Multi-layered Layer Arrangement for a Solid Electrolyte

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This patent describes a novel multi-layer solid-state electrolyte structure used in electrochemical devices, especially high-temperature fuel cells (like solid oxide fuel cells, SOFCs). The electrolyte is made using physical vapour deposition methods to create alternating layers with different oxygen contents, resulting in a compact, gas-impervious, and thin electrolyte. This multi-layer (or 'sandwich') structure improves the overall performance and manufacturing efficiency of SOFCs, particularly those supported by metal substrates, by interrupting columnar structures that cause gas leakage and enhancing ionic conductivity without high-temperature sintering.

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

• Solid oxide fuel cells (SOFCs) for stationary or portable power generation.
• Auxiliary power units (APUs) for vehicles, including cars and utility vehicles.
• Electrolyzers for hydrogen production via water splitting.
• Electrochemical gas separation membranes.
• High-efficiency, compact power supplies for off-grid or remote applications.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables thinner electrolytes, reducing internal resistance and allowing lower operating temperatures, thus increasing fuel cell efficiency.
• Provides enhanced gas impermeability, improving the separation between fuel and oxidant and increasing device reliability.
• Eliminates the need for expensive, high-temperature sintering steps, lowering manufacturing costs and energy use.
• Improves mechanical stability, adhesion, and tolerance to thermal cycling, especially when used with metal substrates.
• Allows scalable manufacturing with precise control over layer thickness and composition through vapour deposition technologies.
• Potentially increases the lifespan and performance of fuel cells by minimizing defects and interruptions in the electrolyte structure.

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Patent Abstract

The invention relates to a cathode-electrolyte-anode unit for an electrochemical functional device, in particular a high-temperature fuel cell, said unit having a multi-layer solid-state electrolyte arranged between a porous anode and a porous cathode. The solid-state electrolyte is produced by means of a vapour deposition method and has a sandwich-type structure consisting of at least one first layer with a lower oxygen content, and at least one second layer with a higher oxygen content, wherein the individual layers have substantially the same composition, with the exception of oxygen.