Low temperature electrolytes for solid oxide cells having high ionic conductivity
Inventors
BUDARAGIN, LEONID V. • Deininger, Mark A. • Pozvonkov, Michael M. • Spears, II, D. Morgan • Fisher, Paul D. • Ludtka, Gerard M. • Pasto, Arvid E.
Assignees
Publication Number
US-12071697-B2
Publication Date
2024-08-27
Expiration Date
2031-02-09
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Abstract
Methods for forming a metal oxide electrolyte include applying a metal compound to a first material in powder form thereby forming a slurry, applying the slurry to an electrode, and converting at least some of the metal compound to form a metal oxide, thereby forming the metal oxide electrolyte on the electrode. Unexpectedly, the metal oxide electrolyte may have an ionic conductivity greater than the bulk ionic conductivity of the first material and of the metal oxide, possibly because of the nature of the interface between the first material and the metal oxide.
Core Innovation
The invention provides methods for fabricating metal oxide electrolytes for use in solid oxide cells without requiring epitaxial growth of electrolyte materials. Specifically, the method involves applying a metal compound to a first material in powder form to create a slurry, applying the slurry to an electrode, and then converting at least some of the metal compound to form a metal oxide. This process forms a metal oxide electrolyte on the electrode.
A core aspect of the invention is that the resulting metal oxide electrolyte exhibits an ionic conductivity greater than the bulk ionic conductivity of both the first material and the metal oxide itself. The unexpectedly high ionic conductivity may be due to the nature of the interface between the first material and the metal oxide, or the inclusion of domain boundaries disposed parallel to the direction of desired ionic conduction.
The problem addressed stems from the high operating temperatures required by conventional solid oxide fuel cells and sensors, which demand costly materials and lead to degradation from thermal cycling, increasing overall complexity and cost. By enhancing ionic conductivity at lower temperatures and providing simpler methods to form thin or composite electrolytes, the invention mitigates the need for expensive processing and materials, broadening applications and improving efficiency.
Claims Coverage
The patent contains one independent claim, which defines a key inventive feature for forming a metal oxide electrolyte with enhanced ionic conductivity.
Method for forming a metal oxide electrolyte with enhanced ionic conductivity
The process comprises: 1. Applying a metal compound to a first material in powder form to form a slurry. 2. Applying the slurry to an electrode. 3. Converting at least some of the metal compound to form a metal oxide, thereby forming the metal oxide electrolyte on the electrode. - The metal oxide electrolyte generated by this process has an ionic conductivity that is greater than the bulk ionic conductivity of the first material and of the metal oxide.
The sole inventive feature in the independent claim covers a method resulting in a metal oxide electrolyte with improved ionic conductivity, formed by applying and converting a metal compound on a powdered substrate and electrode.
Stated Advantages
Enhanced ionic conductivity in metal oxide electrolytes at relatively low temperatures, enabling efficient operation of solid oxide cells at lower temperatures.
Reduced production costs and the ability to use less expensive, more easily fabricated materials due to the lower operating temperature.
Decreased degradation and improved matching of coefficients of thermal expansion among cell components, thereby reducing thermal stresses and potential for cracking or delamination.
Facilitation of fabrication processes by eliminating the requirement for epitaxial growth and high-temperature sintering of electrolyte materials.
Ability to create thinner electrolytes, which can increase overall cell efficiency.
Documented Applications
Solid oxide fuel cells for electrical energy production.
Solid oxide electrolyzer cells for electrolysis reactions such as water splitting and industrial processes like the chlor-alkali process.
Solid oxide sensors, such as lambda sensors for measuring oxygen concentration in exhaust streams and other analyte detection applications.
Interconnects for solid oxide cells, providing electrical and/or material communication between cell components and external systems.
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