Development of multilayer imprint process for solid oxide fuel cells

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Solid oxide fuel cells (SOFCs) are fuel cells made of ceramics. To increase the SOFC energy density, we developed an SOFC with a wavy electrolyte layer. As a wavy electrolyte has a larger reaction surface area than a flat electrolyte, a higher energy density could be obtained. Our proposed process is named micro-powder imprint (µPI) with a multilayer imprint process that is useful for fabricating a microscale pattern on a ceramic sheet such as an SOFC electrolyte layer. µPI is based on nanoimprint lithography; therefore, it also exhibits the same advantages of high resolution and mass productivity. The starting material for µPI is a compound sheet containing ceramic powder and binder materials consisting of thermoplastic resin. In this study, two different sheets were stacked into one sheet as a multilayer sheet for the µPI process to form a wavy compound sheet. As the initial state of the stacked sheet, including the mechanical properties of each layer, affects the final wavy shape, we changed the material composition. As a result, the SOFCs unit cell with a wavy electrolyte was fabricated. Note that the anode layer was formed at the same time. After adding the cathode layer, we succeeded in preparing a complete cell for testing power generation.

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