Patent ID: 8920612
Filing Date: 2014-12-30
Classification: C23C,H01M,Y02E,Y02P

Abstract:
1. A manufacturing process for planar SOFC-MEA with dense electrolyte layer comprising the following steps: a. producing an anode electrode substrate with size in a range from 5×5 cm b. producing a half cell onto the electrode substrate by magnetron sputtering, wherein the magnetron sputtering process comprising either (1) RF magnetron sputtering with oxide target materials, which is one of YSZ+NiO, GDC+NiO, LSGM+NiO, SDC+NiO, YDC+NiO, or YSZ, or GDC, or LSGM, or SDC, or YDC, wherein the RF magnetron sputtering is by dual gun co-sputter to deposit the electrolyte material onto the electrode substrate, or (2) reactive magnetron sputtering with metal alloy target materials, which is one of Zr c. producing the half cell with high-temperature sintering for anode/electrolyte half cell; sintering temperature is about 1400° C.; sintering time is about 6 hours; conducting gas permeability testing by using SEM to examine the microstructure of the half cell to assure the full densification of electrolyte layer having gas permeability less than 1×10 d. building a porous layer of cathode material by screen printing onto the half cell with dense electrolyte layer; conducting sintering at about 1100° C. for about 3 hours to obtain a full unit cell with dense electrolyte layer; conducting electrical performance testing and power density measurement to ensure the full unit cell performance in achieving a power density about 515 mW/cm