Solid Oxide Fuel Cell Having Internal Active Layers

Abstract

A solid oxide electrochemical device includes: a porous support structure having a porous outer surface and a tubular porous inner surface; a first electrode layer disposed radially inside the tubular porous inner surface and supported by the porous support structure; a dense electrolyte layer disposed radially inside and supported by the first electrode composition; and a second electrode layer disposed radially inside and supported by the dense electrolyte.

1 . A solid oxide electrochemical device comprising: 
 a. a porous support structure having a porous outer surface and a tubular porous inner surface;    b. a first electrode layer disposed radially inside said tubular porous inner surface and supported by said porous support structure;    c. a dense electrolyte layer disposed radially inside and supported by said first electrode composition; and    d. a second electrode layer disposed radially inside and supported by said dense electrolyte.    
   
   
       2 . A solid oxide electrochemical device in accordance with  claim 1  wherein said porous support structure comprises a structure selected from the group consisting of a tube and a tube sheet.  
   
   
       3 . A solid oxide electrochemical device in accordance with  claim 1  wherein said porous support structure comprises a composition selected from the group consisting of a non-noble transition metal, a metal alloy, and a cermet comprising at least one metallic component selected from the group consisting of a non-noble transition metal and a non-noble transition metal alloy.  
   
   
       4 . A solid oxide electrochemical device in accordance with  claim 3  wherein said composition comprises a stainless steel composition.  
   
   
       5 . A solid oxide electrochemical device in accordance with  claim 4  wherein said stainless steel composition comprises at least one stainless steel composition selected from the group consisting of a ferritic stainless steel composition and an austenitic steel composition.  
   
   
       6 . A solid oxide electrochemical device in accordance with  claim 1  wherein said first electrode layer is in contact with said porous support structure.  
   
   
       7 . A solid oxide electrochemical device in accordance with  claim 1  further comprising at least one interlayer between said first electrode layer and said porous support structure.  
   
   
       8 . A solid oxide electrochemical device in accordance with  claim 1  wherein said dense electrolyte layer is in contact with said first electrode layer.  
   
   
       9 . A solid oxide electrochemical device in accordance with  claim 1  further comprising at least one interlayer between said dense electrolyte layer and said first electrode layer.  
   
   
       10 . A solid oxide electrochemical device in accordance with  claim 1  wherein said second electrode layer is in contact with said dense electrolyte layer.  
   
   
       11 . A solid oxide electrochemical device in accordance with  claim 1  further comprising at least one interlayer between said second electrode layer and said dense electrolyte layer.  
   
   
       12 . A solid oxide electrochemical device in accordance with  claim 1  wherein said first electrode layer comprises an electrode selected from the group consisting of an anode and a cathode, and wherein said second electrode layer comprises an electrode selected from the group consisting of an anode and a cathode, said first electrode layer and said second electrode layer being dissimilar.  
   
   
       13 . A solid oxide electrochemical device in accordance with  claim 12  wherein said anode comprises a composition selected from the group consisting of Ni—YSZ, Ni—GdCeO 2 , Ni—SmCeO 2 , and Ag—SmCeO 2 .  
   
   
       14 . A solid oxide electrochemical device in accordance with  claim 12  wherein said cathode comprises a composition selected from the group consisting of an alkaline earth substituted lanthanum manganite, an alkaline earth substituted lanthanum ferrite, a lanthanum strontium iron cobaltite, and a mixed ionic-electronic conductor.  
   
   
       15 . A solid oxide electrochemical device in accordance with  claim 1  wherein said solid oxide electrochemical device comprises at least one device selected from the group consisting of a fuel cell and an electrolyzer.  
   
   
       16 . A solid oxide electrochemical device comprising: 
 a. a composite electrode comprising: 
 1) a porous support structure having pores, a porous outer surface, and a tubular porous inner surface; and  
 2) a first electrode layer disposed throughout said pores, said porous outer surface, and said tubular porous inner surface and supported by said porous support structure;  
   b. a dense electrolyte layer disposed radially inside and supported by said composite electrode; and    c. a second electrode layer disposed radially inside and supported by said dense electrolyte.    
   
   
       17 . A solid oxide electrochemical device in accordance with  claim 16  wherein said porous support structure comprises a structure selected from the group consisting of a tube and a tube sheet.  
   
   
       18 . A solid oxide electrochemical device in accordance with  claim 16  wherein said porous support structure comprises a composition selected from the group consisting of a non-noble transition metal, a metal alloy, and a cermet comprising at least one metallic component selected from the group consisting of a non-noble transition metal and a non-noble transition metal alloy.  
   
   
       19 . A solid oxide electrochemical device in accordance with  claim 18  wherein said composition comprises a stainless steel composition.  
   
   
       20 . A solid oxide electrochemical device in accordance with  claim 19  wherein said stainless steel composition comprises at least one stainless steel composition selected from the group consisting of a ferritic stainless steel composition and an austenitic steel composition.  
   
   
       21 . A solid oxide electrochemical device in accordance with  claim 16  wherein said first electrode layer is in contact with said porous support structure.  
   
   
       22 . A solid oxide electrochemical device in accordance with  claim 16  further comprising at least one interlayer between said first electrode layer and said porous support structure.  
   
   
       23 . A solid oxide electrochemical device in accordance with  claim 16  wherein said dense electrolyte layer is in contact with said first electrode layer.  
   
   
       24 . A solid oxide electrochemical device in accordance with  claim 16  further comprising at least one interlayer between said dense electrolyte layer and said first electrode layer.  
   
   
       25 . A solid oxide electrochemical device in accordance with  claim 16  wherein said second electrode layer is in contact with said dense electrolyte layer.  
   
   
       26 . A solid oxide electrochemical device in accordance with  claim 16  further comprising at least one interlayer between said second electrode layer and said dense electrolyte layer.  
   
   
       27 . A solid oxide electrochemical device in accordance with  claim 16  wherein said first electrode layer comprises an electrode selected from the group consisting of an anode and a cathode, and wherein said second electrode layer comprises an electrode selected from the group consisting of an anode and a cathode, said first electrode layer and said second electrode layer being dissimilar.  
   
   
       28 . A solid oxide electrochemical device in accordance with  claim 27  wherein said anode comprises a composition selected from the group consisting of Ni—YSZ, Ni—GdCeO 2 , Ni—SmCeO 2 , and Ag—SmCeO 2 .  
   
   
       29 . A solid oxide electrochemical device in accordance with  claim 27  wherein said cathode comprises a composition selected from the group consisting of an alkaline earth substituted lanthanum manganite, an alkaline earth substituted lanthanum ferrite, a lanthanum strontium iron cobaltite, and a mixed ionic-electronic conductor.  
   
   
       30 . A solid oxide electrochemical device in accordance with  claim 16  wherein said solid oxide electrochemical device comprises at least one device selected from the group consisting of a fuel cell and an electrolyzer.