High strength porous support tubes for high temperature solid electrolyte electrochemical cells

Claim 2

A high temperature electrochemical cell comprising an electrode, a separate solid oxide electrolyte and a separate porous, sintered material supporting said electrolyte and electrode, said porous, sintered material comprising a mixture of thermally stable oxide powder particles and thermally stable oxide fibers, where the oxide powder particles and the oxide fibers are sintered together in interlocking contact, said fibers being thermally stable up to about 1700° C., and comprising from about 3 wt. % to about 45 wt. % of the sintered material.

Claim 3

The electrochemical cell of claim 1, where the coefficient of thermal expansion of the fibers approximates that of the oxide powder particles in the porous sintered material.

Claim 4

In a high temperature, solid electrolyte electrochemical cell having two electrodes with a separate solid electrolyte therebetween, where one of the electrodes is disposed on a separate porous, sintered, support material comprising zirconia powder particles, the improvement comprising inclusion in the sintered support material of from about 3 wt. % to about 45 wt. % of thermally stable oxide fibers, where the coefficient of thermal expansion of the oxide fibers approximates that of the zirconia powder particles, and the zirconia powder particles and the oxide fibers are sintered together in interlocking contact, said fibers being thermally stable up to about 1700° C.

Claim 5

In a high temperature, solid electrolyte electrochemical cell having two electrodes with a separate solid electrolyte therebetween, where one of the electrodes is disposed on a separate porous, sintered, support material comprising zirconia powder particles, the improvement comprising inclusion in the sintered support material of from about 3 wt. % to about 45 wt. % of thermally stable oxide fibers, where the coefficient of thermal expansion of the oxide fibers approximates that of the zirconia powder particles, and the zirconia powder particles and the oxide fibers are sintered together in interlocking contact, said fibers being thermally stable up to about 1700° C.

Claim 6

The electrochemical cell of claim 3, where the oxide fiber material in the support is not substantially reactive with the zirconia particle material at sintering temperatures of the support, and where the fibers in the support have lengths of from about 800 microns to about 2400 microns and diameters of from about 0.5 micron to about 20 microns, and the powder particles have diameters of from about 1 micron to about 100 microns.

Claim 7

The electrochemical cell of claim 3, where the support is from about 0.5 millimeter to about 2 millimeters thick and the oxide fibers in the support are selected from the group consisting of yttria stabilized zirconia fibers, calcia stabilized zirconia fibers, alumina fibers, mullite fibers, and mixtures thereof.

Claim 8

The electrochemical cell of claim 3, where the oxide fibers in the support are selected from the group consisting of yttria stabilized zirconia fibers, calcia stabilized zirconia fibers, and mixtures thereof, the fibers are sinterable to each other and to the zirconia particles in the support at sintering temperatures of up to 1700° C. and do not melt or form a structurally weak phase, and where the fibers in the support comprise from about 5 wt. % to about 20 wt. % of the support material.

Claim 9

The electrochemical cell of claim 3, where the support particles are comprised of calcia stabilized zirconia, the first electrode is comprised of doped and undoped oxides or mixtures of oxides, the electrolyte is cmprised of stabilized zirconia, and the second electrode is selected from the group consisting of nickel zirconia cermet and cobalt zirconia cermet.

Claim 10

A high temperature, solid electrolyte, tubular fuel cell comprising: (1) a porous, sintered, support tube comprising zirconia powder particles and from about 3 wt. % to about 45 wt. % of thermally stable oxide fibers, where the zirconia powder particles and the oxide fibers are sintered together in interlocking contact, said fibers being thermally stable up to about 1700° C., (2) a separate first electrode disposed on the support, (3) a separate second electrode spaced away from the first electrode, and (4) a separate solid electrolyte disposed between the first electrode and the second electrode.

Claim 11

A high temperature, solid electrolyte, tubular fuel cell comprising: (1) a porous, sintered, support tube comprising zirconia powder particles and from about 3 wt. % to about 45 wt. % of thermally stable oxide fibers, where the zirconia powder particles and the oxide fibers are sintered together in interlocking contact, said fibers being thermally stable up to about 1700° C., (2) a separate first electrode disposed on the support, (3) a separate second electrode spaced away from the first electrode, and (4) a separate solid electrolyte disposed between the first electrode and the second electrode.

Claim 12

The fuel cell of claim 8, where the support particles are comprised of calcia stabilized zirconia, the first electrode is comprised of doped and undoped oxides for mixtures of oxides, the electrolyte is comprised of stabilized zirconia, the second electrode is selected from the group consisting of nickel zirconia cermet and cobalt zirconia cermet, and where the coefficient of thermal expansion of the fibers in the support approximates that of the zirconia powder particles in the support.

Claim 13

The fuel cell of claim 8, where the oxide film material in the support is not substantially reactive with the zirconia particle material at sintering temperatures of the support, and where the fibers in the support have lengths of from about 800 microns to about 2400 microns and diameters of from about 0.5 micron to about 20 microns, and the powder particles have diameters of from about 1 micron to about 100 microns.

Claim 14

The fuel cell of claim 8, where the support is from about 0.5 millimeter to about 2 millimeters thick, and the oxide fibers in the support are selected from the group consisting of yttria stabilized zirconia fibers, calcia stabilized zirconia fibers, alumina fibers, mullite fibers, and mixtures thereof.

Claim 15

The fuel cell of claim 8, where the oxide fibers in the support are selected from the group consisting of yttria stabilized zirconia fibers, calcia stabilized zirconia fibers, and mixtures thereof, the fibers are sinterable to each other and to the zirconia particles in the support at sintering temperatures of up to 1700° C. and do not melt or form a structurally weak phase, and where the fibers in the support comprise from about 5 wt. % to about 20 wt. % of the support material.