초록 ▼

To reduce thermal stress and improve bonding in a high temperature monolithic solid oxide fuel cell (SOFC), intermediate layers are provided between the SOFC\s electrodes and electrolyte which are of different compositions. The intermediate layers are comprised of a blend of some of the materials us

To reduce thermal stress and improve bonding in a high temperature monolithic solid oxide fuel cell (SOFC), intermediate layers are provided between the SOFC\s electrodes and electrolyte which are of different compositions. The intermediate layers are comprised of a blend of some of the materials used in the electrode and electrolyte compositions. Particle size is controlled to reduce problems involving differential shrinkage rates of the various layers when the entire structure is fired at a single temperature, while pore formers are provided in the electrolyte layers to be removed during firing for the formation of desired pores in the electrode layers. Each layer includes a binder in the form of a thermosetting acrylic which during initial processing is cured to provide a self-supporting structure with the ceramic components in the green state. A self-supporting corrugated structure is thus formed prior to firing, which the organic components of the binder and plasticizer removed during firing to provide a high strength, high temperature resistant ceramic structure of low weight and density.

대표청구항 ▼

A method for forming an SOFC comprising the steps of: dispersing each of four ceramic powders into respective ones of a plurality of liquid media to form four slips of an anode, a cathode, an electrolyte and an interconnect; milling a binder and a plasticizer into each of said four slips; casting th

A method for forming an SOFC comprising the steps of: dispersing each of four ceramic powders into respective ones of a plurality of liquid media to form four slips of an anode, a cathode, an electrolyte and an interconnect; milling a binder and a plasticizer into each of said four slips; casting the four slips into thin layers or tapes; forming a plurality of said tapes into a stacked array including the step of depositing an intermediate bonding layer between adjacent tapes, wherein said intermediate layers are comprised of portions of each of the adjacent layers between which the intermediate layer is disposed; forming a plurality of corrugations in the stacked array of tapes, wherein said corrugated stacked array is self-supporting; and heating the stacked array of tapes at an elevated temperature so as to increase the density of electrolyte and interconnect tapes, form bonds between adjacent tapes, and rigidify and increase the strength of the stacked array of tapes.