Abstract: A corrosion resistant coated fuel cell plate and method of making the same are embodied in a metal plate provided with a graphite emulsion coating and then a layer of graphite foil which is pressed over the coating. The graphite emulsion bonds the graphite foil to the metal plate and seals fine scale porosities in the graphite foil. Flow fields are formed by stamping the coated fuel cell plate.

Abstract: A method and apparatus for fuel cell packaging are embodied in a pair of complementary fuel cell receptacles within which a stack of fuel cells are housed in a staggered or spiral configuration. The fuel cells are provided with ports positioned in their corner portions. The fuel cell receptacles include a plurality of port interfacing surfaces over which the corners of the fuel cells are positioned, thereby providing direct fluidic interfaces between the flow field areas of the fuel cells and the receptacles. In a preferred embodiment, o-rings are employed at the fluidic interfaces between the fuel cells and the receptacles. The fuel cell receptacles also include manifolds and a plurality of conduits between the port interfacing surfaces and the manifolds. In a preferred embodiment, the manifolds vary in depth along the receptacles such that the conduits are substantially equal in length.

Abstract: A fuel cell stack comprises a plurality of planar fuel cells in a spiral configuration. The fuel cells angularly offset from one another such that immediately adjacent cells only partially overlap one another. The cells are preferably of the unitized type. A manifold assembly is operatively adjacent to the fuel cells. The manifold assembly includes an inlet manifold and an outlet manifold for each of the gases that are in communication with the fuel cells. The unitized solid oxide fuel cell comprises a first planar interconnect, a planar ceramic cell adjacent the first planar interconnect, a second planar interconnect adjacent the opposite side of the planar ceramic cell, and a plurality of gas tubes adjacent the planar ceramic cell. The gas tubes are arranged to a first configuration, a second configuration, a third configuration and a fourth configuration with a cylindrical gas tube shape and a T-shape gas tube designs.

Abstract: A method of supplying supplemental power from a supplemental power source in addition to that from a primary power source in order to meet power demand of a load, comprising: measuring power flow from the primary power source to the power load; developing an error signal by subtracting a fixed power offset from the actual primary power source power measurement; establishing a gain; creating an input by multiplying the error signal by the gain; creating a supplemental power source power adjustment command based upon the input; and adjusting the power output of the supplemental power source based on the supplemental power source power adjustment command.

Abstract: A method and apparatus to increase fuel cell reliability and maintainability is disclosed. The apparatus includes a recuperating loop consisting of a spiral tube that surrounds a stack or a combination of several stacks. If the fuel cell stacks are externally manifolded, the recuperating loop may also surround the external manifold. The spent hot gases from the stack directly flows over the recuperating loop to transfer heat to a coolant flowing through the loop providing heat exchange by convection and radiation. The spent hot gases may be manifolded and may not flow over the recuperating loop. In this case, the heat exchange is by radiation between the hot fuel cell stack(s) and the recuperating loop.

Abstract: A corrosion resistant coated fuel cell plate and method of making the same are embodied in a metal plate provided with a multilayered conductive coating and then with an overcoat which fills in fine scale porosities in the coating. In one preferred embodiment, the overcoating is amorphous graphite applied through a deposition process. In another preferred embodiment, overcoating is a thin layer of oxide created by chemical anodization process.

Abstract: A system and method for controlling a microturbine generator system comprising: providing a computer control unit; providing a utility power grid sensor input line to the computer control unit; and providing a utility power grid disconnect command output line from the computer control unit; and causing, via the computer control unit, automatic transitions of the microturbine generator system between at least four states, the at least four states comprising a generator standby backup mode, a generator standalone mode, a transfer to standby backup mode, and a generator startup battery charging mode.

Abstract: The present invention is directed to apparatus and method for cathode-side disposal of water in an electrochemical fuel cell. There is a cathode plate. Within a surface of the plate is a flow field comprised of interdigitated channels. During operation of the fuel cell, cathode gas flows by convection through a gas diffusion layer above the flow field. Positioned at points adjacent to the flow field are one or more porous gas block mediums that have pores sized such that water is sipped off to the outside of the flow field by capillary flow and cathode gas is blocked from flowing through the medium. On the other surface of the plate is a channel in fluid communication with each porous gas block mediums. The method for water disposal in a fuel cell comprises installing the cathode plate assemblies at the cathode sides of the stack of fuel cells and manifolding the single water channel of each of the cathode plate assemblies to the coolant flow that feeds coolant plates in the stack.

Abstract: A sealless, planar fuel cell stack system, including a continuous bottom plate, a first permeable or interconnect layer, a continuous cell, a second permeable or interconnect layer, a continuous top plate, a fuel supply member, and an oxidant gas supply member, is provided. The fuel cell system of the present invention does not require glass-based sealants to seal its planar components. In the present system, the continuous cell of the system is supported by the first permeable layer. The second permeable layer is supported by the continuous cell. The fuel supply member supplies fuel into the first permeable layer. The fuel supply member extends between an outer edge and a center region of the first permeable layer and allows distribution of the fuel in a radial fashion. Further, the fuel supply member is connected to an external fuel manifold adjacent the outer edge. The oxidant gas supply member supplies oxidant gas into the second permeable layer.

Abstract: A corrosion resistant coated fuel cell plate and method of making the same are embodied in a metal plate provided with a multilayered conductive coating and then with an overcoating which fills in fine scale porosities in the coating. In one preferred embodiment, the overcoating is amorphous graphite applied through a deposition process. In another preferred embodiment, the overcoating is a thin layer of oxide created by a chemical anodization process.

Abstract: A unitized solid oxide fuel cell comprises a first electrically conductive interconnect operatively connected to an anode of the fuel cell, with the first interconnect having a first substantially planar portion and a first skirt portion. A second electrically conductive interconnect is operatively connected to a cathode of the fuel cell, with the second interconnect having a second substantially planar portion and a second skirt portion that is juxtaposed to the first skirt portion. A gas inlet is fixed to at least one of the first and second skirt portions while a gas outlet is fixed to at least one of the first and second skirt portions. The gas inlet and outlet can be releasably attached to a gas manifold.

Abstract: A fuel cell bipolar plate including a plurality of reactant channels defining respective inlets and outlets and at least two flow restrictors respectively associated with at least two adjacent reactant channels.

Abstract: The present invention relates to a multi-layered and multifunctional cathode in solid oxide fuel cells having high conductivity, high catalytic activity, minimized coefficient of thermal expansion (CTE) mismatch, excellent compatibility to other portions of the fuel cell, and reduced temperature operation. The cathode comprises a conductive layer, a catalyst layer and a graded composition layer. The conductive layer has a first density, the catalyst layer has a second density that is less than the first density, and the graded composition layer is characterized by a graded electronic conductivity and a graded ionic conductivity.

Abstract: The present invention is directed to an active converter system for a permanent magnetic turbogenerator. A system in accordance with an embodiment of the present invention includes a DC voltage link and a first active converter including a connection for inputting or outputting a three-phase AC voltage to or from, respectively, an AC voltage source, another connection for inputting or outputting a DC voltage from or to said DC voltage link, and at least six selectively switchable first IGBTs, wherein selective switching of the first IGBTs results in a boosted DC voltage. The system further includes a second active converter including a connection for inputting or outputting a three-phase AC voltage to or from, respectively, a permanent magnetic generator, another connection for inputting or outputting a DC voltage to or from said DC voltage link, and at least six selectively switchable second IGBTs, wherein the second active converter is capable of boosting said DC voltage.

Abstract: A method of controlling a gas booster comprises computing in an engine control unit a reference discharge pressure for the gas booster. In the engine control unit, an actual discharge pressure of the gas booster and the reference discharge pressure are compared. The engine control unit generates a correcting signal derived from the step of comparing. The engine control unit sends the correcting signal to an inlet valve in flow communication with the gas booster. The inlet valve is adjusted in response to the correcting signal. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to ascertain quickly the subject matter of the technical disclosure. The abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Abstract: A parallel electrical connector between a first fuel cell stack having a first conducting plate and a second fuel cell stack having a second conducting plate includes a connector element affixed to the first and second conducting plates. The connector element is positioned adjacent a first open face of the first fuel cell stack and a second open face of the second fuel cell stack, wherein the first and second open faces are juxtaposed to one another. Also, the connector element is positioned substantially parallel to at least one of the first and second conducting plates. It is also configured to substantially match a configuration of at least one of the first and second conducting plates. Series-parallel connection is provided at the cell or higher cell level for two or more stacks.

Abstract: An electrically conductive flow-field plate in a proton exchange membrane fuel cell comprises a composition made of a resin and a plurality of carbon nanotubular fibers having an average diameter is at least about 0.5 nm and up to about 300 nm. The carbon nanotubular fibers are present at not more than about 85 wt. %. The resin can be of a thermoplastic type, a fluorinated type, a thermosetting type and a liquid crystalline type.

Abstract: A solid oxide fuel cell comprises an anode, a cathode opposite to the anode, and an electrolyte between the anode and cathode. The electrolyte includes a barrier layer that prevents chemical interactions between the electrolyte and the anode, in addition to preventing elemental losses from the electrolyte. The electrolyte further includes a strengthening layer having alternating layer elements that provide fracture resistance to the electrolyte.

Abstract: In a hydrogen gas fuel cell a polymer electrolyte membrane, or “PEM,” is located between two layers composed of a catalyst material such that a sandwich-like assembly is formed. An anode electrode and a cathode electrode, each composed of a thin sheet of porous material that is permeable to liquid and gas, are situated on either side of the sandwich-like assembly such that one surface of each electrode abuts a catalyst layer. The remaining surface of each electrode abuts a conductive nonporous bipolar plate having grooves cut therein. Wicking strands composed of a trilobed fiber are located in between each catalyst layer and the adjacent PEM, and arranged in a repetitive pattern such that the strands do not cross over each other. Each wicking strand abutting the PEM surface facing the anode electrode has one end situated in a reservoir of liquid water. Each wicking strand abutting the PEM surface facing the cathode electrode drains into an exhaust reservoir.

Abstract: A composite sealant for in-situ sealing a fuel cell stack is provided. A paste of the sealant mixture is initially formed by mixing a glass precursor powder and a reacting filler material. The sealant mixture paste is applied to selected sealing locations of the fuel cell stack. The sealant mixture paste is then transformed into a composite sealant material to seal the selected sealing locations by heat treatment in air to about 900° C. The composite sealant material comprises a glass matrix phase and a reinforcing phase including a plurality of interlocked elongated single crystal grains. The reacting fillers modify the CTE and significantly improve the gap filling capacity of the composite sealant material and provide superior pressure containment capability at elevated temperatures.