Electrode design for solid state devices, fuel cells and sensors

Abstract

An improved electrode design for solid state devices, fuel cells, sensors and the like is made by incorporation of a porous layer of the electrolyte material over the dense electrolyte, and by the introduction of an electrocatalyst into the porous layer such that it is also continuous. The resulting electrode structure of dense electrolyte/porous electrolyte, continuous electrocatalyst and gas phase are present creating an enhanced three phase (TPB) length over that of conventional designs. The design allows for improved performance at lower temperatures which means a lower cost of materials, fewer problems from oxidation and corrosion, and improved durability. In a preferred embodiment, the dense electrolyte and porous electrolyte is yttria-stabilized zirconia (YSZ), and the electrocatalyst is selected from silver; platinum; rhodium; palladium; iridium; ruthenium;