# US 2021/0242482 A1 · Setter plates and manufacturing methods for ceramic-anode solid oxide fuel cells

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- Number: US 2021/0242482 A1
- Document ID: US20210242482A1
- Status: Published application
- Kind: A1
- Application number: 17/168,357
- Filed: 2021-02-05
- Published: 2021-08-05
- Earliest claimed: 2018-09-19
- Assignees: Redox Power Systems, LLC
- Inventors: Keji PAN; Sean R. BISHOP; Thomas LANGDO; Bryan M. BLACKBURN
- Web page: https://patentgrep.com/patent/US20210242482A1

## CPC

- H01M 8/1286: Fuel cells applied on a support, e.g. miniature fuel cells deposited on silica supports
- H01M 8/1226: characterised by the supporting layer
- H01M 8/1253: the electrolyte containing zirconium oxide
- H01M 8/126: the electrolyte containing cerium oxide
- H01M 2008/1293: {Fuel cells with solid oxide electrolytes}
- 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

In various embodiments, techniques for fabricating solid oxide fuel cells utilize setter plates composed of or having outer surfaces composed of materials unreactive with species found in the layers of the cell.

## Claims

### Claim at position 1

-19. (canceled)

### Claim 20

A sintered layered structure fabricated according to a method comprising:
providing a layered structure comprising (i) a ceramic anode and (ii) a solid electrolyte laver disposed over the anode:
disposing the layered structure on a first setter plate having a top surface (i) in contact with the anode and (ii) comprising ceria and/or doped ceria;
sintering the layered structure; and
separating substantially the entire layered structure from the first setter plate.

### Claim 21 (depends on 20)

The structure of claim 20, further comprising a cathode layer disposed over the electrolyte layer.

### Claim 22 (depends on 21)

The structure of claim 21, further comprising a cathode functional layer disposed between the cathode layer and the electrolyte layer.

### Claim 23 (depends on 22)

The structure of claim 22, wherein the cathode functional layer comprises cobalt oxide mixed with at least one of gadolinium-doped ceria or samarium-doped ceria.

### Claim 24 (depends on 21)

The structure of claim 21, wherein the cathode layer comprises a mixture of samarium strontium cobaltite and doped ceria.

### Claim 25 (depends on 20)

The structure of claim 20, wherein an area of the layered structure is larger than 5 cm×5 cm, and the layered structure is free of cracks.

### Claim 26 (depends on 20)

The structure of claim 20, wherein the anode comprises at least one of (i) a ceramic oxide material containing strontium, iron, cobalt, and molybdenum, (ii) vanadium- and sodium-doped strontium niobate, or (iii) vanadium-doped strontium titanate.

### Claim 27 (depends on 20)

The structure of claim 20, wherein the anode comprises ceria or doped ceria.

### Claim 28 (depends on 20)

The structure of claim 20, wherein the electrolyte layer comprises ceria doped with Gd, Y, La, Pr, Sm, and/or Nd.

### Claim 29 (depends on 20)

The structure of claim 20, wherein the anode comprises (i) a ceramic anode support layer and (ii) a ceramic anode functional layer disposed over the anode support layer, the electrolyte layer being disposed over the anode functional layer.

### Claim 30

A structure comprising:
a layered structure comprising (i) a ceramic anode and (ii) a solid electrolyte layer disposed over the anode; and
a first setter plate having a top surface (i) in contact with the anode and (ii) comprising ceria and/or doped ceria.

### Claim 31 (depends on 30)

The structure of claim 30, wherein an areal dimension of the first setter plate is larger than an areal dimension of the layered structure.

### Claim 32 (depends on 30)

The structure of claim 30, wherein the top surface of the first setter plate comprises ceria doped with Gd, Y, La, Pr, Sm, and/or Nd.

### Claim 33 (depends on 30)

The structure of claim 30, wherein the first setter plate comprises a ceramic setter material coated with a layer of material different from the ceramic setter material.

### Claim 34 (depends on 33)

The structure of claim 33, wherein the first setter plate comprises alumina coated with a layer of ceria or doped ceria.

### Claim 35 (depends on 30)

The structure of claim 30, wherein the first setter plate is composed of ceria or doped ceria.

### Claim 36 (depends on 30)

The structure of claim 30, wherein the top surface of the first setter plate further comprises, mixed with the ceria and/or doped ceria, one or more volatile species selected from the list consisting of Co, Mo, Ni, Cr, V, Bi, Li, Na, and Cu.

### Claim 37 (depends on 30)

The structure of claim 30, further comprising, disposed on the layered structure, a second setter plate having a bottom surface comprising ceria and/or doped ceria.

### Claim 38 (depends on 37)

The structure of claim 37, wherein the bottom surface of the second setter plate comprises ceria doped with Gd, Y, La, Pr, Sm, and/or Nd.

### Claim 39 (depends on 37)

The structure of claim 37, wherein the second setter plate comprises a ceramic setter material coated with a layer of material different from the ceramic setter material.

### Claim 40 (depends on 39)

The structure of claim 39, wherein the second setter plate comprises alumina coated with a layer of ceria or doped ceria.

### Claim 41 (depends on 37)

The structure of claim 37, wherein the second setter plate is composed of ceria or doped ceria.

### Claim 42 (depends on 37)

The structure of claim 37, wherein a weight of the second setter plate ranges between approximately 0.5 g/cm2 and approximately 3 g/cm2.

### Claim 43 (depends on 37)

The structure of claim 37, wherein the bottom surface of the second setter plate further comprises, mixed with the ceria and/or doped ceria, one or more volatile species selected from the list consisting of Co, Mo, Ni, Cr, V, Bi, Li, Na, and Cu.