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 Fuel cell, electrode for the cell and method of preparation thereof

Details
Inventors: Okada, Hideo; Mori, Toshikatsu; Mitsugi, Kouichi; Iwase, Yoshio; Kuroe, Satoshi; Takeuchi, Masato; Kamo, Tomoichi;
Assignee: Hitachi, Ltd. (Tokyo, JP)
Primary Examiner: Walton; Donald L.
Assistant Examiner:
Attorney, Agent or Firm: Antonelli, Terry, Stout & Kraus

The present invention provides a molten carbonate type fuel cell comprising two electrodes as anode and cathode, an electrolyte plate and separators in a single unit and a battery of the unit cells stacked. The electrodes comprise a porous plate of an electron-conducting material such as nickel containing particles of ceramics such as magnesium oxide uniformly dispersed therein in an amount of 2 to 29 atomic %, except for the superficial thin portion free of the ceramic particles on the one-side surface of the plate. The electrodes are prepared by mixing a powder of the electro-conducting material with an organic binder under stirring to obtain a slurry or paste, deaerating the slurry or paste to remove entrained air bubbles therefrom, shaping the slurry or paste plate with or without a metal wire net, drying the electrode plate at room temperature and finally firing the plate in a reducing atmosphere.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The problems of the prior art molten carbonate type fuel cells can be overcome by providing an electrode as anode or cathode comprising a porous electron-conducting body containing ceramic particles uniformly dispersed therein but having a superficial thin portion free of the ceramic particles at the fuel or oxidizing gas-passing side of the body.
This electrode is made by making a porous plate of an electron-conducting material through a usual process, applying a water-repellent onto the surface of the porous plate allowed to face the fuel or oxidizing gas-passing side of a separator, impregnating the plate with a dispersion of a ceramic source, prefiring the plate in an oxidizing atmosphere and finally firing the plate in a reducing atmosphere.
The porous plate of an electron-conducting material is made by a usual process under "step of preparing a metal slurry or paste" 10 as defined in FIG.
2.
That is, a metal powder as a starting material is mixed with an organic binder 12 under stirring 13 for viscosity adjustment to obtain a slurry or paste, which is then deaerated under vacuum 14 to remove entrained air bubbles from the slurry or paste, thus obtaining a predetermined slurry or paste 16.
The metal powder is comprised of at least one metal selected from nickel, cobalt, copper, chromium and iron, mixtures or alloys thereof, and it is of 0.
1 to 10 .
mu.
m, preferably 1 to 5 .
mu.
m in particle size.
To the metal powder is added an organic binder and water, the mixture is kneaded to form a slurry or paste, which is deaerated to adjust the viscosity to 50 to 200 poises, preferably 100 to 200 poises.
The organic binder used herein may be, for example, carboxymethyl cellulose (CMC), hydroxyethyl cellulose (HEC), polyethylene oxide (PEO), polyvinyl alcohol (PVA) or polyvinyl butyral (PVB).
If the particle size of the metal powder is smaller than 0.
1 .
mu.
m, the sintering action is accelerated in the subsequent step of firing in a reducing atmosphere as mentioned below, so that the specific surface area of the electrode is conspicuously reduced, which causes cracks to be generated in the electrode



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