Formulation of nano-scale electrolyte suspensions and its application process for fabrication of solid oxide fuel cell-membrane electrode assembly (SOFC-MEA)

1. A formulation and application process for nano-scale electrolyte suspension for the fabrication of a solid oxide fuel cells-membrane electrolyte assembly (SOFC-MEA) comprising the steps of:

(1) A formulation and a fabrication process for nano-scale electrolyte suspension comprising steps:

Step a: using a hydrothermal co-precipitation process to prepare a nano-scale YSZ ceramic powders with 100% cubic crystal structure;

Step b: mixing the nano-scale YSZ ceramic powder 10˜50% by weight, PAA 0.01˜1% by weight, PVA 0.1˜5% by weight, octanol 0.005˜1% by weight, and deionized water as solvent;

Step c: preparing the nano-scale electrolyte suspension is as follows: the mixture from Step b is subject to homogenization by grinding/dispersing treatment for 1˜24 hours with ZrO 2 beads in 50˜100 μm as grinding beads, and after filtration and separation, nano-scale YSZ suspension is obtained;

(2) The process to apply the nano-scale YSZ suspension to fabricate SOFC-MEA is as follows:

A. The airtight/fully dense electrolyte layer fabrication process comprising steps:

Step d: fixing the center of an anode substrate onto spin coater, test running at 30 rpm to assure the substrate is firmly placed on the spin coater;

Step e: The spin coating process has three stages: (1) putting a suitable amount of suspension onto the anode substrate surface and running the spin coater at 150˜800 rpm for 6 seconds; (2) distributing the suspension evenly onto the anode substrate surface and running the spin coater at 1000˜2000 rpm for 30˜60 seconds; (3) putting the suspension onto the anode substrate surface and running the spin coater at 2000˜3000 rpm for 6 seconds, and spinning off the residual solvent to obtain green tape electrolyte half-cell;

Step f: putting the coated half-cell in an oven at 80° C. and repeating Step d and Step e for about eight times to complete the electrolyte coating process;

Step g: putting the completed half-cell in a high-temperature furnace for sintering at 1450° C. and holding it at 1390° C. for 15 hours while the temperature increase rate is 0.5˜3° C./min and the temperature decrease rate is 1˜3° C./min, and after sintering, a ceramic half-cell of airtight/fully dense YSZ electrolyte layers is obtained;

B. SOFC-MEA fabrication process at least comprising steps:

Step h: fixing the half-cell onto a screen printer by vacuum operation, and adjusting it to a suitable coating thickness, scraper pressure and scraper speed;

Step i: putting a suitable amount of LSM paste on the screen and running the scraper for several times to coat the paste evenly onto the half-cell, and leaving and setting the half-cell in an oven at 80° C.;

Step j: putting the solid oxide fuel cell with completed cathode coating in a high-temperature furnace for sintering at 1100° C. for 3 hours, while the temperature increase rate and the temperature decrease rate are both 1° C./min., thus a solid oxide fuel cell-membrane electrode assembly is obtained; and

Step k: conducting SEM microstructure analysis and electrolyte gas permeability test for the completed SOFC-MEA.

2. The process according to claim 1 , wherein the hydrothermal coprecipitation process in Step a is operated with solution pH value higher than 9.5, reaction temperature at 180° C., pressure at 140 psi and reaction time in 8-24 hours.

3. The process according to claim 1 , wherein the nano-scale electrolyte suspension formulation in Step b contains nano-scale electrolyte powders, dispersant, binder, defoamer and solvent and the electrolyte is YSZ, GDC, LSGM, or SDC (Sm doped ceria).

4. The process according to claim 1 , wherein the process for the airtight/fully dense electrolyte layer in A process of Item (2) is the same as Step d, e, f; while other parameters like rpm and coating time is adjusted.

5. The process according to claim 1 , wherein the cathode material in B process of Item (2) is LSM or LSCF.

6. The process according to claim 1 , wherein the equipment to investigate SOFC-MEA microstructure for Step k in B process of Item (2) is SEM; the gas permeability for airtight/fully dense characteristic is less than 2×10 −6 L/cm 2 /sec.