Solid oxide electrolytic device

Abstract

An interconnect structure is disclosed for use in solid oxide electrolytic devices that use chrome-containing components, such as solid oxide fuel cells and solid oxide oxygen-generators. The invention provides a reliable and durable interconnect for both structural and electrical components of such devices. In general, the interconnect structure relies on a dual-layer, high-temperature seal which provides an effective diffusion barrier for both chrome and oxygen. As a result of the described interconnect, corrosion or loss in electrical conductivity in such solid oxide electrolytic devices is avoided. Also, a novel structure for such solid oxide electrolytic devices is disclosed, which provides an economical and high-integrity structure that utilizes the disclosed interconnect structure. A result of the present invention is that thin film solid oxide fuel cells and solid oxide oxygen generators may be fabricated using only metal alloys as bulk components.

What is claimed is:  
     
         1 . An interconnect structure for use in solid oxide electrolytic devices, comprising: 
 a.) a structural element, the structural element comprised of a chrome-containing alloy, the structural element having a first and a second side;    b.) a first material layer, the first layer covering the first side and the second side, the first layer comprising a chrome-containing oxide compound; and,    c.) a second material layer, the second material layer comprising a platinum-containing metal, the second layer covering the first layer, the second layer covering the first side and the second side, so that the interconnect structure, so that the covered areas of the structure are stable in device operating environments.    
     
     
         2 . The solid oxide electrolytic device of  claim 1 , wherein the electrolytic device is a solid oxide fuel cell.  
     
     
         3 . The solid oxide electrolytic device of  claim 1 , wherein the device is an oxygen generation device.  
     
     
         4 . A solid oxide electrolytic device, comprising: 
 a.) an electrode structural element, the structural element comprised of a chrome-containing alloy, the structural element having a first and a second side, the structural element having a through-hole structure defining a plurality of through-holes that pass between the first side and the second side;    b.) a first material layer, the first layer covering the first side, the second side, and the through-hole structure, the first layer comprising a chrome-containing compound;    c.) a second material layer, the second material layer comprising a platinum-containing metal, the second layer covering the first layer, the second layer covering the first side, the second side, and the through-hole structure; and,    d.) A third material layer, the third layer comprising a solid electrolyte, the third layer covering the second layer, the third layer covering the first side and spanning the through-hole structure, so as to be an effective gas barrier to a gas passing into the through-holes, therein providing an electrolytic membrane for electrolytic separation of gases.    
     
     
         5 . A method for forming an electrical interconnect structure for a solid oxide electrolytic device, comprising: 
 a.) forming a structural element from a chrome-containing alloy, the structural element having a through-hole structure defining through-holes;    b.) forming a first layer on the structural element, the first layer a chrome-containing compound, the first layer covering and conformal to the through-hole structure;    c.) forming a second layer on the structural element, the second layer a platinum-containing metal, the second layer covering and conformal to the through-hole structure;    d.) applying a sacrificial material to the through-hole structure, the sacrificial material;    e.) forming a third layer on the structural element, the third layer a solid oxide electrolyte; and,    f.) removing the sacrificial material, so that the third layer remains disposed over the through-hole structure so as to be an effective gas barrier to a gas passing into the through-holes, therein providing an electrolytic membrane for electrolytic separation of gases.