# US 2019/0356008 A1 · Formation of solid oxide fuel cells by spraying

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- Number: US 2019/0356008 A1
- Document ID: US20190356008A1
- Status: Published application
- Kind: A1
- Application number: 16/526,416
- Filed: 2019-07-30
- Published: 2019-11-21
- Earliest claimed: 2014-10-06
- Assignees: Phillips 66 Company
- Applicants: Phillips 66 Company
- Inventors: Ying Liu; Mingfei Liu; David M. Bierschenk; Ting He
- Web page: https://patentgrep.com/patent/US20190356008A1

## CPC

- H01M 8/1253: the electrolyte containing zirconium oxide
- H01M 4/0419: {involving spraying}
- H01M 8/126: the electrolyte containing cerium oxide
- H01M 2008/1293: {Fuel cells with solid oxide electrolytes}
- H01M 2300/0077: based on zirconium oxide
- Y02E 60/10: Energy storage using batteries
- Y02E 60/50: Fuel cells
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- 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
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The present embodiment describes a method of forming different layers in a solid oxide fuel cell. The method begins by preparing slurries which are then delivered to a spray nozzle. The slurries are then atomized and sprayed subsequently onto a support to produce a layer which is then dried. In this embodiment different layers can comprise an anode, an electrode and a cathode. Also, the support can be a metal or a metal oxide which is later removed.

## Claims

### Claim 1

A method of forming different layers in a solid oxide fuel cell comprising:
preparing a slurry;
delivering the slurry to a spray nozzle;
atomizing and spraying the slurry onto a support to produce a sprayed layer; and
drying the sprayed layer;
wherein the different layers comprise an anode, an electrode and a cathode and wherein the support is a metal or metal oxide which is later removed

### Claim 2 (depends on 1)

The method of claim 1, wherein the method only sprays one anode layer, one electrode layer and one cathode layer.

### Claim 3 (depends on 1)

The method of claim 1, wherein the method only sprays two anode layers, two electrode layers and two cathode layers.

### Claim 4 (depends on 1)

The method of claim 1, wherein the spraying occurs at a temperature ranges from 5° C. to about 50° C.

### Claim 5 (depends on 3)

The method of claim 3, wherein a heat-treatment can be applied after spraying each layer in temperature ranges from about 850° C. to about 1500° C.

### Claim 6 (depends on 1)

The method of claim 1, wherein flow rate of the spraying ranges from about 0.1 ml/min to about 20 ml/min. The method of claim 1, wherein the pressure of the spraying ranges from about 0.5 psi to about 100 psi.

### Claim 8 (depends on 1)

The method of claim 1, wherein thickness of each layer deposited by single spraying pass ranges from about 50 nm to about 1 μm.

### Claim 9 (depends on 1)

The method of claim 1, wherein the atomization method is either ultrasonic or pneumatic.

### Claim 10 (depends on 1)

The method of claim 1, wherein the step of spraying the slurry is repeated at least two times.

### Claim 11 (depends on 1)

The method of claim 1, wherein the step of spraying the slurry is repeated at least three times.

### Claim 12 (depends on 1)

The method of claim 1, wherein the step of spraying the slurry is repeated till the cumulative thickness of each layer is at least 1 μm.

### Claim 13 (depends on 1)

The method of claim 1, wherein the step of spraying the slurry produces a sprayed layer with a thickness variance of less than one sigma.

### Claim 14 (depends on 1)

The method of claim 1, wherein the anode layer is selected from a mixture comprising an electronic conductor and an ionic conductor.

### Claim 15 (depends on 14)

The method of claim 14, wherein the electronic conductor is selected from the group consisting of: NiO, CO-oxide, CuO or combinations thereof.

### Claim 16 (depends on 14)

The method of claim 14, wherein the ionic conductor is selected from the group consisting of: yttria stabilized zirconia, scandia stabilized zirconia, gadolinium doped ceria, samarium doped ceria, doped barium zirconate cerate or combinations thereof.

### Claim 17 (depends on 1)

The method of claim 1, wherein the cathode layer is selected from a mixture comprising an electronic conductor and an ionic conductor.

### Claim 18 (depends on 17)

The method of claim 17, wherein the electronic conductor is selected from the group comprising: lanthanum strontium iron cobalt oxide, strontium samarium cobalt oxide, lanthanum strontium iron oxide, lanthanum strontium cobalt oxide, baraium strontium cobalt iron oxide or combinations thereof.

### Claim 19 (depends on 17)

The method of claim 17, wherein the ionic conductor is selected from the group comprising: doped ceria, stabilized zirconia and combinations thereof.

### Claim 20 (depends on 1)

The solid oxide fuel cell of claim 1, wherein the electrolyte is a dense stabilized zirconia.

### Claim 21 (depends on 1)

The solid oxide fuel cell of claim 1, wherein the electrolyte is a doped ceria.

### Claim 22 (depends on 1)

The solid oxide fuel cell of claim 1, wherein the electrolyte is a porous BZCYYb electrolyte.

### Claim 23 (depends on 1)

The solid oxide fuel cell of claim 1, wherein the electrolyte is a Sc-doped BZCY.