US 12,266,835 B2
SOFC including redox-tolerant anode electrode and method of making the same
Andres Leming, Sunnyvale, CA (US); and Emad El Batawi, Mountain View, CA (US)
Assigned to BLOOM ENERGY CORPORATION, San Jose, CA (US)
Filed by BLOOM ENERGY CORPORATION, San Jose, CA (US)
Filed on Jul. 10, 2019, as Appl. No. 16/508,108.
Application 16/508,108 is a continuation in part of application No. 15/915,281, filed on Mar. 8, 2018, granted, now 10,680,251.
Claims priority of provisional application 62/697,015, filed on Jul. 12, 2018.
Claims priority of provisional application 62/550,845, filed on Aug. 28, 2017.
Prior Publication US 2019/0334190 A1, Oct. 31, 2019
Int. Cl. H01M 8/1246 (2016.01); H01M 4/88 (2006.01); H01M 4/90 (2006.01); H01M 8/0202 (2016.01); H01M 8/12 (2016.01)
CPC H01M 8/1246 (2013.01) [H01M 4/8842 (2013.01); H01M 4/8885 (2013.01); H01M 4/9066 (2013.01); H01M 8/0202 (2013.01); H01M 2008/1293 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A solid oxide fuel cell (SOFC), comprising:
a solid oxide electrolyte;
an anode disposed on a first side of the electrolyte and comprising:
a ceramic phase; and
a metallic phase comprising an alloy of Ni and a dopant comprising Ba, Ca, Sr, or any combination thereof; and
a cathode disposed on an opposing second side of the electrolyte,
wherein the metallic phase has an average grain size ranging from about 100 nanometers (nm) to about 400 nm.
 
14. A method of forming a solid oxide fuel cell (SOFC), the method comprising:
dissolving a dopant precursor, a ceramic anode material, and a metal catalyst in a first organic solvent to form a first mixture, the dopant precursor comprising a salt comprising Al, Ba, Ca, Cr, Fe, Mo, Re, Rh, Ru, Sr, W, or any combination thereof;
drying the first mixture to form a first powder;
pulverizing the first powder to form a second powder;
mixing the second powder with a second organic solvent to form an anode ink;
coating a first side of an electrolyte with the anode ink;
drying the coated electrolyte; and
sintering the dried electrolyte to form an anode comprising:
a ceramic phase; and
a metallic phase comprising Ni and a dopant comprising Al, Ba, Ca, Cr, Fe, Mo, Re, Rh, Ru, Sr, W, or any combination thereof.