Electrode-supported tubular solid-oxide electrochemical cells suitable for use in electrochemical synthesis and processes for manufacturing such are provided.

A co-extrusion die is configured to produce a multilayer extrusion comprising component layers of an electrochemical cell. The die comprises a plurality of inlet ports configured to receive a plurality of pressurized fluids comprising at least a first metallic ink, a second metallic ink, and a polymeric ink. A plurality of channels are configured to separately transport and shape the plurality of fluids from the plurality of inlet ports to a merge section, such that the plurality of fluids flow together in the merge section to form the multilayer extrusion comprising a polymeric membrane layer disposed between and in contact with a first metallic layer and a second metallic layer. A thickness of each layer within the merge section is controllable by adjustment of a pressure of the plurality of pressurized fluids. An outlet port is configured to output the multilayer extrusion onto a substrate.

Described herein are novel alumina substrate-supported thin film SOFCs that may be produced at significantly reduced cost while providing improved robustness, high electrochemical performance, and the capability of effective carbon deposition resistance while still using Ni-cermet as an anode functional layer.

Electrode-supported tubular solid-oxide electrochemical cells suitable for use in electrochemical chemical synthesis and processes for manufacturing such are provided.

Systems and methods are provided for an electrode assembly. In one example, a method for fabricating the electrode assembly includes co-extruding a first layer, comprising a conductive thermoplastic, with a second layer, comprising a nonconductive thermoplastic, to form a stack. The stack may be pressed between a set of rollers and cooled to provide a bipolar plate with an integrated negative electrode spacer bonded to a surface of the bipolar plate.

The presented invention relates to a cell assembly (100) for the controlled guiding of reactive fluids, wherein: the cell assembly (100) comprises a membrane (101), which has a first side and a second side opposite from the first side; on each of the first side and the second side, a catalyst layer (103) and a microporous layer (105) are disposed; the microporous layer (105) and/or the catalyst layer (103) of at least one side is profiled in such a way that the surface roughness of the catalyst layer (103) differs from the surface roughness of the microporous layer (105), so that the catalyst layer (103) and the microporous layer (105) fit together in parts.

A method of forming an electrode for an electrochemical device includes mixing at least a first amount of a catalyst and a second amount of an ionomer or an uncharged polymer to form a liquid mixture; delivering the liquid mixture into a metallic needle having a needle tip; applying a voltage between the needle tip and a collector substrate positioned at a distance from the needle tip; and extruding the liquid mixture from the needle tip at a flow rate such as to generate electrospun fibers and deposit the generated fibers on the collector substrate to form a mat comprising a porous network of fibers, where each fiber has a plurality of particles of the catalyst distributed thereon.

In one aspect, a method of forming an electrode for an electrochemical device is disclosed. In one embodiment, the method includes the steps of mixing at least a first amount of a catalyst and a second amount of an ionomer or uncharged polymer to form a solution and delivering the solution into a metallic needle having a needle tip. The method further includes the steps of applying a voltage between the needle tip and a collector substrate positioned at a distance from the needle tip, and extruding the solution from the needle tip at a flow rate such as to generate electrospun fibers and deposit the generated fibers on the collector substrate to form a mat with a porous network of fibers. Each fiber in the porous network of the mat has distributed particles of the catalyst. The method also includes the step of pressing the mat onto a membrane.

A method for forming tubular solid oxide cells is described. The methods include co-extrusion of an electrode precursor and a sacrificial material to form a multi-layered precursor followed by phase inversion and sintering to remove the sacrificial layer and form an electrode substrate for use in a tubular solid oxide cell. Upon phase inversion and sintering of the precursor, a micro-channel array can be generated in the electrode that is generally perpendicular to the tube surface. The open pored micro-scale geometry of the porous electrode substrate can significantly reduce resistance for fuel/gas transport and increase effective surface area for electrochemical reactions.

A three dimensional electrode structure having a first layer of interdigitated stripes of material oriented in a first direction, and a second layer of interdigitated stripes of material oriented in a second direction residing on the first layer of interdigitated stripes of material. A method of manufacturing a three dimensional electrode structure includes depositing a first layer of interdigitated stripes of an active material and an intermediate material on a substrate in a first direction, and depositing a second layer of interdigitated stripes of the active material and the intermediate material on the first layer in a second direction orthogonal to the first direction.