Laminated SOFC Electrolyte Structure to Prevent Thin-Layer Cracking

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Solution Overview

Problem

Thinner electrolytes in solid oxide fuel cells (SOFCs) are prone to cracking due to stress from anode firing and thermal cycling, which increases electrical resistivity and reduces cell performance.

Innovation Solution

The electrolyte and anode precursor layers are formed separately and laminated together through pressing methods like hot isostatic pressing, followed by sintering, to reduce stress and prevent cracking, allowing for a thickness of 100 microns or less without significant damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the electrolyte thickness is reduced to decrease electrical resistivity, then electrical resistivity decreases and cell performance improves, but the electrolyte becomes more prone to cracking due to stress from anode firing and thermal cycling

Engineering Contradiction:

Improveelectrical resistivityVSAvoidelectrolyte cracking resistance

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The electrolyte and anode are formed as a laminated composite structure where the anode is integrated directly onto the electrolyte surface. This merging of components allows the anode to provide mechanical support to the thin electrolyte layer, distributing stress and preventing cracking while maintaining the low electrical resistivity achieved through reduced electrolyte thickness

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fuel cell employs a composite structure combining the electrolyte layer with a laminated anode layer. This composite material approach creates a hybrid structure where the anode serves dual functions: electrochemical reaction and mechanical reinforcement, enabling the electrolyte to be made thinner without compromising its structural integrity under thermal and mechanical stress

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method reduces electrolyte cracking and maintains low electrical resistivity, enhancing the performance and durability of SOFCs by minimizing stress-induced damage.

Implementation Method 1

The fuel cell, operating at a typical temperature between 750° C. and 950° C., enables the transport of negatively charged oxygen ions from the cathode flow stream to the anode flow stream

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 2

stacking the formed at least one anode precursor layer in contact with a first side of the ceramic electrolyte precursor layer, laminating the at least one anode precursor layer and the ceramic electrolyte precursor layer

Methodology Applied

Scientific EffectHot isostatic pressing: Hot Isostatic Pressing

Implementation Method 3

a first anode precursor layer and a second anode precursor layer are tape cast, dried and stacked on opposite sides of a tape cast, dried electrolyte precursor layer. The stacked precursor layers are then sintered in any suitable sequence and/or at any suitable temperature

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS20250309305A1Solid oxide fuel cell having laminated anode and electrolyte layers and method of making thereof

Publication Date: 2025.10.02 BLOOM ENERGY CORP

AI summary

A solid oxide fuel cell (SOFC) includes a ceramic electrolyte having a thickness of 100 microns or less, an anode laminated to a first side of the electrolyte. and a cathode located on a second side of the electrolyte opposite to the first side.