High-throughput systems and methods for the fabrication and optimization of materials and components for solid oxide fuel cells

A system for the fabrication of an array of electrode or electrolyte materials suitable for use in a solid oxide fuel cell, the system comprising:

• a liquid handling device operable for delivering one or more materials to a plurality of regions of a non-sintered or partially-sintered substrate;
• a mask operable for controlling which of the plurality of regions of the substrate receive the one or more materials;
• and
• a vacuum device operable for drawing the one or more materials into the interior of the substrate.

A method for the fabrication and evaluation of an array of solid oxide fuel cells, the method comprising:

• attaching a host material to an anode material, wherein the host material displays a desired electrolyte performance characteristic;
• selectively doping a plurality of regions of the host material with a predetermined chemical species, wherein each of the plurality of doped regions of the host material forms a cathode material, and wherein the plurality doped regions of the host material form an array of electro-active compositions;
• wherein the cathode material is disposed adjacent to and in a spaced-apart relationship with the anode material;
• and
• sintering the array of solid oxide fuel cells.

A method for determining the relative performance of a plurality of cathode compositions for use in solid oxide fuel cells, the method comprising:

• providing a substrate, wherein the substrate comprises a dense electrolyte having a cathode-side and a counter electrode-side;
• disposing a porous layer on the cathode-side of the dense electrolyte, wherein the porous layer is positioned distally from the counter electrode-side;
• infiltrating a predetermined amount of each of a plurality of precursor solutions into a plurality of regions of the porous layer, forming a plurality of potential cathode compositions within the substrate;
• reacting the plurality of precursor solutions, forming oxides;
• and
• measuring the relative performance of each of the plurality of cathode compositions.

A method for determining the relative performance of a plurality of cathode compositions for use in solid oxide fuel cells, the method comprising:

• providing a substrate, wherein the substrate comprises a dense yttria-stabilized zirconia electrolyte, and wherein the substrate comprises a cathode-side and a counter electrode-side;
• coupling a counter electrode to the counter electrode-side of the substrate;
• disposing a porous yttria-stabilized zirconia layer on the cathode-side of the dense yttria-stabilized zirconia electrolyte, wherein the porous yttria-stabilized zirconia layer is positioned distally from the counter electrode;
• infiltrating a predetermined amount of each of a plurality of precursor solutions into a plurality of regions of the porous yttria-stabilized zirconia layer, forming a plurality of potential cathode compositions within the substrate;
• reacting the plurality of precursor solutions, forming oxides;
• and
• measuring the relative performance of each of the plurality of cathode compositions.

A high-throughput method for fabricating an array of materials suitable for use in a solid oxide fuel cell, wherein each of a plurality of members of the array of materials may be evaluated for its relative performance, the method comprising:

• providing a plurality of components;
• delivering a predetermined amount of each of the plurality of components to the surface of a substrate, wherein the predetermined amount of each of the plurality of components is delivered to the surface of the substrate from a common location;
• moving the substrate relative to the common location;
• and
• reacting the plurality of components.

A high-throughput system operable for fabricating an array of materials suitable for use in a solid oxide fuel cell, wherein each of a plurality of members of the array of materials may be evaluated for its relative performance, the system comprising:

• a plurality of devices operable for delivering a predetermined amount of each of a plurality of components to the surface of a substrate, wherein the predetermined amount of each of the plurality of components is delivered to the surface of the substrate from a common location;
• a stage operable for moving the substrate relative to the common location;
• and
• means for reacting the plurality of components.

A method for the fabrication of an array comprising a plurality of electrode materials suitable for use in a solid oxide fuel cell, wherein each of plurality of electrode materials may be evaluated for its relative performance in a high-throughput manner, the method comprising:

• tape casting a dense electrolyte to a predetermined size;
• disposing a plurality of porous regions on a first surface of the dense electrolyte;
• sintering the dense electrolyte and the plurality of porous regions at a first predetermined temperature;
• infiltrating the plurality of porous regions with soluble metal solutions;
• attaching a reference electrode to a second surface of the dense electrolyte;
• and
• sintering the dense electrolyte, the plurality of porous regions, and the reference electrode at a second predetermined temperature.

A method for the fabrication of an array comprising a plurality of electrode materials suitable for use in a solid oxide fuel cell, wherein each of plurality of electrode materials may be evaluated for its relative performance in a high-throughput manner, the method comprising:

• tape casting a dense yttria-stabilized zirconia electrolyte to a predetermined size;
• disposing a plurality of porous yttria-stabilized zirconia regions on a first surface of the dense yttria-stabilized zirconia electrolyte;
• sintering the dense yttria-stabilized zirconia electrolyte and the plurality of porous yttria-stabilized zirconia regions at a first predetermined temperature;
• infiltrating the plurality of porous yttria-stabilized zirconia regions with soluble metal solutions;
• attaching a reference electrode to a second surface of the dense yttria-stabilized zirconia electrolyte;
• and
• sintering the dense yttria-stabilized zirconia electrolyte, the plurality of porous yttria-stabilized zirconia regions, and the reference electrode at a second predetermined temperature.