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Method for making thin-film ceramic membrane on non-shrinking continuous or porous substrates by electrophoretic deposition

United States Patent

6,887,361
May 3, 2005
View the Complete Patent at the US Patent & Trademark Office
Lawrence Berkeley National Laboratory - Visit the Technology Transfer and Intellectual Property Management Department Website
Low Cost Fabrication of Thin-Film Ceramic Membranes for Nonshrinking Substrates
A disclosed method provides techniques for forming low-cost, mechanically strong, highly electronically conductive porous structures for solid-state electrochemical devices. In particular, a method of forming a ceramic film on a substrate using electrophoretic deposition (EPD) is described. The method employs a colloidal dispersion of particles during the EPD process where a distribution of particle sizes is selected to eliminate drying cracks in the ceramic film prior to firing of the ceramic film-coated substrate. The method may be used to provide a high-density green film which can be sintered on to a non-shrinking substrate. For instance, a thin film of YSZ with a high green density may be sintered on to a non-shrinking LSM substrate. In particular embodiments, the distribution of particle sizes used in the EPD process may be selected to reduce a firing temperature and a firing time during sintering of the film coated substrate.
Visco; Steven J. (Berkeley, CA), Jacobson; Craig (Lafayette, CA), DeJonghe; Lutgard C. (Lafayette, CA)
The Regents of the University of California (Oakland, CA)
10/ 061,127
January 30, 2002