METHODS OF FABRICATING SOLID OXIDE FUEL CELLS
In various embodiments, a solid oxide fuel cell is fabricated in part by disposing a functional layer between the cathode and the solid electrolyte.
1 .- 16 . (canceled)
17 . A solid oxide fuel cell configured to operate at an operating temperature of less than 550° C., the solid oxide fuel cell comprising:
a cathode;
a solid electrolyte for conducting oxygen ions from the cathode to an anode;
an anode for reacting oxygen ions from the solid electrolyte with a hydrogen-containing fuel; and
a functional layer disposed between the cathode and the solid electrolyte,
wherein the functional layer has a thickness of less than 5 μm.
18 . The solid oxide fuel cell of claim 17 , wherein the thickness of the functional layer is greater than 0.1 μm.
19 . The solid oxide fuel cell of claim 17 , wherein the solid oxide fuel cell is configured to operate at an operating temperature of 300° C. or more.
20 . The solid oxide fuel cell of claim 17 , wherein the solid oxide fuel cell comprises an anode functional layer disposed between the anode layer and the solid electrolyte layer.
21 . The solid oxide fuel cell of claim 20 , wherein the anode functional layer comprises (i) a cermet of nickel oxide and gadolinium-doped ceria, and/or (ii) a ceramic oxide material containing strontium, iron, cobalt, and molybdenum.
22 . The solid oxide fuel cell of claim 20 , wherein a thickness of the anode function layer ranges from approximately 5 μm to approximately 50 μm.
23 . The solid oxide fuel cell of claim 17 , wherein the functional layer comprises at least one of cobalt-doped gadolinium-doped ceria or cobalt-doped samarium-doped ceria.
24 . The solid oxide fuel cell of claim 17 , wherein (i) the functional layer contains cobalt and (ii) at least a first portion of the solid electrolyte layer contains cobalt.
25 . The solid oxide fuel cell of claim 24 , wherein a concentration of cobalt in the first portion of the solid electrolyte layer is less than a concentration of cobalt in the functional layer.
26 . The solid oxide fuel cell of claim 24 , wherein a second portion of the solid electrolyte layer does not contain cobalt.
27 . The solid oxide fuel cell of claim 26 , wherein the first portion of the solid electrolyte layer is disposed between the functional layer and the second portion of the solid electrolyte layer.
28 . A solid oxide fuel cell configured to operate at an operating temperature of greater than 550° C., the solid oxide fuel cell comprising:
a cathode;
a solid electrolyte for conducting oxygen ions from the cathode to an anode;
an anode for reacting oxygen ions from the solid electrolyte with a hydrogen-containing fuel; and
a functional layer disposed between the cathode and the solid electrolyte,
wherein the functional layer has a thickness of greater than 5 μm.
29 . The solid oxide fuel cell of claim 28 , wherein the thickness of the functional layer is less than 20 μm.
30 . The solid oxide fuel cell of claim 28 , wherein the solid oxide fuel cell is configured to operate at an operating temperature of 800° C. or less.
31 . The solid oxide fuel cell of claim 28 , wherein the solid oxide fuel cell comprises an anode functional layer disposed between the anode layer and the solid electrolyte layer.
32 . The solid oxide fuel cell of claim 31 , wherein the anode functional layer comprises (i) a cermet of nickel oxide and gadolinium-doped ceria, and/or (ii) a ceramic oxide material containing strontium, iron, cobalt, and molybdenum.
33 . The solid oxide fuel cell of claim 31 , wherein a thickness of the anode function layer ranges from approximately 5 μm to approximately 50 μm.
34 . The solid oxide fuel cell of claim 28 , wherein the functional layer comprises at least one of cobalt-doped gadolinium-doped ceria or cobalt-doped samarium-doped ceria.
35 . The solid oxide fuel cell of claim 28 , wherein (i) the functional layer contains cobalt and (ii) at least a first portion of the solid electrolyte layer contains cobalt.
36 . The solid oxide fuel cell of claim 35 , wherein a concentration of cobalt in the first portion of the solid electrolyte layer is less than a concentration of cobalt in the functional layer.
37 . The solid oxide fuel cell of claim 35 , wherein a second portion of the solid electrolyte layer does not contain cobalt.
38 . The solid oxide fuel cell of claim 37 , wherein the first portion of the solid electrolyte layer is disposed between the functional layer and the second portion of the solid electrolyte layer.