Method of making sulfur tolerant composite cermet electrodes for solid oxide electrochemical cells

Claim 1

A method of bonding a separate, porous, active layer on an electronically conductive fuel cell electrode attached to a solid electrolyte, oxygen ion transporting oxide layer comprising the steps: (A) forming a coating of particles of an electronic conductor selected from the group consisting of nickel, cobalt, and mixtures thereof on a first surface of an oxygen ion transporting, solid oxide electrolyte layer comprising zirconia; (B) applying a source of oxygen to a second surface of said solid oxide electrolyte layer; (C) applying a metal halide vapor to said first surface of said solid oxide electrolyte layer; (D) heating said oxygen transporting, solid oxide electrolyte layer to a temperature sufficient to induce oxygen to diffuse through said oxide layer and react with said metal halide vapor, whereby essentially only an ion conductive metal oxide skeletal structure, comprising zirconia, grows partially around said particles of said electronic conductor, embedding them, and forming an electrode attached to the electrolyte; (E) coating both the particles and the ion conducting metal oxide skeletal structure with a separate, salt coating which upon heating will form an oxide selected from the group consisting of ceria, doped ceria, uranium oxide, doped uranium oxide, and mixtures thereof; and then (F) heating the salt coated structure at a temperature of from about 500° C. to about 1400° C., to form a separate, porous, ionic-electronic conductive, active coating comprising an oxide selected from the group consisting of ceria, doped ceria, uranium oxide, doped uranium oxide, and mixtures thereof, where the ionic-electronic conductive coating formed in step (F) is effective to provide electrochemically active sites over its entire surface, and where the heating in step (F) is effective to diffuse elements from the salt coating into the skeletal structure, introducing increased electronic conduction into the skeletal structure.

Claim 2

A method of bonding a separate, porous, active layer on an electronically conductive fuel cell electrode attached to a solid electrolyte, oxygen ion transporting oxide layer comprising the steps: (A) forming a coating of particles of an electronic conductor selected from the group consisting of nickel, cobalt, and mixtures thereof on a first surface of an oxygen ion transporting, solid oxide electrolyte layer comprising zirconia; (B) applying a source of oxygen to a second surface of said solid oxide electrolyte layer; (C) applying a metal halide vapor to said first surface of said solid oxide electrolyte layer; (D) heating said oxygen transporting, solid oxide electrolyte layer to a temperature sufficient to induce oxygen to diffuse through said oxide layer and react with said metal halide vapor, whereby essentially only an ion conductive metal oxide skeletal structure, comprising zirconia, grows partially around said particles of said electronic conductor, embedding them, and forming an electrode attached to the electrolyte; (E) coating both the particles and the ion conducting metal oxide skeletal structure with a separate, salt coating which upon heating will form an oxide selected from the group consisting of ceria, doped ceria, uranium oxide, doped uranium oxide, and mixtures thereof; and then (F) heating the salt coated structure at a temperature of from about 500° C. to about 1400° C., to form a separate, porous, ionic-electronic conductive, active coating comprising an oxide selected from the group consisting of ceria, doped ceria, uranium oxide, doped uranium oxide, and mixtures thereof, where the ionic-electronic conductive coating formed in step (F) is effective to provide electrochemically active sites over its entire surface, and where the heating in step (F) is effective to diffuse elements from the salt coating into the skeletal structure, introducing increased electronic conduction into the skeletal structure.