Anode for a high temperature fuel cell and production of same

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The patent describes a substrate-supported anode for high-temperature solid oxide fuel cells (SOFCs). This anode consists of a three-layer laminate made from yttrium oxide-stabilized zirconia (YSZ) and nickel, applied on a metallic substrate, with a grain size gradient in the nickel component across layers for optimized performance. The metallic substrate is made from chromium-based alloys, and a diffusion barrier is placed between substrate and anode layers. The design enables smooth, high-quality surfaces suitable for thin, gas-tight electrolyte layers, allowing the fuel cell to operate efficiently at lower temperatures (650-750°C) with simplified and more cost-effective manufacturing.

Use CasesContent extracted from patent full text and abstract with AI.

• Solid oxide fuel cells (SOFCs) for stationary power generation and combined heat and power (CHP) systems
• Auxiliary power units (APUs) for vehicles, such as trucks and recreational vehicles
• Backup and distributed power supply solutions
• Micro-CHP systems for residential or commercial buildings
• Portable high-efficiency fuel cell stacks for remote sites or off-grid applications
• Clean energy production in industrial and research facilities

BenefitsContent extracted from patent full text and abstract with AI.

• Improved mechanical strength and durability compared to fully ceramic supports, thanks to the metallic substrate.
• Lower operating temperatures (650-750°C), enabling the use of less expensive materials and improving system longevity.
• Enhanced electrochemical performance through controlled multi-layer structure and grain size optimization in the anode.
• Superior surface smoothness facilitates the deposition of very thin, gas-tight electrolyte layers, reducing internal resistance and losses.
• Improved manufacturing process efficiency and compatibility with established screen printing and sintering techniques.
• Reduced costs by using cheaper metal substrates rather than all-ceramic designs.

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Patent Abstract

The substrate-supported anode for a high-temperature fuel cell, comprises 3-layer anode laminate (AI, A2, A3) on a metal substrate (S), where the individual layers of the anode laminate each comprise yttrium-oxide-stabilized zirconium dioxide (YSZ) and nickel, a metallic substrate made of chromium based alloy with a chromium content of more than 65 wt.% or a ferritic FeCrMx alloy with a chromium content of 20-30 wt.% and with Mx = an element or an oxide of the group of rare earth metal such as scandium, titanium, aluminum, manganese, molybdenum or cobalt, and a diffusion barrier (D). The substrate-supported anode for a high-temperature fuel cell, comprises 3-layer anode laminate (AI, A2, A3) on a metal substrate (S), where the individual layers of the anode laminate each comprise yttrium-oxide-stabilized zirconium dioxide (YSZ) and nickel, a metallic substrate made of chromium based alloy with a chromium content of more than 65 wt.% or a ferritic FeCrMx alloy with a chromium content of 20-30 wt.% and with Mx = an element or an oxide of the group of rare earth metal such as scandium, titanium, aluminum, manganese, molybdenum or cobalt, and a diffusion barrier (D) arranged between the metallic substrate and the first layer of the anode laminate. The average grain size of the nickel decreases from layer to layer with increasing distance from the substrate. The last layer of the anode laminate, which is intended for contact with the electrolyte has a rootmean- square roughness Rq of less than 4 mu m. The metallic substrate has an average grain size of 20-50 mu m. The last layer of the anode laminate has an average grain size of less than 4 mu m in the nickel phase or an overall average grain size of less than 1.5 mu m. The first layer of the anode laminate has an average grain size of 4-15 mu m in the nickel phase or overall average grain size of 1-8 mu m. The second layer of the anode laminate has an average grain size of 2-7 mu m in the nickel phase or overall average grain size of 0.5-4 mu m. An independent claim is included for a method for producing a substrate-supported anode for a high-temperature fuel cell.