One-step Preparation Large-Size 1.5-Μm-thickness Robust YSZ Electrolyte Using for High CH4 Conversion Efficiency SOFCs at 600 °C

Ultrathin electrolytes can lower the operating temperature of yttria-stabilized zirconia (YSZ)-based solid oxide fuel cells (SOFCs) to below 600 degrees C, accelerating their commercialization. However, current technologies for fabricating robust electrolytes with large areas and a thickness of a few microns for SOFCs suffer from substantial practical limitations, including high manufacturing costs, intricate technical demands, and multistep fabrication processes. This study introduces a low-cost, high-yield, and facile one-step phase inversion technology to fabricate large-area and shape-variable ultrathin YSZ electrolyte-based SOFCs (disc diameter >12 cm and area of 10 cm x 10 cm). An integrated form of SOFCs with dendritic YSZ microchannels supporting a 1.5-mu m-thick dense YSZ thin film was fabricated. The ultrathin electrolyte layer lowered ohmic and polarization losses, enhancing SOFC electrochemical performance. The integrated anode/electrolyte structure overcame the interfacial thermal mismatch, resulting in more than 210 h of long-term stability even with cells operating in rapidly changing environments. The single cell also exhibited a high CH4 conversion efficiency (55%), which was attributed to the fast gas diffusion and excellent catalytic activity within the integrated anode. In addition, our 4 cm x 4 cm flat SOFCs exhibited a high power output (5.1 W) at 600 degrees C, paving the way for the mass production of ultrathin and robust YSZ electrolytes.