Fabrication process for production of SOFC-MEA with a pore array anode structure for improving output power density

A fabrication process for production of a planar type solid oxide fuel cell membrane electrode assembly (“SOFC-MEA”) with pore array anode structure, comprising the steps of:

• Step 1:
• producing thin strip anode green tapes by tape casting;
• Step 2:
• providing a pore array structure having a specified diameter for each pore and a specified spacing between adjacent pores on the surface of the anode green tapes, laminating multiple layers of the anode green tapes that include perforated and non-perforated anode green tapes through heat lamination and equalized water pressure lamination process to produce an anode supported substrate of green tapes having thickness between 300 μm and 800 μm;
• wherein the pore array perforation is furnished on a plurality of layers of the anode green tapes on the utmost outside of the anode supported substrate, wherein the pore array perforation furnished on the plurality of layers is distributed and interlaced in a complementary manner on different layers of anode green tapes, respectively;
• Step 3:
• conducting sintering on the anode supported substrate of green tapes at temperature about 1250° C. for 4 hours with temperature increment/decrement rate less than 3° C./min to obtain a first stage SOFC anode supported substrate;
• Step 4:
• conducting surface abrasion and polishing for the first stage SOFC anode supported substrate, firstly using a coarse sand paper to perform a surface pre-abrasion and polishing, followed by using a finer sand paper to produce a flat and smooth surface of the first stage SOFC anode supported substrate;
• Step 5:
• building an electrolyte layer of a thickness less than 10 μm by spin coating on the flat and smooth surface of the first stage SOFC anode supported substrate to produce a SOFC half cell, conducting sintering on the SOFC half cell between 1200° C. and 1600° C. for more than 6 hours with temperature increment/decrement rate less than 3° C./min to obtain a first stage ceramic half cell, and using SEM to analyze the microstructure of the first stage ceramic half cell to assure good adhesion between the SOFC anode supported substrate and the electrolyte layer and that the electrolyte layer is open pore free, and, if open pores still exist in the electrolyte layer, fixing the open pores with spin coating or sintering at temperature about 1350° C. for more than 6 hours to make the electrolyte layer open pore free and fully dense;
• and
• Step 6:
• building a porous cathode layer of LSM material onto the electrolyte layer by screen printing, followed by sintering at about 1200° C. for 3 hours with a sintering temperature rate less than 3° C./min to complete the production of a unit cell of SOFC-MEA.