Catalyst interlayer for the fuel electrode of thin electrolyte solid oxide cell and method of forming the same

Patent metadata

Field	Value
Publication number	US-9893367-B1
Application number	US-201715399066-A
Country	US
Kind code	B1
Filing date	Jan 5, 2017
Priority date	Oct 13, 2016
Publication date	Feb 13, 2018
Grant date	Feb 13, 2018

Abstract

Provided is an interlayer for a thin electrolyte solid oxide cell, a thin electrolyte solid oxide cell including the same, and a method of forming the same. In various embodiments, functional elements (a fuel electrode, an electrolyte and a cathode) of the solid oxide cell are formed by means of a thin film process, and thus a nanostructure of the catalyst is not seriously lost due to agglomeration, different from a powder process. Thus, it is possible to accomplish catalyst activation according to a high specific surface area.

First claim

What is claimed is:

1. A method of forming an interlayer for a thin electrolyte solid oxide cell, comprising:
(A1) forming a first heterogeneous catalyst layer on a fuel electrode, forming a first nanostructure fuel electrode functional layer,
and then {circle around (1)} (A2) forming a second heterogeneous catalyst layer on the first nanostructure fuel electrode functional layer and then forming a second nanostructure fuel electrode functional layer,
wherein the first and the second heterogeneous catalyst layers have a thickness of 5 to 20 nm, respectively.

2. The method of forming an interlayer for a thin electrolyte solid oxide cell according to claim 1 , after the step (A2), further comprising any one of processes {circle around (2)} to {circle around (5)} below:
{circle around (2)} (A3) forming a third heterogeneous catalyst layer on the second nanostructure fuel electrode functional layer and then forming a third nanostructure fuel electrode functional layer, wherein the third heterogeneous catalyst layer has a thickness of 5 to 20 nm;
{circle around (3)} (A3) forming a third heterogeneous catalyst layer on the second nanostructure fuel electrode functional layer and then forming a third nanostructure fuel electrode functional layer, (A4) forming a fourth heterogeneous catalyst layer on the third nanostructure fuel electrode functional layer and then forming a fourth nanostructure fuel electrode functional layer,
wherein the third and the fourth heterogeneous catalyst layers have a thickness of 5 to 20 nm, respectively;
{circle around (4)} (A3) forming a third heterogeneous catalyst layer on the second nanostructure fuel electrode functional layer and then forming a third nanostructure fuel electrode functional layer, (A4) forming a fourth heterogeneous catalyst layer on the third nanostructure fuel electrode functional layer and then forming a fourth nanostructure fuel electrode functional layer, (A5) forming a fifth heterogeneous catalyst layer on the fourth nanostructure fuel electrode functional layer and then forming a fifth nanostructure fuel electrode functional layer,
wherein the third, the fourth, and the fifth heterogeneous catalyst layers have a thickness of 5 to 20 nm, respectively; and
{circle around (5)} (A3) forming a third heterogeneous catalyst layer on the second nanostructure fuel electrode functional layer and then forming a third nanostructure fuel electrode functional layer, (A4) forming a fourth heterogeneous catalyst layer on the third nanostructure fuel electrode functional layer and then forming a fourth nanostructure fuel electrode functional layer, (A5) forming a fifth heterogeneous catalyst layer on the fourth nanostructure fuel electrode functional layer and then forming a fifth nanostructure fuel electrode functional layer, (A6) forming a sixth heterogeneous catalyst layer on the fifth nanostructure fuel electrode functional layer and then forming a sixth nanostructure fuel electrode functional layer,
wherein the third, the fourth, the fifth, and the sixth heterogeneous catalyst layers have a thickness of 5 to 20 nm, respectively.

3. A method of forming an interlayer for a thin electrolyte solid oxide cell, comprising:
(B1) forming a nanostructure fuel electrode functional layer, which forms an interface with a fuel electrode, on the fuel electrode, forming a first heterogeneous catalyst layer thereon, forming a first nanostructure fuel electrode functional layer, and then {circle around (1)} (B2) forming a second heterogeneous catalyst layer on the first nanostructure fuel electrode functional layer and then forming a second nanostructure fuel electrode functional layer,
wherein the first and the second heterogeneous catalyst layers have a thickness of 5 to 20 nm, respectively.

4. The method of forming an interlayer for a thin electrolyte solid oxide cell according to claim 3 , after the step (B2), further comprising any one of processes {circle around (2)} to {circle around (5)} below:
(B3) forming a third heterogeneous catalyst layer on the second nanostructure electrode functional layer and then forming a third nanostructure fuel electrode functional layer,
wherein the third heterogeneous catalyst layer has a thickness of 5 to 20 nm;
(B3) forming a third heterogeneous catalyst layer on the second nanostructure fuel electrode functional layer and then forming a third nanostructure fuel electrode functional layer, (B4) forming a fourth heterogeneous catalyst layer on the third nanostructure fuel electrode functional layer and then forming a fourth nanostructure fuel electrode functional layer,
wherein the third and the fourth heterogeneous catalyst layers have a thickness of 5 to 20 nm, respectively;
(B3) forming a third heterogeneous catalyst layer on the second nanostructure fuel electrode functional layer and then forming a third nanostructure fuel electrode functional layer, (B4) forming a fourth heterogeneous catalyst layer on the third nanostructure fuel electrode functional layer and then forming a fourth nanostructure fuel electrode functional layer, (B5) forming a fifth heterogeneous catalyst layer on the fourth nanostructure fuel electrode functional layer and then forming a fifth nanostructure fuel electrode functional layer; and
(B3) forming a third heterogeneous catalyst layer on the second nanostructure fuel electrode functional layer and then forming a third nanostructure fuel electrode functional layer, (B4) forming a fourth heterogeneous catalyst layer on the third nanostructure fuel electrode functional layer and then forming a fourth nanostructure fuel electrode functional layer, (B5) forming a fifth heterogeneous catalyst layer on the fourth nanostructure fuel electrode functional layer and then forming a fifth nanostructure fuel electrode functional layer, (B6) forming a sixth heterogeneous catalyst layer on the fifth nanostructure fuel electrode functional layer and then forming a sixth nanostructure fuel electrode functional layer,
wherein the third, the fourth, the fifth, and sixth heterogeneous catalyst layers have a thickness of 5 to 20 nm, respectively.

5. The method of forming an interlayer for a thin electrolyte solid oxide cell according to claim 1 ,
wherein the heterogeneous catalyst layer is formed by means of sputtering, and the nanostructure fuel electrode functional layer is formed by means of pulsed laser deposition (PLD).

Assignees

• Korea Inst Sci & Tech
• Global Frontier Ct Multiscale Energy Systems

Inventors

• Son Ji Won
• Anh Thieu Cam
• Hong Jongsup
• Kim Hyoungchul
• Yoon Kyung Joong
• Lee Jong Ho
• Lee Hae Weon
• Kim Byung Kook

Classifications

• H01M2004/8684

  Negative electrodes · CPC title

• H01M4/928

  Unsupported catalytic particles; loose particulate catalytic materials, e.g. in fluidised state · CPC title

• H01M4/9025

  Oxides specially used in fuel cell operating at high temperature, e.g. SOFC · CPC title

• H01M4/8889

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

• H01M4/8657 Primary

  layered · CPC title