Electrochemical cell

Patent metadata

Field	Value
Publication number	US-2026088309-A1
Application number	US-202319110960-A
Country	US
Kind code	A1
Filing date	Sep 12, 2023
Priority date	Sep 13, 2022
Publication date	Mar 26, 2026
Grant date	—

Abstract

An electrochemical cell is disclosed having a porous metal support, at least one layer of a first electrode on the porous metal support, a first electron-blocking electrolyte layer of rare earth doped zirconia on the at least one layer of the first electrode, and a second bulk electrolyte layer of rare earth doped ceria on the first electron-blocking electrolyte layer. The first electron-blocking electrolyte layer of rare earth doped zirconia may have a thickness of 0.5 μm or greater, and the second bulk electrolyte layer of rare earth doped ceria may have a thickness of 4 μm or greater.

First claim

1 . An electrochemical cell comprising:
a porous metal support, at least one layer of a first electrode on the porous metal support, a first electron-blocking electrolyte layer of rare earth doped zirconia on the at least one layer of the first electrode, and a second bulk electrolyte layer of rare earth doped ceria on the first electron-blocking electrolyte layer.

2 . An electrochemical cell as claimed in claim 1 , wherein the first electron-blocking electrolyte layer of rare earth doped zirconia has a thickness of 0.5 μm or greater.

3 . An electrochemical cell as claimed in claim 1 , wherein the second bulk electrolyte layer of rare earth doped ceria has a thickness of 4 μm or greater.

4 . An electrochemical cell as claimed in claim 1 , wherein the first electron-blocking electrolyte layer of rare earth doped zirconia has a thickness of 5 μm or lower.

5 . An electrochemical cell as claimed in claim 1 , wherein the second bulk electrolyte layer of rare earth doped ceria has a thickness of 17 μm or lower.

6 . An electrochemical cell as claimed claim 1 , wherein the electrochemical cell is a solid oxide cell.

7 . An electrochemical cell as claimed in claim 1 , wherein the rare earth doped zirconia comprises zirconia doped with at least one rare earth element selected from Y, Sc or a lanthanide (Ln).

8 . An electrochemical cell as claimed in claim 1 , wherein the rare earth doped ceria comprises ceria doped with at least one rare earth element selected from Y, Sc or a lanthanide (Ln).

9 . (canceled)

10 . An electrochemical cell as claimed in claim 1 , wherein the layer of the first electrode comprises doped ceria, optionally wherein the layer of the first electrode comprises doped ceria gadolinium oxide (CGO).

11 . (canceled)

12 . An electrochemical cell as claimed in claim 1 , wherein the layer of the first electrode comprises nickel CGO cermet.

13 . An electrochemical cell as claimed in claim 1 , wherein the layer of the first electrode has a thickness of 3 μm or higher, optionally 5 μm or higher, optionally 10 μm or higher, optionally 15 μm or higher.

14 . An electrochemical cell as claimed in claim 1 , wherein the layer of the first electrode has a thickness of 50 μm or lower, optionally 45 μm or lower, optionally 40 μm or lower, optionally 35 μm or lower.

15 . (canceled)

16 . An electrochemical cell as claimed in claim 1 , further comprising a second electrode on the second electrolyte layer, optionally wherein the second electrode is an air electrode.

17 . An electrochemical cell as claimed in claim 1 , wherein the porous metallic substrate comprises a steel substrate, preferably a stainless steel substrate.

18 . (canceled)

19 . An electrochemical cell as claimed in claim 1 , wherein the porous metallic substrate comprises a barrier layer on the surface thereof and the layer of the first electrode is on the barrier layer.

20 . A stack of electrochemical cells, wherein each electrochemical cell is as claimed in claim 1 .

21 . A method of producing an electrochemical cell, the method comprising
providing a porous metallic substrate having on a surface thereof at least one layer of a first electrode, providing a first ink comprising a precursor for a first electron-blocking electrolyte layer of rare earth doped zirconia, applying the first ink on to the at least one layer of the first electrode, to form the first electron-blocking electrolyte layer of rare earth doped zirconia, optionally drying, optionally sintering; providing a second ink comprising a precursor for a second bulk electrolyte layer of rare earth doped ceria, applying the second ink on to the first electron-blocking electrolyte layer, to form the second electrolyte layer of rare earth doped ceria, optionally drying, and optionally sintering.

22 . A method as claimed in claim 21 , wherein the first and/or the second ink is applied by printing, optionally screen-printing.

23 . An electrochemical cell obtainable by a method as claimed in either claim 21 .

24 . (canceled)

25 . A method of operating an electrochemical cell in electrolysis mode, the method comprising providing an electrochemical cell as claimed in claim 1 , contacting the electrochemical cell with a reagent to be subject to electrolysis, and applying a potential to the electrochemical cell.

Assignees

• Ceres Ip Co Ltd

Inventors

• Hjalmarsson Per
• Macauley Chandra

Classifications

• H01M2008/1293

  Fuel cells with solid oxide electrolytes · CPC title

• H01M8/1253

  the electrolyte containing zirconium oxide · CPC title

• H01M8/1226

  characterised by the supporting layer · CPC title

• H01M4/9066

  of metal-ceramic composites or mixtures, e.g. cermets · CPC title

• H01M4/8885

  Sintering or firing · CPC title