Heterogeneous ceramic composite SOFC electrolyte

Abstract

A solid oxide fuel cell (SOFC) includes a cathode electrode, a solid oxide electrolyte, and an anode electrode. The electrolyte includes yttria stabilized zirconia and scandia stabilized zirconia, such as scandia ceria stabilized zirconia.

1 . A solid oxide fuel cell (SOFC), comprising:
 a cathode electrode;   a solid oxide electrolyte; and   an anode electrode;   wherein the electrolyte comprises a yttria stabilized zirconia and a scandia stabilized zirconia.   
   
   
       2 . The electrolyte of  claim 1 , wherein the electrolyte comprises a mixture of the yttria stabilized zirconia and the scandia stabilized zirconia. 
   
   
       3 . The SOFC of  claim 2 , wherein the scandia stabilized zirconia comprises up to 1 molar percent ceria, alumina or yttria, about 6 to about 11 molar percent scandia and a balance comprising zirconia. 
   
   
       4 . The SOFC of  claim 3 , wherein the electrolyte comprises a mixture of the yttria stabilized zirconia and scandia ceria stabilized zirconia. 
   
   
       5 . The SOFC of  claim 1 , wherein the electrolyte comprises a mixture of yttria stabilized zirconia and [(ZrO 2 ) 1-y (CeO 2 ) y ] 1-x (Sc 2 O 3 ) x , where 0.06≦x≦0.11 and 0≦y≦0.01. 
   
   
       6 . The SOFC of  claim 5 , wherein the yttria stabilized zirconia comprises 3 to 10 molar percent yttria. 
   
   
       7 . The SOFC of  claim 1 , wherein a weight ratio of the yttria stabilized zirconia to the scandia stabilized zirconia in the electrolyte ranges from 1:4 to 1:1. 
   
   
       8 . The SOFC of  claim 7 , wherein the weight ratio of the yttria stabilized zirconia to the scandia stabilized zirconia in the electrolyte ranges from 1:2 to 1:3. 
   
   
       9 . The SOFC of  claim 1 , wherein the electrolyte is about 150 to about 300 microns thick. 
   
   
       10 . A solid oxide fuel cell (SOFC), comprising:
 a cathode electrode;   a solid oxide electrolyte comprising a mixture of about 25 weight percent yttria stabilized zirconia which comprises 3 molar percent yttria, and about 75 weight percent scandia ceria stabilized zirconia which comprises 1 molar percent ceria and 10 molar percent scandia; and   an anode electrode.   
   
   
       11 . The SOFC of  claim 10 , wherein the anode electrode comprises:
 a first sublayer comprising samaria doped ceria; and   a second sublayer comprising a scandia ceria stabilized zirconia and gadolinia doped ceria ceramic phase and a nickel containing phase.   
   
   
       12 . A method of making a solid oxide fuel cell, comprising:
 mixing yttria stabilized zirconia powder with scandia stabilized zirconia powder to form a powder mixture;   shaping the powder mixture;   sintering the shaped powder mixture to form an electrolyte;   forming an anode electrode on a first side of the electrolyte; and   forming a cathode electrode on a second side of the electrolyte.