Manufacturing Method for Electrochemical Element and Electrochemical Element

Abstract

Provided is a low-cost electrochemical element that has excellent performance, reliability, and durability. Also, provided is a manufacturing method for an electrochemical element including a metal substrate (metal support) and an electrode layer formed on/over the metal substrate. The method includes an electrode layer forming step of forming an electrode layer having a region with a surface roughness of 1.0 μm or less on/over the metal substrate, and an electrolyte layer forming step of forming an electrolyte layer by spraying aerosolized metal oxide powder onto the electrode layer.

1 . A manufacturing method for an electrochemical element including a metal support and an electrode layer formed on/over the metal support, the method comprising:
 an electrode layer forming step of forming an electrode layer having a region with a surface roughness (Ra) of 1.0 μm or less on the metal support; and   an electrolyte layer forming step of forming an electrolyte layer by spraying aerosolized metal oxide powder onto the electrode layer.   
     
     
         2 . A manufacturing method for an electrochemical element including a metal support, an electrode layer formed on/over the metal support, and an intermediate layer formed on/over the electrode layer, the method comprising:
 an intermediate layer forming step of forming an intermediate layer having a region with a surface roughness (Ra) of 1.0 μm or less on the electrode layer; and   an electrolyte layer forming step of forming an electrolyte layer by spraying aerosolized metal oxide powder onto the intermediate layer.   
     
     
         3 . The manufacturing method for an electrochemical element according to  claim 2 , wherein the electrolyte layer contains stabilized zirconia. 
     
     
         4 . An electrochemical element provided with a dense electrolyte layer formed by spraying aerosolized metal oxide powder onto an electrode layer that is formed on/over a metal support and has a region with a surface roughness (Ra) of 1.0 μm or less. 
     
     
         5 . An electrochemical element provided with a dense electrolyte layer formed by spraying aerosolized metal oxide powder onto an intermediate layer that is formed on/over an electrode layer on/over a metal support and has a region with a surface roughness (Ra) of 1.0 μm or less.