Electrode support structures for planar solid oxide fuel cells

The present work has focused on increasing the strength of planar solid oxide fuel cells (SOFCs) by providing an internal structural framework of zirconia embedded within an electrode. A honeycomb of zirconia is fabricated by an extrusion technique. This structure is laminated to the electrolyte prior to sintering such that after densification the open surface can be infiltrated with electrode material. The honeycomb provides improved mechanical support, allowing for a thinner electrode. In addition to increasing the mechanical strength, the zirconia substructure mitigates expansion mismatch issues between the electrolyte and electrodes in both anode- and cathode-supported cells. The invention may also provide a solution to spalling of anode materials during cell cycling of anode-supported SOFCs.