US20090169958A1 - Ceramic interconnect for fuel cell stacks - Google Patents

Ceramic interconnect for fuel cell stacks Download PDF

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Publication number
US20090169958A1
US20090169958A1 US12/316,806 US31680608A US2009169958A1 US 20090169958 A1 US20090169958 A1 US 20090169958A1 US 31680608 A US31680608 A US 31680608A US 2009169958 A1 US2009169958 A1 US 2009169958A1
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Prior art keywords
equal
electrode
interconnect
sub
layer
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Guangyong Lin
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Saint Gobain Ceramics and Plastics Inc
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Saint Gobain Ceramics and Plastics Inc
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Priority to US12/316,806 priority Critical patent/US20090169958A1/en
Assigned to SAINT-GOBAIN CERAMICS & PLASTICS, INC. reassignment SAINT-GOBAIN CERAMICS & PLASTICS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LIN, GUANGYONG
Publication of US20090169958A1 publication Critical patent/US20090169958A1/en
Priority to US14/104,795 priority patent/US10008727B2/en
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Definitions

  • a fuel cell is a device that generates electricity by a chemical reaction.
  • solid oxide fuel cells use a hard, ceramic compound of metal (e.g., calcium or zirconium) oxide as an electrolyte.
  • an oxygen gas such as O 2
  • oxygen ions O 2 ⁇
  • a fuel gas such as hydrogen gas (H 2 ) gas
  • H 2 hydrogen gas
  • Interconnects are one of the critical issues limiting commercialization of solid oxide fuel cells.
  • metal interconnects are relatively easy to fabricate and process, they generally suffer from high power degradation rates (e.g. 10%/1,000 h) partly due to formation of metal oxides, such as Cr 2 O 3 , at an interconnect-anode/cathode interface during operation.
  • Ceramic interconnects based on lanthanum chromites (LaCrO 3 ) have lower degradation rates than metal interconnects partly due to relatively high thermodynamic stability and low Cr vapor pressure of LaCrO 3 compared to Cr 2 O 3 formed on interfaces of the metal interconnects and electrode.
  • lanthanum chromites generally are difficult to fully densify and require high temperatures, such as at or above about 1,600° C., for sintering.
  • high temperatures such as at or above about 1,600° C.
  • doped lanthanum chromites such as strontium-doped and calcium-doped lanthanum chromites, can be sintered at lower temperatures, they tend to be either unstable or reactive with an electrolyte (e.g., a zirconia electrolyte) and/or an anode.
  • an electrolyte e.g., a zirconia electrolyte
  • the invention is directed to a fuel cell, such as a solid oxide fuel cell (SOFC), that includes a plurality of sub-cells and to a method of preparing the fuel cell.
  • Each sub-cell includes a first electrode in fluid communication with a source of oxygen gas, a second electrode in fluid communication with a source of a fuel gas, and a solid electrolyte between the first electrode and the second electrode.
  • the fuel cell further includes an interconnect between the sub-cells.
  • the interconnect includes a first layer in contact with the first electrode of each sub-cell, and a second layer in contact with the second electrode of each sub-cell.
  • the first layer includes a (La,Mn)Sr-titanate based pertovskite represented by the empirical formula of La y Sr (1 ⁇ y) Ti (1 ⁇ x) Mn x O b , wherein x is equal to or greater than zero, and equal to or less than 0.6; y is equal to or greater than 0.2, and equal to or less than 0.8; and b is equal to or greater than 2.5, and equal to or less than 3.5.
  • La,Mn)Sr-titanate based pertovskite represented by the empirical formula of La y Sr (1 ⁇ y) Ti (1 ⁇ x) Mn x O b , wherein x is equal to or greater than zero, and equal to or less than 0.6; y is equal to or greater than 0.2, and equal to or less than 0.8; and b is equal to or greater than 2.5, and equal to or less than 3.5.
  • the second layer includes a (Nb,Y)Sr-titanate based pertovskite represented by the empirical formula of Sr (1 ⁇ 1.5z ⁇ 0.5k ⁇ k) Y z Nb k Ti (1 ⁇ k) O d , wherein each of k and z independently is equal to or greater than zero, and equal to or less than 0.2; d is equal to or greater than 2.5 and equal to or less than 3.5; and ⁇ is equal to or greater than zero, and equal to or less than 0.05.
  • a (Nb,Y)Sr-titanate based pertovskite represented by the empirical formula of Sr (1 ⁇ 1.5z ⁇ 0.5k ⁇ k) Y z Nb k Ti (1 ⁇ k) O d , wherein each of k and z independently is equal to or greater than zero, and equal to or less than 0.2; d is equal to or greater than 2.5 and equal to or less than 3.5; and ⁇ is equal to or greater than zero, and equal to or less than 0.05.
  • the interconnect has a thickness of between about 10 ⁇ m and about 100 ⁇ m
  • the second layer of the interconnect includes a (Sr)La-titanate based perovskite represented by the empirical formula of Sr (1 ⁇ z ⁇ ) La z TiO d , wherein z is equal to or greater than zero, and equal to or less than 0.4; d is equal to or greater than 2.5, and equal to or less than 3.5; and ⁇ is equal to or greater than zero, and equal to or less than 0.05.
  • the first layer of (La,Mn)Sr-titanate based perovskite which is in contact with the first electrode exposed to an oxygen source, can provide relatively high sinterability (e.g., sinterability to over 95% of theoretical density at a temperature lower than about 1,500° C.), stability in the oxidizing atmosphere and/or electrical conductivity.
  • the second layer of (Nb,Y)Sr-titanate based perovskite and/or (La)Sr-titanate based perovskite, which is in contact with the second electrode exposed to a fuel source can provide high electrical conductivity and stability in the reducing atmosphere.
  • the (La,Mn)Sr-titanate based perovskite and the (Nb,Y)Sr-titanate based perovskite materials have similar thermal expansion coefficients with each other.
  • La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O 3 has an average thermal expansion coefficient of 11.9 ⁇ 10 ⁇ 6 K ⁇ 1 at 30° C.-1,000° C. in air
  • Sr 0.86 Y 0.08 TiO 3 has an average thermal expansion coefficient of 11-12 ⁇ 10 ⁇ 6 K ⁇ 1 at 25° C.-1,000° C. in air.
  • both of the first layer of (La,Mn)Sr-titanate based perovskite and the second layer of (Nb,Y)Sr-titanate based perovskite can be co-sintered at the same time, minimizing process steps.
  • the present invention is directed to a method of forming a fuel cell that includes a plurality of sub-cells.
  • the method includes connecting each of the sub-cells with an interconnect.
  • Each sub-cell includes a first electrode in fluid communication with a source of oxygen gas, a second electrode in fluid communication with a source of a fuel gas, and a solid electrolyte between the first electrode and the second electrode.
  • the interconnect includes a first layer that includes a (La,Mn)Sr-titanate-based perovskite represented by the empirical formula of La y Sr (1 ⁇ y) Ti (1 ⁇ x) Mn x O b , wherein x is equal to or greater than zero and equal to or less than 0.6, y is equal to or greater than 0.2 and equal to or less than 0.8, and b is equal to or greater than 2.5 and equal to or less than 3.5.
  • the first layer is in contact with the first electrode of each sub-cell.
  • the interconnect also includes a second layer that includes a (Nb,Y)Sr-titanate-based perovskite represented by the empirical formula of Sr (1 ⁇ 1.5z ⁇ 0.5k ⁇ ) Y z Nb k Ti (1 ⁇ k) O d , wherein each of k and z independently is equal to or greater than zero and equal to or less than 0.2, d is equal to or greater than 2.5 and equal to or less than 3.5, and ⁇ is equal to or greater than zero and equal to or less than 0.05.
  • the second layer is in contact with the second electrode of each sub-cell.
  • the method includes forming at least one component of each sub-cell.
  • the method includes forming at least one of the electrodes of each sub-cell, and forming the interconnect. In yet another embodiment, at least one of the electrodes of each sub-cell is formed independently from the formation of the interconnect, and at least one of the electrodes of each sub-cell is formed together with the formation of the interconnect.
  • the first electrode of a first sub-cell of the plurality of sub-cells is formed together with the first and the second layers of the interconnect, and the formation of the first electrode, the first layer and the second layer includes disposing a second-layer material of the interconnect over the second electrode of a first sub-cell, disposing a first-layer material of the interconnect over the second-layer material, disposing a first-electrode material of a second sub-cell over the first-layer, of the interconnect, and heating the materials such that the first-layer and second-layer materials of the interconnect form the first and second layers of the interconnect, respectively, and that the first-electrode material forms the first electrode.
  • the present invention is directed to a method of forming a fuel cell that includes a plurality of sub-cells, comprising the step of connecting each of the sub-cells with an interconnect having a thickness of between about 10 ⁇ m and about 100 ⁇ m.
  • Each sub-cell includes a first electrode in fluid communication with a source of oxygen gas, a second electrode in fluid communication with a source of a fuel gas, and a solid electrolyte between the first electrode and the second electrode.
  • the interconnect includes a first layer that includes a (La,Mn)Sr-titanate-based perovskite represented by the empirical formula of La y Sr (1 ⁇ y) Ti (1 ⁇ x) Mn x O b , wherein x is equal to or greater than zero and equal to or less than 0.6, y is equal to or greater than 0.2 and equal to or less than 0.8, and b is equal to or greater than 2.5 and equal to or less than 3.5.
  • the first layer is in contact with the first electrode of each sub-cell.
  • the interconnect also includes a second layer that includes a (La)Sr-titanate based perovskite represented by the empirical formula of Sr (1 ⁇ z ⁇ ) La z TiO d , wherein z is equal to or greater than zero and equal to or less than 0.4, d is equal to or greater than 2.5 and equal to or less than 3.5, and ⁇ is equal to or greater than zero and equal to or less than 0.05.
  • the second layer is in contact with the second electrode of each sub-cell.
  • the method includes forming at least one component of each sub-cell.
  • the method includes forming at least one of the electrodes of each sub-cell, and forming the interconnect.
  • At least one of the electrodes of each sub-cell is formed independently from the formation of the interconnect, and at least one of the electrodes of each sub-cell is formed together with the formation of the interconnect.
  • the first electrode of a first sub-cell of the plurality of sub-cells is formed together with the first and the second layers of the interconnect, and the formation of the first electrode, the first layer and the second layer includes disposing a second-layer material of the interconnect over the second electrode of a first sub-cell, disposing a first-layer material of the interconnect over the second-layer material, disposing a first-electrode material of a second sub-cell over the first-layer of the interconnect, and heating the materials such that the first-layer and second-layer materials of the interconnect form the first and second layers of the interconnect, respectively, and that the first-electrode material forms the first electrode.
  • Bi-layer ceramic interconnects of the invention meet all the major requirements for solid oxide fuel cell (SOFC) stack interconnects.
  • SOFC solid oxide fuel cell
  • (La,Mn)Sr-titanate based perovskite is stable and its electrical conductivity is high in an oxidizing atmosphere, and therefore this material can be used on the air side in the bi-layer ceramic interconnect.
  • (Nb,Y)Sr-titanate based perovskite and (La)Sr-titanate based perovskite is stable and its electrical conductivity is high in a reducing atmosphere, and therefore this material can be used on the fuel side in the bi-layer ceramic interconnect.
  • the present invention can be used in a solid oxide fuel cell (SOFC) system, particularly in planar SOFC stacks.
  • SOFCs offer the potential of high efficiency electricity generation, with low emissions and low noise operation. They are also seen as offering a favorable combination of electrical efficiency, co-generation efficiency and fuel processing simplicity.
  • One example of a use for SOFCs is in a home or other building.
  • the SOFC can use the same fuel as used to heat the home, such as natural gas.
  • the SOFC system can run for extended periods of time to generate electricity to power the home and if excess amounts are generated, the excess can be sold to the electric grid. Also, the heat generated in the SOFC system can be used to provide hot water for the home. SOFCs can be particularly useful in areas where electric service is unreliable or non-existent.
  • FIG. 1 is a schematic cross-sectional view of one embodiment of the invention.
  • FIG. 2 is a schematic diagram of a fuel cell of the invention in a planar, stacked design.
  • FIG. 3 is a schematic diagram of a fuel cell of the invention in a tubular design.
  • FIG. 4 is a scanning electron microscopic (SEM) image of an interconnect of the invention made of La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O 3 ⁇ and Sr 0.86 Y 0.08 TiO 3 ⁇ layers.
  • FIG. 1 shows fuel cell 10 of the invention.
  • Fuel cell 10 includes a plurality of sub-cells 12 .
  • Each sub-cell 12 includes first electrode 14 and second electrode 16 .
  • first and second electrodes 14 and 16 are porous.
  • first electrode 14 at least in part defines a plurality of first gas channels 18 in fluid communication with a source of oxygen gas, such as air.
  • Second electrode 16 at least in part defines a plurality of second gas channels 20 in fluid communication with a fuel gas source, such as H 2 gas or a natural gas which can be converted into H 2 gas in situ at second electrode 16 .
  • a fuel gas source such as H 2 gas or a natural gas which can be converted into H 2 gas in situ at second electrode 16 .
  • first electrodes 14 and second electrodes 16 define a plurality of gas channels 18 and 20
  • other types of gas channels such as a microstructured channel (e.g., grooved channel) at each of the electrodes or as a separate layer in fluid communication with the electrode, can also be used in the invention.
  • first gas channel 18 is defined at least in part by first electrode 14 and by at least in part by interconnect 24
  • second gas channel 20 is defined at least in part by second electrode 16 and by at least in part by interconnect 24 .
  • first electrode 14 includes a La-manganate (e.g, La 1 ⁇ a MnO 3 , where a is equal to or greater than zero, and equal to or less than 0.1) or La-ferrite based material.
  • La-manganate or La-ferrite based materials are doped with one or more suitable dopants, such as Sr, Ca, Ba, Mg, Ni, Co or Fe.
  • LaSr-manganates e.g., La 1 ⁇ k Sr k MnO 3 , where k is equal to or greater than 0.1, and equal to or less than 0.3, (La+Sr)/Mn is in a range of between about 1.0 and about 0.95 (molar ratio)
  • LaCa-manganates e.g., La 1 ⁇ k Ca k MnO 3 , k is equal to or greater than 0.1, and equal to or less than 0.3
  • La+Ca)/Mn is in a range of between about 1.0 and about 0.95 (molar ratio)
  • first electrode 14 includes at least one of a LaSr-manganate (LSM) (e.g., La 1 ⁇ k Sr k MnO 3 ) and a LaSrCo-ferrite (LSCF).
  • LSM LaSr-manganate
  • LSCF LaSrCo-ferrite
  • Common examples include (La 0.8 Sr 0.2 ) 0.98 MnO 3 ⁇ ( ⁇ is equal to or greater than zero, and equal to or less than 0.05) and La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3 .
  • second electrode 16 includes a nickel (Ni) cermet.
  • Ni cermet means a ceramic metal composite that includes Ni, such as about 20 wt %-70 wt % of Ni.
  • Ni cermets are materials that include Ni and yttria-stabilized zirconia (YSZ), such as ZrO 2 containing about 15 wt % of Y 2 O 3 , and materials that include Ni and Y-zirconia or Sc-zirconia.
  • An additional example of anode materials include Cu-cerium oxide.
  • Specific examples of Ni cermet include 67 wt % Ni and 33 wt % YSZ, and 33 wt % Ni and 67 wt % YSZ.
  • each of first and second electrodes 14 and 16 is independently is in a range of between about 0.5 mm and about 2 mm. Specifically, the thickness of each of first and second electrodes 14 and 16 is, independently, in a range of between about 1 mm and about 2 mm.
  • Solid electrolyte 22 is between first electrode 14 and second electrode 16 .
  • electrolyte 22 includes ZrO 2 doped with 8 mol % Y 2 O 3 (i.e., 8 mol % Y 2 O 3 -doped ZrO 2 .)
  • the thickness of solid electrolyte 22 is in a range of between about 5 ⁇ m and about 20 ⁇ m, such as between about 5 ⁇ m and about 10 ⁇ m.
  • the thickness of solid electrolyte 22 is thicker than about 100 ⁇ m (e.g., between about 100 ⁇ m and about 500 100 ⁇ m).
  • solid electrolyte 22 can provide structural support for fuel cell 10 .
  • Fuel cell 10 further includes interconnect 24 between sub-cells 12 .
  • Interconnect 24 includes first layer 26 in contact with first electrode 14 , and second layer 28 in contact with second electrode 16 .
  • First layer 26 includes a (La,Mn)Sr-titanate based perovskite represented by the empirical formula of La y Sr (1 ⁇ y) Ti (1 ⁇ x) Mn x O b , wherein x is equal to or greater than zero, and equal to or less than 0.6; y is equal to or greater than 0.2, and equal to or less than 0.8; and b is equal to or greater than 2.5, and equal to or less than 3.5.
  • the (La,Mn)Sr-titanate based perovskite is represented by the empirical formula of La 0.4 Sr 0.6 Ti (1 ⁇ x) Mn x O b , wherein values of x and b are as described above.
  • suitable (La,Mn)Sr-titanate based perovskites include La 0.4 Sr 0.6 TiO b , La 0.4 Sr 0.6 Ti 0.8 Mn 0.2 O b , La 0.4 Sr 0.6 Ti 0.6 Mn 0.4 O b and La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O b .
  • a La 0.4 Sr 0.6 Ti (1 ⁇ x) Mn x O b material is employed, and the material has an electrical conductivity of between about 20 S/cm and about 25 S/cm in air (e.g. about 22.6 S/cm) at about 810° C., and has an average density equal to or greater than 95% theoretical density.
  • Second layer 28 includes a (Nb,Y)Sr-titanate based perovskite represented by the empirical formula of Sr (1 ⁇ 1.5z ⁇ 0.5k ⁇ k) Y z Nb k Ti (1 ⁇ k) O d , or a (La)Sr-titanate based perovskite represented by the empirical formula of Sr (1 ⁇ z ⁇ ) La z TiO d , wherein each of k and z independently is equal to or greater than zero, and equal to or less than 0.4; and d is equal to or greater than 2.5, and equal to or less than 3.5 (e.g., equal to or greater than 2.9, and equal to or less than 3.2); and ⁇ is equal to or greater than zero, and equal to or less than 0.05.
  • a (Nb,Y)Sr-titanate based perovskite represented by the empirical formula of Sr (1 ⁇ 1.5z ⁇ 0.5k ⁇ k) Y z Nb k Ti (1 ⁇ k) O d
  • (Nb,Y)Sr-titanate based perovskite examples include Sr 0.86 Y 0.08 TiO 3 ⁇ , and Sr 0.995 Ti 0.99 Nb 0.01 O 3 ⁇ (wherein ⁇ is equal to or greater than zero, and equal to or less than 0.05).
  • a specific example of the (La)Sr-titanate based perovskites includes Sr 0.67 La 0.33 TiO 3 ⁇ (wherein ⁇ is equal to or greater than zero, and equal to or less than 0.05).
  • a Sr 0.86 Y 0.08 TiO 3 ⁇ or Sr 0.995 Ti 0.99 Nb 0.01 O 3 ⁇ material is employed, and has an average density equal to or greater than 95% theoretical density.
  • the Sr 0.86 Y 0.08 TiO 3 ⁇ and Sr 0.995 Ti 0.99 Nb 0.01 O 3 ⁇ materials have an electrical conductivity of about 82 S/cm and 10 S/cm, respectively, in a reducing environment (oxygen partial pressure of 10 ⁇ 19 atm) at about 800° C.
  • perovskite has the perovskite structure known in the art.
  • the perovskite structure is adopted by many oxides that have the chemical formula of ABO 3 .
  • the general crystal structure is a primitive cube with the A-cation in the center of a unit cell, the B-cation at the corners of the unit cell, and the anion (i.e., O 2 ⁇ ) at the centers of each edge of the unit cell.
  • the idealized structure is a primitive cube, but differences in ratio between the A and B cations can cause a number of different so-called distortions, of which tilting is the most common one.
  • perovskite with or without other terms in combination therewith (e.g., “(La,Mn)Sr-titanate based perovskite, “”(Nb,Y)Sr-titanate based perovskite,” and “(La)Sr-titanate based perovskite”) also includes such distortions.
  • the term “(La,Mn)Sr-titanate based perovskite” means a La- and/or Mn-substituted SrTiO 3 (Sr-titanate) having the perovskite structure.
  • La-substituted, Sr-titanate based perovskites have the perovskite structure of SrTiO 3 wherein a portion of the Sr atoms of SrTiO 3 are substituted with La atoms.
  • Mn-substituted, Sr-titanate based perovskites have the perovskite structure of SrTiO 3 wherein a portion of the Ti atoms of SrTiO 3 are substituted with Mn atoms.
  • La- and Mn-substituted, Sr-titanate based perovskites have the perovskite structure of SrTiO 3 wherein a portion of the Sr atoms of SrTiO 3 are substituted with La atoms, and a portion of the Ti atoms of SrTiO 3 are substituted with Mn atoms.
  • the term “(Nb,Y)Sr-titanate based perovskite” means a Nb- and/or Y-substituted, SrTiO 3 (Sr-titanate) having the perovskite structure.
  • Y-substituted, Sr-titanate based perovskites have the perovskite structure of SrTiO 3 wherein a portion of the Sr atoms of SrTiO 3 are substituted with Y atoms.
  • Nb-substituted, Sr-titanate based perovskites have the perovskite structure of SrTiO 3 wherein a portion of the Ti atoms of SrTiO 3 are substituted with Nb atoms.
  • Nb- and Y-substituted, Sr-titanate based perovskites have the perovskite structure of SrTiO 3 wherein a portion of the Sr atoms of SrTiO 3 are substituted with Y atoms, and a portion of the Ti atoms of SrTiO 3 are substituted with Nb atoms.
  • (La)Sr-titanate based perovskite means La-substituted SrTiO 3 (Sr-titanate) having the perovskite structure, wherein a portion of the Sr atoms of SrTiO 3 are substituted with La atoms.
  • La and Sr atoms occupy the A-cation sites, while Ti and Mn atoms occupy the B-cation sites.
  • Sr and Y atoms occupy the A-cation sites, while Ti and Nb atoms occupy the B-cation sites.
  • Sr and La atoms occupy the A-cation sites, while Ti atoms occupy the B-cation sites.
  • first layer 26 includes La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O 3 ⁇ and second layer 28 includes Sr 0.86 Y 0.08 TiO 3 ⁇ .
  • first layer 26 includes La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O 3 ⁇ and second layer 28 includes Sr 0.995 Ti 0.99 Nb 0.01 O 3 ⁇ .
  • first layer 26 includes La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O 3 ⁇ and second layer 28 includes Sr 0.67 La 0.33 TiO 3 ⁇ .
  • first electrode 14 includes (La 0.8 Sr 0.2 ) 0.98 MnO 3 ⁇ or La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3
  • second electrode 16 includes 67 wt % Ni and 33 wt % YSZ.
  • first electrode 14 includes (La 0.8 Sr 0.2 ) 0.98 MnO 3 ⁇ or La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3
  • second electrode 16 includes 67 wt % Ni and 33 wt % YSZ
  • electrolyte 22 includes 8 mol % Y 2 O 3 -doped ZrO 2 .
  • the thickness of each of first layer 26 and second layer 28 is in a range of between about 5 ⁇ m and about 1000 ⁇ m. Specifically, the thickness of each of first layer 26 and second layer 28 is in a range of between about 10 ⁇ m and about 1000 ⁇ m. In one specific embodiment, the thickness of second layer 28 is about 0.005 to about 0.5 of the total thickness of interconnect 24 .
  • Interconnect 24 can be in any shape, such as a planar shape (see FIG. 1 ) or a microstructured (e.g., grooved) shape (see FIG. 2 ). In one specific embodiment, at least one interconnect 24 of fuel cell 10 is substantially planar.
  • the thickness of interconnect 24 is in a range of between about 10 ⁇ m and about 1,000 ⁇ m. Alternatively, the thickness of interconnect 24 is in a range of between about 0.005 mm and about 2.0 mm. In one specific embodiment, the thickness of interconnect 24 is in a range of 10 ⁇ m and about 500 ⁇ m. In another embodiment, the thickness of interconnect 24 is in a range of 10 ⁇ m and about 200 ⁇ m. In yet another embodiment, the thickness of interconnect 24 is between about 10 ⁇ m and about 100 ⁇ m. In yet another embodiment, the thickness of interconnect 24 is between about 10 ⁇ m and about 75 ⁇ m. In yet another embodiment, the thickness of interconnect 24 is between about 15 ⁇ m and about 65 ⁇ m.
  • first electrode 14 and/or second electrode 16 has a thickness of between about 0.5 mm and about 2 mm thick; and interconnect 24 has a thickness of between about 10 ⁇ m and about 200 ⁇ m, specifically between about 10 ⁇ m and about 200 ⁇ m, and more specifically between about 10 ⁇ m and about 100 ⁇ m.
  • second layer 28 includes a SrLa-titanate based perovskite described above; and interconnect 24 has a thickness of between about 10 ⁇ m and about 100 ⁇ m, specifically between about 10 ⁇ m and about 75 ⁇ m, and more specifically between about 15 ⁇ m and about 65 ⁇ m.
  • At least one cell 12 includes porous first and second electrodes 14 and 16 , each of which is between about 0.5 mm and about 2 mm thick; solid electrolyte 22 has a thickness of between about 5 ⁇ m and about 20 ⁇ m; and interconnect 24 is substantially planar and has a thickness of between about 10 ⁇ m and about 200 ⁇ m.
  • electrolyte 22 includes 8 mol % Y 2 O 3 -doped ZrO 2 .
  • Fuel cell 10 of the invention can include any suitable number of a plurality of sub-cells 12 .
  • fuel cell 10 of the invention includes at least 30-50 sub-cells 12 .
  • Sub-cells 12 of fuel cell 10 can be connected in series or in parallel.
  • a fuel cell of the invention can be a planar stacked fuel cell, as shown in FIG. 2 .
  • a fuel cell of the invention can be a tubular fuel cell.
  • Fuel cells shown in FIGS. 2 and 3 independently have the characteristics, including specific variables, as described for fuel cell 10 shown in FIG. 1 (for clarity, details of cell components are not depicted in FIGS. 2 and 3 ).
  • the components are assembled in flat stacks, with air and fuel flowing through channels built into the interconnect.
  • the components are assembled in the form of a hollow tube, with the cell constructed in layers around a tubular cathode; air flows through the inside of the tube and fuel flows around the exterior.
  • the invention also includes a method of forming fuel cells as described above.
  • the method includes forming a plurality of sub-cells 12 as described above, and connecting each sub-cell 12 with interconnect 24 .
  • Fabrication of sub-cells 12 and interconnect 24 can employ any suitable techniques known in the art.
  • planar stacked fuel cells of the invention can be fabricated by particulate processes or deposition processes.
  • Tubular fuel cells of the invention can be fabricated by having the cell components in the form of thin layers on a porous cylindrical tube, such as calcia-stabilized zirconia.
  • a suitable particulate process such as tape casting or tape calendering, involves compaction of powders, such as ceramic powders, into fuel cell components (e.g., electrodes, electrolytes and interconnects) and densification at elevated temperatures.
  • suitable powder materials for electrolytes, electrodes or interconnects of the invention are made by solid state reaction of constituent oxides.
  • Suitable high surface area powders can be precipitated from nitrate and other solutions as a gel product, which are dried, calcined and comminuted to give crystalline particles.
  • the deposition processes can involve formation of cell components on a support by a suitable chemical or physical process. Examples of the deposition include chemical vapor deposition, plasma spraying and spray pyrolysis.
  • interconnect 24 is prepared by laminating a first-layer material of interconnect 24 , and a second-layer material of interconnect 24 , side by side at a temperature in a range of between about 50° C. and about 80° C. with a loading of between about 5 and about 50 tons, and co-sintered at a temperature in a range of 1,300° C. and about 1,500° C. for a time period sufficient to form interconnect layers having a high theoretical density (e.g., greater than about 90% theoretical density, or greater than about 95% theoretical density), to thereby form first layer 26 and second layer 28 , respectively.
  • a high theoretical density e.g., greater than about 90% theoretical density, or greater than about 95% theoretical density
  • interconnect 24 is prepared by sequentially forming first layer 26 and then second layer 28 (or forming second layer 28 and then first layer 26 ).
  • each of the first and second slurries can be sintered at a temperature in a range of 1,300° C. and about 1,500° C.
  • the first slurry of La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O b is sintered at about 1300° C. in air
  • the second slurry of Sr 0.86 Y 0.08 TiO d or Sr 0.995 Ti 0.99 Nb 0.01 O d is sintered at about 1400° C. in air.
  • sub-cells 12 are connected via interconnect 24 .
  • at least one of the electrodes of each sub-cell 12 is formed independently from interconnect 24 .
  • Formation of electrodes 14 and 16 of each sub-cell 12 can be done using any suitable method known in the art, as described above.
  • a second-layer material of interconnect 24 is disposed over second electrode 16 of a first sub-cell;
  • a first-layer material of interconnect 24 is disposed over the second-layer material, and
  • first electrode 14 of a second sub-cell is then disposed over the first-layer material of interconnect 24 .
  • a first-layer material of interconnect 24 is disposed over first electrode 14 of a second sub-cell; ii) a second-layer material of interconnect 24 is disposed over the first-layer material of interconnect 24 ; and iii) second electrode 16 of a first sub-cell is disposed over the second-layer material.
  • sintering the first-layer and second-layer materials forms first layer 26 and second layer 28 of interconnect 24 , respectively.
  • one or more electrodes of sub-cells 12 are formed together with formation of interconnect 24 .
  • a second-layer material of interconnect 24 is disposed over a second-electrode material of a first sub-cell; ii) a first-layer material of interconnect 24 is then disposed over the second-layer material; iii) a first-electrode material of a second sub-cell is disposed over the first-layer of interconnect 24 ; and iv) heating the materials such that the first-layer and second-layer materials of interconnect 24 form first layer 26 and second layer 28 of interconnect 24 , respectively, and that the first-electrode and second-electrode materials form first electrode 14 and second electrode 16 , respectively.
  • a second-layer material of interconnect 24 is disposed over second electrode 16 of a first sub-cell; ii) a first-layer material of interconnect 24 is disposed over the second-layer material; iii) disposing a first-electrode material of a second sub-cell over the first-layer of interconnect 24 , and iv) heating the materials such that the first-layer and second-layer materials of the interconnect form first layer 26 and second layer 28 of interconnect 24 , respectively, and that the first-electrode material forms first electrode 14 .
  • the fuel cells of the invention can be portable. Also, the fuel cells of the invention, such as SOFCs, can be employed as a source of electricity in homes, for example, to generate hot water.
  • the La 0.4 Sr 0.6 Ti 0.4 Mn 0.6 O 3 ⁇ powder was binderized before die-pressing with 0.5 wt % polyethylene glycol (PEG-400) and 0.7 wt % polyvinyl alcohol (PVA 21205) in order to increase the strength of the green body for handling.
  • the die-pressed LSTM/YST powders with a bi-layer structure were then co-sintered pressurelessly at 1350° C. for one hour in air.
  • the LSTM/YST bi-layer structure was cross sectioned, mounted in an epoxy, and polished for SEM (scanning electron microscope) examination.
  • FIG. 4 shows an SEM result of the fabricated LSTM/YST bi-layer structure. As shown in FIG.
  • both LSTM and YST materials were bonded very well to each other, and had a very high density.
  • the total thickness of the LSTM-YST bi-layer structure was about 1.20 mm; the thickness of LSTM layer was about 0.72 mm, and the thickness of YST layer was about 0.48 mm.
  • the relative densities of the LSTM layer and the YST layer were about 98% and about 94%, respectively.

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