Donald E Busch

US Patent:

48834971, Nov 28, 1989

Filed:

Mar 28, 1988

Appl. No.:

7/174146

Inventors:

Terry D. Claar - Tisle IL
Donald E. Busch - Hinsdale IL
John J. Picciolo - Lockport IL

Assignee:

Arch Development Corporation - Chicago IL

International Classification:

H01M 810

US Classification:

296235

Abstract:

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.