Layer System for an Electrolyte of a High-Temperature Fuel Cell and Method for Producing the Same

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This patent describes a novel multilayer system for the electrolyte of a high-temperature fuel cell (specifically solid oxide fuel cells, SOFCs). The invention enables the construction of very thin (less than 3 μm) and dense electrolytes using physical vapor deposition (PVD) techniques, rather than conventional methods like screen printing or slurry casting. The system comprises at least three layers: two good ion conductors (which may also conduct electrons) and a central electrically insulating layer, all optimized for oxygen ion transport, gas-tightness, electronic insulation, and chemical stability. The process also allows optional adhesion layers for improved electrode contact. The method delivers superior fuel cell performance, lower resistance, and allows greater flexibility in the materials used.

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• High-temperature solid oxide fuel cells (SOFCs) for stationary power generation and combined heat-and-power systems.
• Electrolytes in gas separation membranes for industrial or environmental monitoring applications.
• Electrolyte layers in high-temperature electrolysers for hydrogen production.
• Advanced portable or mobile fuel cell systems requiring lightweight, high-performance components.
• Integration into energy systems where fuel cell efficiency and longevity are paramount, such as backup power for critical infrastructure.

BenefitsContent extracted from patent full text and abstract with AI.

• Greatly reduced electrolyte thickness (below 3 μm), which leads to lower cell resistance and higher fuel cell power output.
• Elimination of high-temperature sintering steps, thus reducing manufacturing costs and expanding the range of usable substrate and electrode materials.
• Improved mechanical and electrochemical contact between electrolyte and electrodes due to tailored adhesion layers, reducing performance losses at interfaces.
• Multilayer design inhibits chemical interactions between electrodes and electrolyte, improving long-term stability and device lifespan.
• Physical vapor deposition enables precise control over layer structure, composition, and thickness, which allows for customization for specific applications.
• Overall improved efficiency, reduced fuel consumption, and enhanced environmental friendliness of fuel cell systems.

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Patent Abstract

The invention relates to a series of layers for using as an electrolyte in a high-temperature fuel cell, in a gas separating membrane or an electrolyser, said series comprising the following layers: (EO) optional adhesion layer for optimising the anode/electrolyte contact and for the transition of the O2- ions from the electrolyte into the anode, these functions being optionally taken on by E1; E1 sealing element for ensuring gas-tightness between the anode and the cathode, sealing the surface pores of the anode and providing a base for the layer E2, E1 having sufficiently good O2- ion transporting properties; E2 sealing element for ensuring gas-tightness between the anode and the cathode and preventing an electron flow between the cathode and the anode, E2 having sufficiently good O2- ion transporting properties; E3 sealing element for ensuring gas-tightness between the anode and the cathode, and an additional blocking layer for cations of the cathode, E3 having sufficiently good O2- ion transporting properies; (E4) optional adhesion layer for optimising the cathode/electrolyte contact, improving the mechanical adhesion, and optimising the transition of the O2 ions from the cathode into the electrolyte. A cathode is inserted in order to complete a cell.