Direct hydrocarbon fuel cells

Abstract

A solid oxide fuel cell assembly (SOFC) having an array of SOFC's ( 12 ) connected in series by thin-film interconnects ( 22 ) are deposited onto a porous, insulating support ( 14 ), the layer ( 12 ) can be deposited in the order of electrode, electrolyte, interconnect and electrode. The patterning is such that the electrolyte ( 20 ) and interconnect ( 22 ), both of which are dense layers, are continuous, and form a gas-tight seal over the entire surface.

1 . A solid oxide fuel cell assembly, comprising: 
 a substantially planar array of fuel cells on a substrate, each said cell comprising cathode, anode, electrolyte and electrode interconnect component structures, each said component structure of each said cell having a sub-planar arrangement of one said component structure to another;    an oxidant cavity adjacent said substrate; and    a fuel cavity adjacent said sub-planar anode arrangement.    
     
     
         2 . The assembly of  claim 1  wherein said anode comprises a composite having a catalytic metal and a ceria material, said metal present in an amount less than 60 weight percent of said anode.  
     
     
         3 . The assembly of  claim 2  wherein said metal is catalytic for the cracking of hydrocarbons.  
     
     
         4 . The assembly of  claim 3  wherein said metal is selected from the group consisting of Pt, Ru, Pd, Fe, Co and Ni.  
     
     
         5 . The assembly of  claim 4  wherein each said metal is present in an amount less than about 40 weight percent.  
     
     
         6 . The assembly of  claim 2  wherein said ceria material further includes a dopant.  
     
     
         7 . The assembly of  claim 2  wherein said anode is a nickel composite.  
     
     
         8 . The assembly of  claim 7  wherein said composite further includes zirconia.  
     
     
         9 . The assembly of  claim 2  wherein said zirconia is an electrolyte, said zirconia doped with yttria.  
     
     
         10 . A solid oxide fuel cell composite comprising: 
 a substantially planar electrically-insulating substrate;    a plurality of cathode components on said substrate, each said cathode component spaced one from another;    an electrolyte on and between each said cathode component;    a plurality of anode components, each said anode component spaced one from another and corresponding in number to said plurality of cathode components; and    an interconnect component contacting a portion of each said cathode component and a portion of each said corresponding anode component.