# US 2018/0323443 A1 · Fabrication processes for solid state electrochemical devices

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- Number: US 2018/0323443 A1
- Document ID: US20180323443A1
- Status: Published application
- Kind: A1
- Application number: 15/968,917
- Filed: 2018-05-02
- Published: 2018-11-08
- Earliest claimed: 2017-05-03
- Assignees: The Regents of the University of California
- Inventors: Michael C. Tucker; Emir Dogdibegovic
- Web page: https://patentgrep.com/patent/US20180323443A1

## CPC

- H01M 4/8882: {Heat treatment, e.g. drying, baking}
- H01M 4/8621: {containing only metallic or ceramic material, e.g. made by sintering or sputtering}
- H01M 4/8842: {Coating using a catalyst salt precursor in solution followed by evaporation and reduction of the precursor}
- H01M 4/8846: {Impregnation}
- H01M 8/1007: with both reactants being gaseous or vaporised (H01M8/12 takes precedence)
- H01M 4/885: {followed by reduction of the catalyst salt precursor}
- H01M 4/8885: {Sintering or firing}
- H01M 2008/1293: {Fuel cells with solid oxide electrolytes}
- Y02E 60/50: Fuel cells
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

This disclosure provides systems, methods, and apparatus related to electrode structures. In one aspect, a method includes: providing an electrode layer comprising a ceramic, the ceramic being porous; providing a catalyst precursor, the catalyst precursor being a cathode catalyst precursor or an anode catalyst precursor; infiltrating the catalyst precursor in a first side of the electrode layer; after the infiltrating operation, heating the electrode layer to about 750° C. to 950° C., the catalyst precursor forming a catalyst, the catalyst being a cathode catalyst or an anode catalyst; infiltrating the catalyst precursor in the first side of the electrode layer; after the infiltrating operation, heating the electrode layer to about 300° C. to 700° C., the catalyst precursor forming the catalyst, the catalyst being the cathode catalyst or the anode catalyst.

## Claims

### Claim 1

A method of fabricating an electrode structure comprising:
(a) providing an electrode layer comprising a ceramic, the ceramic being porous;
(b) providing a catalyst precursor, the catalyst precursor being a cathode catalyst precursor or an anode catalyst precursor;
(c) infiltrating the catalyst precursor in a first side of the electrode layer;
(d) after operation (c), heating the electrode layer to about 750° C. to 950° C., the catalyst precursor forming a catalyst, the catalyst being a cathode catalyst or an anode catalyst;
(e) infiltrating the catalyst precursor in the first side of the electrode layer;
(f) after operation (e), heating the electrode layer to about 300° C. to 700° C., the catalyst precursor forming the catalyst, the catalyst being the cathode catalyst or the anode catalyst.

### Claim 2 (depends on 1)

The method of claim 1, wherein when the catalyst precursor is infiltrated in the first side of the electrode layer the catalyst precursor is heated to about 90° C. to 95° C.

### Claim 3 (depends on 1)

The method of claim 1, wherein operations of infiltrating the catalyst precursor in the first side of the electrode layer are performed in a vacuum of about 600 millibar to 800 millibar.

### Claim 4 (depends on 1)

The method of claim 1, further comprising:
before operation (d), heating the electrode layer to about 40° C. to 90° C.; and
before operation (f), heating the electrode layer to about 40° C. to 90° C.

### Claim 5 (depends on 1)

The method of claim 1, further comprising:
infiltrating the catalyst precursor in the first side of the electrode layer; and
heating the electrode layer to about 300° C. to 700° C., wherein the infiltrating and the heating are performing until a specified amount of the catalyst is deposited on the electrode layer.

### Claim 6 (depends on 1)

The method of claim 1, wherein operations (d) and (f) are performed for about 30 minutes to 5 hours.

### Claim 7 (depends on 1)

The method of claim 1, wherein the ceramic comprises stabilized zirconia or doped ceria.

### Claim 8 (depends on 1)

The method of claim 1, wherein the catalyst precursor comprises a metal salt.

### Claim 9 (depends on 1)

The method of claim 1, wherein the catalyst precursor comprises citric acid.

### Claim 10 (depends on 1)

The method of claim 1, wherein excess catalyst is removed from the electrode layer after operations (d) and (f).

### Claim 11 (depends on 1)

The method of claim 1, wherein the electrode layer is about 10 microns to 250 microns thick.

### Claim 12 (depends on 1)

The method of claim 1, wherein the method forms a structure comprising a catalyst layer that is about 10 microns to 100 microns thick.

### Claim 13

A method of fabricating an electrode structure comprising:
(a) providing an electrode layer comprising a ceramic, the ceramic being porous;
(b) providing a cathode catalyst precursor and an anode catalyst precursor;
(c) infiltrating the cathode catalyst precursor in a first side of the electrode layer;
(d) infiltrating the anode catalyst precursor in a second side of the electrode layer;
(e) after operations (c) and (d), heating the electrode layer to about 750° C. to 950° C., the cathode catalyst precursor forming a cathode catalyst and the anode catalyst precursor forming an anode catalyst;
(f) infiltrating the cathode catalyst precursor in the first side of the electrode layer;
(g) infiltrating the anode catalyst precursor in the second side of the electrode layer; and
(h) after operations (f) and (g), heating the electrode layer to about 300° C. to 700° C., the cathode catalyst precursor forming the cathode catalyst and the anode catalyst precursor forming the anode catalyst.

### Claim 14 (depends on 13)

The method of claim 13, wherein the method forms a structure comprising a cathode catalyst layer that is about 10 microns to 100 microns thick, an anode catalyst layer that is about 10 microns to 100 microns thick, and an electrolyte layer that is about 5 microns to 50 microns thick disposed between the cathode catalyst layer and the anode catalyst layer.

### Claim 15 (depends on 13)

The method of claim 13, wherein the cathode catalyst layer and the anode catalyst layer are the same thickness.

### Claim 16 (depends on 13)

The method of claim 13, wherein the cathode catalyst precursor and the anode catalyst precursor are the same composition.

### Claim 17 (depends on 13)

The method of claim 13, wherein the electrode layer is about 10 microns to 250 microns thick.

### Claim 18 (depends on 13)

The method of claim 13, wherein the cathode catalyst precursor comprises a first metal salt, and wherein the anode catalyst precursor comprises a second metal salt.

### Claim 19 (depends on 13)

The method of claim 13, further comprising:
infiltrating the cathode catalyst precursor in the first side of the electrode layer; and
heating the electrode layer to about 300° C. to 700° C., wherein the infiltrating and the heating are performing until a specified amount of the cathode catalyst is deposited on the electrode layer.

### Claim 20 (depends on 13)

The method of claim 13, further comprising:
infiltrating the anode catalyst precursor in the second side of the electrode layer; and
heating the electrode layer to about 300° C. to 700° C., wherein the infiltrating and the heating are performing until a specified amount of the anode catalyst is deposited on the electrode layer.