- Inventors: Sean M. Garner; Lanrik Kester; Jeffrey A. Miller
- Web page: https://patentgrep.com/patent/US7410716B2

## CPC

- C04B 35/486: Fine ceramics
- C04B 35/62218: {obtaining ceramic films, e.g. by using temporary supports}
- C04B 35/6264: {Mixing media, e.g. organic solvents}
- C04B 35/632: Organic additives
- C04B 35/634: Polymers (C04B35/636 takes precedence)
- C04B 35/6342: {Polyvinylacetals, e.g. polyvinylbutyral [PVB]}
- H01M 4/9033: {Complex oxides, optionally doped, of the type M1MeO3, M1 being an alkaline earth metal or a rare earth, Me being a metal, e.g. perovskites}
- H01M 8/1016: characterised by the electrolyte material (H01M8/12 takes precedence)
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/602: Making the green bodies or pre-forms by moulding
- C04B 2235/6025: Tape casting, e.g. with a doctor blade
- C04B 2235/77: Density
- C04B 2235/945: Products containing grooves, cuts, recesses or protusions
- H01M 8/1253: the electrolyte containing zirconium oxide
- Y02E 60/50: Fuel cells
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- Y10T 428/24479: including variation in thickness
- Y10T 428/2457: Parallel ribs and/or grooves
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

According to one embodiment of the present invention an electrolyte sheet includes a body of varied thickness, the electrolyte sheet having a textured surface with multiple protruding features. The protruding features form an undercut angle with respect to the normal of the electrolyte sheet, the undercut angle being more than 0 degrees and less than 15 degrees.

## Claims

### Claim 1

An electrolyte sheet comprising a body of varied thickness, said electrolyte sheet having a textured surface with multiple protruding features, said protruding features forming an undercut angle with respect to the normal of said electrolyte sheet, said undercut angle being more than 0 degrees and less than 15 degrees.

### Claim 2 (depends on 1)

The electrolyte sheet of claim 1, wherein said undercut angle is 1 to 10 degrees.

### Claim 3 (depends on 1)

The electrolyte sheet of claim 1, wherein the thickest part of said electrolyte sheet is at least 0.5 microns greater than the thinnest part of said electrolyte sheet.

### Claim 4 (depends on 1)

The electrolyte sheet of claim 1, wherein the electrolyte sheet is a ceramic sheet formed of a polycrystalline ceramic selected from a group consisting of partially stabilized zirconia or stabilized zirconia, and being doped with a dopant selected from the group consisting of the oxides of Y, Ce, Ca, Mg, Sc, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, In, Ti, Sn, Nb, Ta, Mo, W and mixtures thereof.

### Claim 5 (depends on 1)

The fuel cell device of claim 1, wherein the thickest part of said electrolyte sheet is at least 2 micrometers greater than the thinnest part of said electrolyte sheet.

### Claim 6 (depends on 1)

A solid oxide electrode/electrolyte assembly comprising:
the electrolyte sheet according to claim 1, said electrolyte sheet having an average electrolyte sheet thickness between 0.5 micrometers and 45 micrometers,;
at least one cathode disposed on a one surface of said electrolyte sheet; and
at least one anode disposed opposite the cathode on another surface of said electrolyte sheet.

### Claim 7 (depends on 6)

A solid oxide electrode/electrolyte assembly according to claim 6, comprising a plurality of cathodes situated on one side of said electrolyte sheet and a plurality of anodes situated on an opposite side of said electrolyte sheet.