Patent ID: 6887361

Claim:
A method of forming a ceramic coating on a solid state electrochemical device substrate, comprising: providing a non-shrinking solid state electrochemical device substrate, the substrate consisting essentially of a material selected from the group consisting of a porous non-noble transition metal, a porous non-noble transition metal alloy, a porous cermet incorporating one or more of a non-noble non-nickel transition metal and a non-noble transition metal alloy, a porous cermet, and a porous metal oxide or mixed metal oxide; generating a suspension of ceramic material in a liquid medium of isopropyl alcohol (IPA), the suspension having a concentration and size distribution of ceramic particles selected to provide a uniform and intact dense ceramic following drying and sintering of the coated substrate; applying a coating of the suspension of the ceramic material directly to the non-shrinking substrate material using electrophoretic deposition with a ramped voltage profile; drying the coated substrate material; and sintering the coated, substrate in an inert or reducing atmosphere.