US 12,021,246 B2
Methods of forming bilayer cathodes for electrochemical cells
Sossina M. Haile, Evanston, IL (US); Sihyuk Choi, Evanston, IL (US); Christopher James Kucharczyk, Evanston, IL (US); Yangang Liang, Richland, WA (US); Xiaohang Zhang, North Potomac, MD (US); and Ichiro Takeuchi, Laurel, MD (US)
Assigned to Northwestern University, Evanston, IL (US); and University of Maryland, College Park, College Park, MD (US)
Filed by Northwestern University, Evanston, IL (US); and University of Maryland, College Park, College Park, MD (US)
Filed on Nov. 11, 2022, as Appl. No. 17/985,218.
Application 17/985,218 is a division of application No. 16/754,575, abandoned, previously published as PCT/US2018/055987, filed on Oct. 16, 2018.
Claims priority of provisional application 62/572,680, filed on Oct. 16, 2017.
Prior Publication US 2023/0077350 A1, Mar. 16, 2023
Int. Cl. H01M 4/90 (2006.01); C01G 25/00 (2006.01); C01G 25/02 (2006.01); H01M 4/86 (2006.01); H01M 4/88 (2006.01); H01M 8/1213 (2016.01); H01M 8/1246 (2016.01); H01M 8/1253 (2016.01); H01M 8/126 (2016.01); H01M 8/12 (2016.01)
CPC H01M 4/9033 (2013.01) [C01G 25/006 (2013.01); C01G 25/02 (2013.01); H01M 4/861 (2013.01); H01M 4/8657 (2013.01); H01M 4/881 (2013.01); H01M 4/8828 (2013.01); H01M 4/8867 (2013.01); H01M 4/9066 (2013.01); H01M 8/1213 (2013.01); H01M 8/1246 (2013.01); H01M 8/1253 (2013.01); H01M 8/126 (2013.01); H01M 2008/1293 (2013.01); H01M 2300/0074 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method of forming a bilayer cathode, the method comprising:
forming a dense proton permeable interlayer of a proton permeable cathode material on a solid proton conducting electrolyte by depositing a film of the cathode material via a vapor deposition process;
forming a porous overlayer of the proton permeable cathode material on the dense proton permeable interlayer, wherein the porous overlayer has a higher porosity than the dense proton permeable interlayer and;
sintering the dense proton permeable interlayer and the porous overlayer.