Solid oxide fuel cell components tuned by atomic layer deposition

Abstract

A reduced cost solid oxide fuel cell having enhanced surface exchange rates and diffusivity of oxide ions is provided. The invention cell includes a first porous electrode and a second porous electrode, where the porous electrodes have a layer of electronically conductive porous non-precious metal, and the porous non-precious metal layer is a gas diffusion layer. The porous electrodes further include at least one atomic layer of catalytic metal deposited on the non-precious metal layer, and an electrolyte layer disposed between the first porous electrode and the second porous electrode. The electrolyte layer includes a first dense ion-conductive doped oxide film layer, and a second dense ion-conductive doped oxide film layer deposited on the first doped oxide film layer, where the catalytic metal layer on the conductive porous non-metal layer enhances surface exchange rates and diffusivity of the oxide ions, thus the material costs of the fuel cell are reduced.