Patent ID: 7947213

Claim:
A method of making solid oxide electrolyte sheet, said method comprising the steps of: (a) providing a green slip on a carrier, said slip containing a volatile material to form a green electrolyte sheet having (i) transition temperature Tg, wherein −10° C.<Tg<30° C., and (ii) an average thickness of less than 100 microns; (b) at least partially evaporating said volatile material; (c) embossing said green electrolyte sheet with at least 0.5 micrometer variations in its thickness thereby providing textured green sheet; (d) sintering the textured green sheet to provide an electrolyte sheet with substantially non-porous body, the non porous body having a textured surface with multiple indentations therein, wherein the thickest part of the electrolyte sheet is 0.5 to 6 micrometers greater than the thinnest part of the electrolyte sheet said indentations have depth to width ratio between 1:1 and 6:1, and the electrolyte sheet has an average thickness of less than 100 microns.