Solid oxide electrochemical cell fabrication process

Claim 1

A method of bonding an electrolyte, and an outer electrode layer on a porous, doped lanthanum manganite tubular electrode, comprising the steps: (A) thermal spraying a thin, axially elongated, electrically conductive, ceramic oxide interconnection strip over a narrow segment of a porous, doped lanthanum manganite tubular electrode, and then (B) thermal spraying yttria stabilized zirconia over the remaining portion of the lanthanum manganite tubular electrode to provide a high temperature oxygen ion conductive electrolyte layer having an open pore structure, which overlaps a portion of the interconnection strip, and then (C) forming a coating of particles of an electronic conductor on the electrolyte, and then (D) pressurizing the outside of the electrolyte layer, and then (E) feeding halide vapors of yttrium and zirconium to the outside of the electrolyte layer, where the vapors penetrate into the pores of the electrolyte without initiating formation of a metal oxide, and then applying a source of oxygen to the inside of the porous, tubular electrode to contact the inside of the electrolyte layer, and then (F) heating the tube and electrolyte to a temperature sufficient to cause oxygen reaction with the halide vapors, closing electrolyte pores, and inducing oxygen ions to diffuse through the electrolyte causing reaction with the halide vapors, to form a metal oxide coating on and between the particles of electronic conductor, which coating is attached to the electrolyte layer, providing a porous exterior electrode.

Claim 2

A method of bonding an electrolyte, and an outer electrode layer on a porous, doped lanthanum manganite tubular electrode, comprising the steps: (A) thermal spraying a thin, axially elongated, electrically conductive, ceramic oxide interconnection strip over a narrow segment of a porous, doped lanthanum manganite tubular electrode, and then (B) thermal spraying yttria stabilized zirconia over the remaining portion of the lanthanum manganite tubular electrode to provide a high temperature oxygen ion conductive electrolyte layer having an open pore structure, which overlaps a portion of the interconnection strip, and then (C) forming a coating of particles of an electronic conductor on the electrolyte, and then (D) pressurizing the outside of the electrolyte layer, and then (E) feeding halide vapors of yttrium and zirconium to the outside of the electrolyte layer, where the vapors penetrate into the pores of the electrolyte without initiating formation of a metal oxide, and then applying a source of oxygen to the inside of the porous, tubular electrode to contact the inside of the electrolyte layer, and then (F) heating the tube and electrolyte to a temperature sufficient to cause oxygen reaction with the halide vapors, closing electrolyte pores, and inducing oxygen ions to diffuse through the electrolyte causing reaction with the halide vapors, to form a metal oxide coating on and between the particles of electronic conductor, which coating is attached to the electrolyte layer, providing a porous exterior electrode.