Metal Supported Solid Oxide Fuel Cell

Patent metadata

Field	Value
Publication number	US-2016254549-A1
Application number	US-201614992531-A
Country	US
Kind code	A1
Filing date	Jan 11, 2016
Priority date	Sep 4, 2013
Publication date	Sep 1, 2016
Grant date	—

Abstract

A process for forming a metal supported solid oxide fuel cell, the process comprising the steps of: a) applying a green anode layer including nickel oxide, copper oxide and a rare earth-doped ceria to a metal substrate; b) firing the green anode layer to form a composite including oxides of nickel, copper, and a rare earth-doped ceria; c) providing an electrolyte; and d) providing a cathode. Metal supported solid oxide fuel cells comprising an anode a cathode and an electrolyte, wherein the anode includes nickel, copper and a rare earth-doped ceria, fuel cell stacks and uses of these fuel cells.

First claim

1 . A process for forming a metal supported solid oxide fuel cell, the process comprising the steps of:
a) applying a green anode layer including nickel oxide, copper oxide and a rare earth-doped ceria to a metal substrate; b) firing the green anode layer to form a composite including oxides of nickel, copper, and a rare earth-doped ceria; c) providing an electrolyte; and d) providing a cathode.

2 . The process according to claim 1 , further comprising a step of compressing the green anode layer at pressures in the range 100 to 300 MPa.

3 . The process according to claim 1 , wherein the firing of the green anode layer occurs at a temperature in the range 950 to 1100° C.

4 . The process according to claim 1 , wherein the nickel oxide, copper oxide and rare earth-doped ceria are powdered, the powders being of particle size distribution d90 in the range 0.1 to 4 μm.

5 . The process according to claim 1 , wherein the nickel oxide, copper oxide and rare earth-doped ceria are applied as an ink.

6 . The process according to claim 5 , wherein the ink comprises in the range 5 to 50 wt % of the total metal oxide of copper oxide.

7 . The process according to claim 6 , wherein the application of the green anode layer includes an initial application of the ink to the metal substrate, and drying the ink to provide a printed layer of thickness in the range 5 to 40 μm.

8 . The process according to claim 1 , further comprising heating the printed layer to remove the ink base leaving a green anode layer comprising nickel oxide, copper oxide and a rare earth-doped ceria.

9 . The process according to claim 1 , wherein the step of providing an electrolyte occurs before the step of firing the green anode layer, so that the electrolyte and green anode layer are simultaneously fired.

10 . A metal supported solid oxide fuel cell comprising an anode, a cathode and an electrolyte, wherein the anode includes nickel, copper and a rare earth-doped ceria.

11 . The fuel cell according to claim 10 , wherein the nickel, copper and rare earth-doped ceria are sintered.

12 . The fuel cell according to claim 10 , wherein a weight ratio of nickel oxide to copper oxide is in the range 20:1 to 4:1.

13 . The fuel cell according to claim 10 , wherein the nickel is in a form selected from metallic nickel, nickel oxide, a nickel-copper alloy, a nickel-copper oxide and combinations thereof.

14 . The fuel cell according to claim 10 , wherein the copper is in a form selected from metallic copper, copper (II) oxide, copper (I) oxide, a nickel-copper alloy, a nickel-copper oxide and combinations thereof.

15 . The fuel cell according to claim 10 , comprising:
(i) a ferritic stainless steel support including a porous region and a non-porous region bounding the porous region; (ii) a ferritic stainless steel bi-polar plate located under one surface of the porous region of the support and being sealingly attached to the non-porous region of the support about the porous region thereof; (iii) an anode comprising an anode layer located over the other surface of the porous region of the support; (iv) an electrolyte comprising an electrolyte layer located over the anode layer; and (v) a cathode comprising a cathode layer located over the electrolyte layer; wherein the anode includes nickel, copper and a rare earth-doped ceria.

16 . The fuel cell according to claim 10 , wherein the rare earth-doped ceria comprises gadolinium doped cerium oxide.

17 . A fuel cell stack comprising two or more fuel cells according to claim 10 .

Assignees

• Ceres Ip Co Ltd

Inventors

• Leah Robert
• Lankin Mike
• Pierce Robin
• Bone Adam

Classifications

• H01M4/9033

  Complex oxides, optionally doped, of the type M1MeO3, M1 being an alkaline earth metal or a rare earth, Me being a metal, e.g. perovskites · CPC title

• H01M4/8828 Primary

  Coating with slurry or ink · CPC title

• H01M4/8621 Primary

  containing only metallic or ceramic material, e.g. made by sintering or sputtering · CPC title

• H01M2004/8684

  Negative electrodes · CPC title

• H01M4/8889

  Cosintering or cofiring of a catalytic active layer with another type of layer · CPC title