Template-assisted fabrication of macroporous thin films for solid oxide fuel cells

Template-assisted fabrication based on polystyrene (PS) colloidal crystals has been used to prepare three-dimensionally ordered macroporous (3-DOM) thin films of yttria stabilized zirconia (YSZ). This material has direct application in solid oxide fuel cells (SOFCs). High quality 3-DOM thin films were successfully fabricated, and the microstructures of both the polystyrene opal and the thus-prepared YSZ thin film were characterized using scanning electron microscopy (SEM). Remarkably although a large shrinkage of the thin film was observed, the YSZ domains still retained adherence to the substrate. A new mechanism for shrinkage is proposed and discussed.