Disclosed is an electrode having a novel configuration for improving performance of the electrode used in solid-oxide fuel cells, sensors and solid state devices, in which the electrode providing electron conductivity is coated with ion conductive ceramic ceria film, enabling an electron conductive path and an ion conductive path to be independently and continuously maintained, and additionally extending a triple phase boundary where electrode/electrolyte/gas are in contact, and a method for manufacturing the same. The electrode is manufactured by coating the prefabricated electrode for use in a SOFC or sensor with a porous oxygen ion conductive ceramic ceria film by a sol-gel method, whereby the electron conductive material and ion conductive material exist independently, having a new microstructure configuration with a greatly extended triple phase boundary, thus improving electrode performance. Accordingly, such electrode does not require high cost equipment or starting materials, owing to the sol-gel method by which low temperature processes are possible. Moreover, the electrode microstructure can be controlled in an easy manner, realizing economic benefits, and the electrode/electrolyte interfacial resistance and electrode resistance can be effectively decreased, thereby improving performance of electrodes used in SOFCs, sensors and solid state devices.

A method of fabricating solid oxide fuel cell electrodes, and in particular anodes, includes the steps of forming a microcomposite element comprising a plurality of layers of an electrically conductive tape and an electrolyte tape, with the plurality of layers forming a first electrically conductive pattern. A plurality of microcomposite subelements are created from the microcomposite element, with each microcomposite subelement having the first electrically conductive pattern. A plurality of the microcomposite subelements are juxtaposed to one another and also rotated in planes substantially parallel to one another. Thereby, a totality of the first electrically conductive patterns form a second electrically conductive pattern in the anode. Electrical conduction is established with the patterns all being in electrical contact with one another.

A method for preparation of an anode for a solid oxide fuel cell in which a plurality of zircon fibers are mixed with a yttria-stabilized zirconia (YSZ) powder, forming a fiber/powder mixture. The fiber/powder mixture is formed into a porous YSZ layer and cacined. The calcined porous YSZ layer is then impregnated with a metal-containing salt solution. Preferred metals are Cu and Ni.

A method of preventing anode oxidation in a fuel cell is disclosed comprising applying a negative current to an anode of said fuel cell, such that the anode is disposed in ionic communication with a cathode through an electrolyte. Oxygen is transferred from the anode through the electrolyte to the cathode. A method preventing anode oxidation in a fuel cell by storing and using a reformate and doping an anode are also disclosed.

A solid state ionic device includes a dense electrolyte sandwiched between two porous electrodes. In one embodiment, the device is anode supported and the cathode is formed of a porous three-dimensional solid phase structure having an electrocatalytic phase of a plurality of electrocatalytic particles and an ionic conducting phase of a plurality of ionic conductor particles. The mean or median size of the electrocatalytic particles is larger than the mean or median size of the ionic conductor particles. The device may further include a long range electronic conducting layer of lanthanum cobaltate or other electronically conducting material.