Abstract: A fuel cell assembly or system including flexible metal bellows elements in one or more tubes intended for carrying hot gases during operation of the assembly. The bellows elements include a tubing element having plurality of annular corrugated folds. Thermal expansion and contraction of rigid tubes and of the non-tubular elements of the assembly can lead to buckling, cracking, and failure of the tubes and failure of the assembly or system. The flexible bellows elements, having relatively low axial and radial spring rates thus are able to absorb thermal and vibrational dimensional changes in the assembly. In addition, the corrugations provide significant resistance to axial heat flow and large radiant surface area, thus increasing thermal isolation where desired between relatively hot and relatively cold regions of the assembly.

Abstract: A method for attaching a gasket to a non-gasketed bipolar plate for a PEM fuel cell, including the steps of making a pattern of the gasket; preparing the bipolar plate surface; priming the bipolar plate surface for adhesive according to the gasket pattern; aging the primer coat; screen-printing an adhesive coat onto the primer according to the gasket pattern; positioning the gasket face-down in a mirror-image fixture having channels in the form of the gasket; positioning the bipolar plate face down onto the fixture and gasket; applying pressure to the plate to adhere the gasket thereto in the adhesive-coated areas; removing the plate and gasket subassembly from the fixture; and curing the adhesive to provide a gasketed bipolar plate.

Abstract: A load frame with mechanical springs for providing compression to a fuel cell stack during assembly and operation of a fuel cell assembly. The stack assembly load frame includes a base plate for supporting the stack, a moveable spring holder above the stack, a retaining plate above the spring holder, and tubular supports or rods retaining the post-sintered spacing established by the applied load defining the spacing of the base plate from the retaining plate. A spring for maintaining compression in each stack is positioned between the spring holder and the retaining plate. The invention further comprises a method for assembling a fuel cell assembly to provide an adequate compressive load to the stack during assembly and operation.

Abstract: In a solid-oxide fuel cell system, the fuel cell tail gas contains significant residual amounts of combustibles which are burned in a combustor with spent cathode air to reduce system emissions and to reclaim chemical energy in the form of heat, the hot exhaust being used to pre-heat air entering the fuel cell system. The tail gas combustibles content can vary widely as can the combustion temperature. When the temperature becomes unacceptably low, a control valve in the spent cathode air return is adjusted to divert a portion of the air around the combustor, thus enriching the fuel/air mixture and causing the combustion temperature to increase. When the temperature becomes unacceptably high, a control valve in the combustor fresh air supply is adjusted to provide more air, thus causing the mixture to become leaner and the combustion temperature to decrease.

Abstract: A method and apparatus for spin forming a portion of a workpiece where the formed portion has a formed axis that is non-coaxial with the non-processed axis of the workpiece includes at least two rollers rotatable about a spin axis. Each one of the rollers is axially and radially offset from the others. An axial drive mechanism reciprocates the rollers or workpiece to causes the first roller and then the second roller to sequentially engage the workpiece. A pivoting mechanism rotates the rollers or workpiece about a pivot point from a first angular position to a second angular position during a forming operation to create a formed portion that is oblique to the non-processed portion or is substantially curved. A higher reduction ratio is achieved which enables improved efficiency. The present invention reduces floor space requirements as the forming operation may be completed on a single machine.

Abstract: A method of operating a fuel cell includes the step of selectively connecting and disconnecting the fuel cell to at least one electrical load dependent at least in part upon at least one of a fuel cell voltage, a fuel cell current and a fuel cell temperature.

Abstract: A fuel cell assembly having manifold means for providing fuel and air to, and removing spent fuel and air from, flow passageways across the anodes and cathodes in a fuel cell stack. The sizes and proportions of the supply and return manifolds are optimized, and the total cross-sectional area of the return manifold is about twice the cross-sectional area of the supply manifold. The pressure drop in the manifolds is less than about one-quarter of the total pressure drop across the anode and cathode passageways in the stack, which ratio may be attained by adjusting the thickness of the anode and cathode spacers and/or the size of the chimneys. Widthwise uniformity of flow across the anodes and cathodes is improved by forming each of the manifolds as a plurality of smaller, parallel flow conduits.

Abstract: A method for preparing a non-thermal plasma reactor substrate includes disposing electrical vias on green stage first and second ceramic plates; filling the electrical vias with conductive material; and forming electrical contact via cover pads; disposing conductive material on the first ceramic plate to form an electrode plate having a main electrode portion and a terminal lead for electrically connecting the main electrode portion to the electrical vias; laminating the electrode plate and the second ceramic plate together, embedding the electrode therebetween; co-firing the plates to form a laminated co-fired embedded-conductor element; stacking a plurality of the laminated co-fired embedded-conductor elements to form a multi-cell stack, the filled electrical vias aligning in the stack to provide an electrical bus for connecting alternating elements in the stack; and disposing spacers with matching vias and via cover pads between adjacent pairs of elements to form exhaust gas passages.

Abstract: In a solid-oxide fuel cell system, the electronic control unit which measures and controls temperatures, pressures, valve sequencing, valve positioning, blower power, electric output, and flows of air and fuel gas, is disposed in a “cool zone” within a structural housing. Electric leads from the control unit to the individual system components therefore do not pass through the housing. The few leads from the control unit required for connection of the fuel cell system to a load are gathered into a single electrical connector mounted through a wall of the structural enclosure.

Abstract: In a solid-oxide fuel cell assembly, a co-flow heat exchanger is provided in the flow paths of the reformate gas and the cathode air ahead of the fuel cell stack, the reformate gas being on one side of the exchanger and the cathode air being on the other. The reformate gas is at a substantially higher temperature than is desired in the stack, and the cathode gas is substantially cooler than desired. In the co-flow heat exchanger, the temperatures of the reformate and cathode streams converge to nearly the same temperature at the outlet of the exchanger. Preferably, the heat exchanger is formed within an integrated component manifold (ICM) for a solid-oxide fuel cell assembly.

Abstract: An apparatus including a stepper motor for actuating a moveable element of the apparatus. The maximum torque that can be generated at each step is a function of the voltage supplied to the motor. In some applications, however, torque greater than the nominal maximum may be required for brief periods. Under such conditions, the need for greater torque is sensed and a controller supplies a higher voltage to the motor, thereby increasing temporarily the output torque. When increased torque is no longer required, the voltage is reduced to nominal. The invention is useful, for example, for extending the range of a stepper motor actuator for an intake air control valve in a fuel cell assembly.

Abstract: A heat-conducting element having known length D is disposed at a first end in a first region having a first temperature T1 to be inferred. The second end of the element is disposed in a second region having a measureable second temperature T2 different from the first temperature. The element is well-insulated between the first and second regions. Heat flows along the element from the higher temperature region to the lower temperature region, and the temperature of the element at any point along the element is proportional to the temperature difference between the two regions and the distance from either one of the regions. By measuring the second temperature and also a third temperature T3 at a point along the element, and knowing accurately the position Dn of that point with respect to the first and second ends of the element, the first temperature can be inferred by proportionality.

Abstract: A non-thermal plasma reactor and method for preparing same for conversion of exhaust gas constituents is prepared from an extruded monolith comprising a plurality of conductive and exhaust channels separated by substantially planar dielectric barriers. Conductive material printed onto selected monolith channels form the conductive channels, which are connected along bus paths to form an alternating sequence of polarity, separated by exhaust channels. Conductive channels and channels not selected for exhaust flow are plugged to exclude exhaust gases and to prevent electrical leakage. During operation, exhaust gas flows through exhaust channels and is treated by the high voltage alternating current flowing through the conductive channels. The substantially planar dielectric barriers provide a uniform electrical response throughout the exhaust channels.

Abstract: A solid-oxide fuel cell system having “hot” components, e.g., the fuel cell stacks, the fuel reformer, tail gas combuster, heat exchangers, and fuel/air manifold, contained in a “hot zone” within a thermal enclosure intended specifically for minimizing heat transfer to its exterior and having no significant structural or protective function for its contents. A two-part clamshell arrangement allows all piping and leads which must pass through the enclosure to do so at the join line between the parts, thus eliminating need for ports and fittings in the thermal enclosure. A separate and larger structural enclosure surrounds the thermal enclosure, defining a “cool zone” outside the thermal enclosure for incorporation of “cool” components, e.g., the air supply system and the electronic control system, and providing structural protection for all components of the fuel cell system.

Abstract: An apparatus and method for a preheated micro-reformer system is disclosed comprising a reformer and a micro-reformer in fluid communication with the reformer. The micro-reformer being electrically preheatable. An apparatus comprising a micro-reformer including a first zone and a second zone, the first zone being preheatable to a first temperature and the second zone being preheatable to a second temperature, the second temperature being higher than the first temperature. A method of using a micro-reformer that is electrically preheatable is disclosed comprising initiating an electrically preheatable micro-reformer. The micro-reformer is preheated. The preheating can be accomplished by converting electrical energy into thermal energy. A method of using a preheated micro-reformer is disclosed comprising preheating a first zone, preheating a second zone to a temperature higher than the first zone, vaporizing a fuel air mixture in the first zone, and reforming the fuel air mixture in the second zone.

Abstract: In one embodiment, a catalyst configuration, comprises: a substrate, a NiO layer disposed on the substrate, wherein the NiO layer comprises greater than or equal to about 75 wt % of the NiO in the catalyst configuration; and a catalyst layer comprising a NOx adsorbing catalyst. In another embodiment, a catalyst configuration, comprises: a substrate, a catalyst layer disposed on the substrate, wherein the catalyst layer comprises a NOx adsorbing catalyst and thermally treated NiO. In one embodiment, the method for making a NOx adsorber comprises: thermally treating NiO to a temperature of about a maximum catalyst application temperature minus 100° C. and the maximum catalyst application temperature, disposing a catalyst configuration on the substrate, wherein the catalyst configuration comprises the thermally treated NiO and a NOx adsorption catalyst, and disposing the substrate in a housing.

Abstract: A solid-oxide fuel cell system including an integrated reforming unit comprising a hydrocarbon fuel reformer; an integral tail gas and cathode air combustor and reformer heat exchanger; a fuel pre-heater and fuel injector cooler; a fuel injector and fuel/air mixer and vaporizer; a reforming air pre-heating heat exchanger; a reforming air temperature control valve and means; and a pre-reformer start-up combustor. The integration of a plate reformer, tail gas combustor, and combustor gas heat exchanger allows for efficient operation modes of the reformer, both endothermic and exothermic as desired. The combustor gas heat exchanger aids in temperature regulation of the reformer and reduces significant thermal gradients in the unit.

Abstract: A low-profile integrated catalytic converter with a coupling assembly comprises a catalytic converter with a coupling assembly integrated into the inlet end of the catalytic converter, which is attached to a mounting flange or exhaust pipe. The coupling assembly comprises two or more flexible bellows, joined together at their periphery, and containing a plurality of undulating ribs. The respective ends of the flexible bellows assembly are secured to the catalytic converter. A coupling travel limiter can optionally be concentrically disposed within the bellows assembly to limit the flexibility of the coupling and direct an exhaust gas stream into the catalytic converter.

Abstract: A catalytic converter comprises a catalyst substrate concentrically disposed in a shell and having a mat support material located concentrically in between the catalyst substrate and shell. The catalyst substrate includes structural features located on its outer surface that engage the mat support material. The shear forces exerted between the catalyst substrate and mat support material, in addition to the normally present frictional forces, reduce the axial movement of the catalyst substrate during assembly and operation of the catalytic converter.

Abstract: A power generation system and method providing an engine configured to produce hydrogen rich reformate to feed a solid oxide fuel cell includes an engine having an intake and an exhaust; an air supply in fluid communication with the engine intake; a fuel supply in fluid communication with the engine intake; at least one solid oxide fuel cell having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with the engine exhaust, a solid oxide fuel cell effluent and an air effluent. Engines include a free piston gas generator with rich homogenous charge compression, a rich internal combustion engine cylinder system with an oxygen generator, and a rich inlet turbo-generator system with exhaust heat recovery. Oxygen enrichment devices to enhance production of hydrogen rich engine exhaust include pressure swing absorption with oxygen selective materials, and oxygen separators such as an solid oxide fuel cell oxygen separator and a ceramic membrane oxygen separator.