METHOD OF MAKING A LAYERED ELECTROLYTE

• US 20200136150A1
• Filed: 10/30/2019
• Published: 04/30/2020
• Est. Priority Date: 10/30/2018
• Status: Active Application

• Current Assignee: Phillips 66 Company
• Original Assignee: Phillips 66 Company
• Inventors: Liu, Mingfei, Liu, Ying
• Application Number:
  US16/668,792
• Publication Number:
  US 20200136150A1
• Time in Patent Office: Days
• CPC Class Codes: H01M 2004/8684 Negative electrodes
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 2300/0074 Ion conductive at high temperature
• CPC Class Codes: H01M 2300/0077 based on zirconium oxide
• CPC Class Codes: H01M 2300/0094 in the form of layered products, e.g. coatings
• CPC Class Codes: H01M 4/8621 containing only metallic or ceramic material, e.g. made by sintering or sputtering
• CPC Class Codes: H01M 4/8803 Supports for the deposition of the catalytic active composition H01M4/90 takes precedence
• CPC Class Codes: H01M 4/8828 Coating with slurry or ink
• CPC Class Codes: H01M 4/8889 Cosintering or cofiring of a catalytic active layer with another type of layer
• CPC Class Codes: H01M 4/9025 Oxides specially used in fuel cell operating at high temperature, e.g. SOFC
• CPC Class Codes: H01M 4/9066 of metal-ceramic composites or mixtures, e.g. cermets
• CPC Class Codes: H01M 8/1213 characterised by the electrode/electrolyte combination or the supporting material
• CPC Class Codes: H01M 8/124 characterised by the process of manufacturing or by the material of the electrolyte
• CPC Class Codes: H01M 8/1253 the electrolyte containing zirconium oxide
• CPC Class Codes: H01M 8/126 the electrolyte containing cerium oxide
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A method of forming a solid oxide fuel cell. The method begins by tape casting an anode support. Next an anode functional layer slurry comprising of NiO and ScCeSZ ceramic powder is coated onto the anode support. The anode functional layer slurry is then dried to form an NiO—ScCeSZ anode functional layer on the anode support. A first electrolyte layer comprising of a ScCeSZ slurry is then coated onto the NiO—ScCeSZ functional layer. The first electrolyte layer is then dried to form a ScCeSZ electrolyte layer on the NiO—ScCeSZ functional layer. A second electrolyte layer comprising of a samarium doped CeO₂ (SDC) slurry is then coated onto the ScCeSZ electrolyte layer. The second electrolyte layer is then dried to form a SDC electrolyte layer on the ScCeSZ electrolyte layer. The combined anode support, the NiO—ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer is then sintered together. A cathode slurry is then coated onto the SDC electrolyte layer to form a cathode layer. A solid oxide fuel cell is then formed when the combined anode support, the NiO—ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, the SDC electrolyte layer, and the cathode layer is then sintered together.

Claims

1. A method comprising:

tape casting an anode support;

coating an anode functional layer slurry comprising of NiO and ScCeSZ ceramic powder onto the anode support;

drying the anode functional layer slurry to form an NiO—

ScCeSZ anode functional layer on the anode support;

coating a first electrolyte layer comprising of a ScCeSZ slurry onto the NiO—

ScCeSZ functional layer;

drying the first electrolyte layer to form a ScCeSZ electrolyte layer on the NiO—

ScCeSZ functional layer;

coating a second electrolyte layer comprising of a samarium doped CeO₂ (SDC) slurry onto the ScCeSZ electrolyte layer;

drying the second electrolyte layer to form a SDC electrolyte layer on the ScCeSZ electrolyte layer;

sintering the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer together;

coating a cathode slurry onto the SDC electrolyte layer to form a cathode layer;

sintering the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, the SDC electrolyte layer, and the cathode layer to form a solid oxide fuel cell.

2. The method of claim 1, wherein the sintering of the combined anode support, the NiO—

ScCeSZ functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer occurs at temperatures from about 1,200°

C. to about 1,300°

C. for around 2 hours.

3. The method of claim 1, wherein the weight percent of the NiO of the anode functional layer slurry ranges from about 5 wt % to about 6 wt %.

4. The method of claim 1, wherein the weight percent of the ScCeSZ ceramic powder of the anode functional layer slurry ranges from about 4 wt % to about 5 wt %.

5. The method of claim 1, wherein the thickness of the NiO—

ScCeSZ anode functional layer ranges from about 5 to about 50 μ

m.

6. The method of claim 1, wherein the weight percent of the ScCeSZ slurry of the first electrolyte layer ranges from about 2.5 wt % to about 3.5 wt %.

7. The method of claim 1, wherein the thickness of the ScCeSZ electrolyte layer ranges from about 1.5 μ

m to about 2.5 μ

m.

8. The method of claim 1, wherein the weight percent of the SDC slurry of the second electrolyte layer ranges from about 9 wt % to about 11 wt %.

9. The method of claim 1, wherein the thickness of the SDC electrolyte layer ranges from about 9.5 μ

m to about 10.5 μ

m.

10. The method of claim 1, wherein the drying of the first electrolyte layer occurs at temperatures less than 50°

C.

11. The method of claim 1, wherein the drying of the second electrolyte layer occurs at temperatures less than 50°

C.

12. The method of claim 1, wherein the coating can be done by spray coating, ultrasonic spray coating, thermal spray coating, spin coating, dip coating, sputtering, e-beam evaporation, and electrophoretic deposition.

13. A method comprising:

tape casting an anode support;

spray coating an anode functional layer slurry consisting of NiO, ScCeSZ ceramic powder, and ethyl alcohol onto the anode support;

drying the anode functional layer slurry, at temperatures less than 50°

C., to form an NiO—

ScCeSZ anode functional layer on the anode support;

spray coating a first electrolyte layer consisting of a ScCeSZ slurry onto the NiO—

ScCeSZ functional layer;

drying the first electrolyte layer, at temperatures less than 50°

C., to form a ScCeSZ electrolyte layer on the NiO—

ScCeSZ functional layer;

spray coating a second electrolyte layer consisting of a samarium doped CeO₂ (SDC) slurry onto the ScCeSZ electrolyte layer;

drying the second electrolyte layer, at temperatures less than 50°

C., to form a SDC electrolyte layer on the ScCeSZ electrolyte layer;

sintering the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer together, at temperatures from about 1,000°

C. to about 1,300°

C.;

cooling the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer to room temperature;

spray coating a cathode slurry onto the SDC electrolyte layer to form a cathode layer;

sintering the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, the SDC electrolyte layer, and the cathode layer, at a temperature below 1,000°

C., to form a solid oxide fuel cell.

14. The method of claim 13, wherein the sintering of the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer occurs at temperatures from about 1,200°

C. to about 1,300°

C. for around 2 hours.

15. The method of claim 13, wherein the weight percent of the NiO of the anode functional layer slurry ranges from about 5 wt % to about 6 wt %.

16. The method of claim 13, wherein the weight percent of the ScCeSZ ceramic powder of the anode functional layer slurry ranges from about 4 wt % to about 5 wt %.

17. The method of claim 13, wherein the thickness of the NiO—

ScCeSZ anode functional layer ranges from about 5 to about 50 μ

m.

18. The method of claim 13, wherein the weight percent of the ScCeSZ slurry of the first electrolyte layer ranges from about 2.5 wt % to about 3.5 wt %.

19. The method of claim 13, wherein the thickness of the ScCeSZ electrolyte layer ranges from about 1.5 μ

m to about 2.5 μ

m.

20. The method of claim 13, wherein the weight percent of the SDC slurry of the second electrolyte layer ranges from about 9 wt % to about 11 wt %.

21. The method of claim 13, wherein the thickness of the SDC electrolyte layer ranges from about 9.5 μ

m to about 10.5 μ

m.

22. A method comprising:

tape casting an anode support;

ultrasonic spray coating an anode functional layer slurry comprising of 5.5 wt % NiO and 4.5 wt % ScCeSZ ceramic powder, and ethyl alcohol onto the anode support, wherein the spray coating is done four times at a deposition rate of 1.0 mL/min;

drying the anode functional layer slurry, at temperatures less than 50°

C., to form an NiO—

ScCeSZ anode functional layer on the anode support;

ultrasonic spray coating a first electrolyte layer consisting of a 3 wt % ScCeSZ slurry onto the NiO—

ScCeSZ anode functional layer;

drying the first electrolyte layer, at temperatures less than 50°

C., to form a ScCeSZ electrolyte layer on the NiO—

ScCeSZ anode functional layer, wherein the thickness of the ScCeSZ electrolyte layer ranges from about 1.5 m to about 2.5 m;

ultrasonic spray coating a second electrolyte layer consisting of a 10 wt % samarium doped CeO₂ (SDC) slurry onto the ScCeSZ electrolyte layer;

drying the second electrolyte layer, at temperatures less than 50°

C., to form a SDC electrolyte layer on the ScCeSZ electrolyte layer, wherein the thickness of the SDC electrolyte layer ranges from about 9.5 μ

m to about 10.5 μ

m;

sintering the combined anode support, the NiO—

ScCeSZ functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer together, at temperatures from about 1,000°

C. to about 1,300°

C.;

cooling the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, and the SDC electrolyte layer to room temperature;

ultrasonic spray coating a cathode slurry onto the SDC electrolyte layer to form a cathode layer;

sintering the combined anode support, the NiO—

ScCeSZ anode functional layer, the ScCeSZ electrolyte layer, the SDC electrolyte layer, and the cathode layer, at a temperature below 1,000°

C., to form a solid oxide fuel cell.