US 12,381,247 B2
Solid oxide fuel cells and methods of forming thereof
Toshio Suzuki, Fremont, CA (US); and Vlad Kalika, Ladera Ranch, CA (US)
Assigned to Proof Energy Inc., Fremont, CA (US)
Filed by Proof Energy Inc., Fremont, CA (US)
Filed on Aug. 26, 2021, as Appl. No. 17/458,010.
Prior Publication US 2023/0067972 A1, Mar. 2, 2023
Int. Cl. H01M 8/1213 (2016.01); H01M 4/86 (2006.01); H01M 4/88 (2006.01); H01M 4/90 (2006.01); H01M 8/12 (2016.01); H01M 8/126 (2016.01); H01M 8/2428 (2016.01)
CPC H01M 8/1213 (2013.01) [H01M 4/8621 (2013.01); H01M 4/8885 (2013.01); H01M 4/9033 (2013.01); H01M 4/9066 (2013.01); H01M 8/126 (2013.01); H01M 8/2428 (2016.02); H01M 2008/1293 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A solid oxide fuel cell comprising:
a first current collector;
a second current collector;
an electrolyte layer;
a cathode layer, comprising a cathode porous base, cathode catalyst sites, and a cathode conductive layer, wherein:
the cathode layer is disposed between and in contact with the first current collector and the electrolyte layer,
the cathode conductive layer provides electrical conduction between the first current collector and the cathode catalyst sites,
the cathode conductive layer comprises a first cathode conductive layer portion and a second cathode conductive layer portion,
the first cathode conductive layer portion is disposed between and contacts the cathode porous base and first current collector,
the first cathode conductive layer portion has a conductivity greater than 0.1 S/cm,
the cathode catalyst sites are disposed over the second cathode conductive layer portion such that the second cathode conductive layer portion is positioned between the cathode porous base and the cathode catalyst sites and prevents interaction between the cathode porous base and the cathode catalyst sites, and
the cathode conductive layer comprises 430 stainless steel alloy, 434 stainless steel alloy, or a Fe—Cr alloy; and
an anode layer, comprising an anode porous base, anode catalyst sites, and an anode conductive layer, wherein:
the anode layer is disposed between and in contact with the second current collector and the electrolyte layer,
the anode conductive layer provides electrical conduction between the second current collector and the anode catalyst sites,
the anode conductive layer comprises Sm-doped CeO2, and
the anode catalyst sites are disposed over the anode conductive layer such that the anode conductive layer is positioned between the anode porous base and the anode catalyst sites.