Solid electrolyte thin film and method for producing the same

Details Solid electrolyte thin film and method for producing the same Solid electrolyte thin film and method for producing the same

1996-03-08

1999-10-19

Krynski, William

Stock material or miscellaneous articles

Composite

Of inorganic material

428209, 428323, 428320, 428370, 428375, 428516, 428522, 428689, 429 30, 429 33, 429 41, 429 44, 429104, 429193, 20419215, 204242, 204421, 204424, 338 34, 501103, B32B 900

Patent

active

059686731

DESCRIPTION:

BRIEF SUMMARY
FIELD OF THE INVENTION

The present invention relates to a dense solid electrolyte thin film utilized in solid electrolyte type fuel cells (hereafter denoted SOFC), oxygen sensors, oxygen pumps, and the like and a method for producing the same.


PRIOR ART

Solid electrolyte thin films having permeability to oxygen ions (O.sup.2-) as well as gas tightness are used in SOFC and such. These solid electrolyte thin films (made of ZrO.sub.2, CeO.sub.2, and such) are required to be thin and dense to achieve these characteristics. In addition, they are required to be economically formed into large sized thin films.
The conventional art technique is described herein with reference, as an example, to solid electrolyte thin films for SOFC. For SOFC, in general, an air electrode (made of LaMnO.sub.3, and such materials) having a thickness of 30.about.2000 .mu.m is formed on a porous substrate having a thickness of 0.3.about.5.00 mm, and a solid electrolyte thin film having a thickness of 30.about.1000 .mu.m is formed over the air electrode. Over the solid electrolyte thin film, a fuel electrode (made of Ni base cermets, and such materials) is formed.
In order to obtain solid electrolyte thin films which are thin and dense, and at the same time, low in production cost and excellent in mass productivity as a goal, the following have been proposed in the past: Kokai sho: 61-198570):
This production process is characterized in that solid electrolyte starting materials comprising cerium-oxides or zirconium-oxides and divalent or trivalent metal-oxides of alkaline earth metals or rare earth elements and the like are formed into a solid solution. Then, the starting material in the form of a solid solution are crushed, and the grain size of the obtained powder is regulated, and then the powder is coated as an electrolyte film on a fuel cell substrate by plasma spray coating. According to an example described in the published specification, a solid electrolyte thin film having a thickness of 200 .mu.m and terminal voltage of 790 mv is obtained by using plasma spray powder having a grain size of 2 .mu.m or less. (Patent publication number Kokai sho: 61-91880):
This production process is characterized in that the first electrode is adhered onto a porous support member, an intermediate layer substance with electrical conductivity and oxygen permeability is adhered onto the first electrode to protect the first electrode from a high temperature vapor of halides, the intermediate layer substance is contacted with a high temperature vapor of metal halide to form a solid electrolyte composed of metal oxides on the whole surface of the intermediate layer, and the second electrode is adhered on the whole surface of the solid electrolyte. Hei:1-93065)
This production process is a process for manufacturing a cylindrically-shaped solid electrolyte wherein a fuel electrode layer and an air electrode layer are overlapped and an electrolyte layer is interposed there between, and characterized in that either one of the air electrode layer or the fuel electrode layer is formed into a tubular shape. A powder slurry of each material for forming the electrolyte and the other electrode layer is coated on the surface of the tube one by one and dried, and then the tube is baked. According to an example of the published specification, an yttrium stabilized zirconia (YSZ) thin film having a thickness of 150 .mu.m is obtained. publication number Kokai Hei:2-220361)
This production process relates to a tubular type SOFC formed by laying up a fuel electrode, a solid electrolyte and an air electrode on the outside of a substrate tube, and is characterized in that a filler material containing 40 wt % or more (solids concentration) of yttrium stabilized zirconia is coated on openings of laid-up solid electrolyte on the substrate tube, and then the tube is dried and baked. According to an example described in the published specification, a slurry containing YSZ powders with a grain size of 0.05 to 2.5 .mu.m is coated (brush coating) on an air plasma spray coa

REFERENCES:
patent: 3957500 (1976-05-01), Pitts
patent: 5292693 (1994-03-01), Kaya et al.
patent: 5624542 (1997-04-01), Shen et al.

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