Reactive deposition for electrochemical cell production

• US 7,521,097 B2
• Filed: 05/27/2004
• Issued: 04/21/2009
• Est. Priority Date: 06/06/2003
• Status: Expired due to Fees

• Current Assignee: Nanogram Corporation (Teijin Limited)
• Original Assignee: Nanogram Corporation (Teijin Limited)
• Inventors: McGovern, William E., Horne, Craig R., Mosso, Ronald J., Lynch, Robert B.
• Primary Examiner(s): Meeks; Timothy H
• Assistant Examiner(s): TUROCY, DAVID P
• Application Number:
  US10/854,931
• Publication Number:
  US 20050016839A1
• Time in Patent Office: 1,790 Days
• Field of Search: 427/585, 427/596, 427/115, 427/248.1, 429/12, 429/34, 429/40, 429/122, 429/209
• US Class Current: 427/585
• CPC Class Codes: C23C 16/403 of aluminium, magnesium or beryllium
• CPC Class Codes: C23C 16/405 of refractory metals or yttrium
• CPC Class Codes: C23C 16/483 using coherent light, UV to IR, e.g. lasers
• CPC Class Codes: C23C 18/06 Coating on selected surface areas, e.g. using masks
• CPC Class Codes: C23C 18/1204 inorganic material, e.g. non-oxide and non-metallic such as sulfides, nitrides based compounds
• CPC Class Codes: C23C 18/1216 Metal oxides C23C18/1212 takes precedence
• CPC Class Codes: C23C 18/1241 Metallic substrates
• CPC Class Codes: C23C 18/143 Radiation by light, e.g. photolysis or pyrolysis
• CPC Class Codes: C23C 24/00 Coating starting from inorganic powder spraying of the coating material in molten state C23C4/00; solid state diffusion C23C8/00 - C23C12/00
• CPC Class Codes: C23C 26/00 Coating not provided for in groups C23C2/00 - C23C24/00
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 2300/0082 Organic polymers
• 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 4/8885 Sintering or firing
• CPC Class Codes: H01M 4/9066 of metal-ceramic composites or mixtures, e.g. cermets
• CPC Class Codes: H01M 4/92 Metals of platinum group H01M4/94 , H01M4/9058 take precedence
• CPC Class Codes: H01M 8/0271 Sealing or supporting means around electrodes, matrices or membranes
• CPC Class Codes: H01M 8/0273 with sealing or supporting means in the form of a frame
• CPC Class Codes: H01M 8/1213 characterised by the electrode/electrolyte combination or the supporting material
• CPC Class Codes: H01M 8/1246 : the electrolyte consisting of oxides
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

Light reactive deposition can be adapted effectively for the deposition of one or more electrochemical cell components. In particular, electrodes, electrolytes, electrical interconnects can be deposited form a reactive flow. In some embodiments, the reactive flow comprises a reactant stream that intersects a light beam to drive a reaction within a light reactive zone to produce product that is deposited on a substrate. The approach is extremely versatile for the production of a range of compositions that are useful in electrochemical cells and fuel cell, in particular. The properties of the materials, including the density and porosity can be adjusted based on the deposition properties and any subsequent processing including, for example, heat treatments.

Claims

1. A method for forming an electrochemical cell, the method comprising performing the sequential reactive deposition of an elemental metal or metal alloy, and a metalloid oxide, wherein the reactive deposition comprises moving a substrate or platen relative to a product flow for at least a portion of the time period when deposition is being performed and wherein the sequential reactive depositions are performed with respect to a single reaction zone, wherein a reactant flow intersects with a light beam to drive a reaction that forms the product flow and wherein the reactant flow is generated from an inlet nozzle.

2. The method of claim 1 wherein the metalloid oxide comprises silicon oxide.

3. The method of claim 1 wherein the sequential deposition is performed on a metal support layer.

4. The method of claim 1 wherein the elemental metal or alloy comprises copper.

5. The method of claim 1 wherein the reactant flow comprises an aerosol.

6. A method for forming a fuel cell component, the method comprising contacting a cell assembly with a solvent to dissolve a soluble material and to form reactant flow channels to an electrode wherein the soluble material is deposited from a reactive flow involving a reactant stream that intersects a light beam to form a product flow that intersects with the substrate to deposit a reaction product onto the substrate.

7. The method of claim 6 wherein the soluble material comprises a soluble metal/metalloid composition.

8. A method of sealing fuel cells comprising heating a stack of cells wherein each cell has a rim that contacts the rim of an adjacent cell and wherein a sealing material is deposited along the rim, the sealing material having been deposited from a reactive flow wherein the reactive flow involves a reactant flow that intersects a light beam that drives a reaction to form a product flow that intersects a substrate to deposit the product material.

9. The method of claim 8 wherein the sealing material is a glass.

10. The method of claim 8 wherein the sealing material comprises a metal ceramic.