Abstract: A fuel cell end plate configured to transmit substantially constant compressive forces along a surface of a fuel cell is provided. The fuel cell end plate is configured such that the compressive force is substantially constant along the surface of the fuel cell even when the surface of the fuel cell is non-parallel. The fuel cell end plate is also configured such that the surfaces of the end plate remain substantially parallel when the fuel cell end plate is in contact with a non-parallel surface of a fuel cell or fuel cell stack. The fuel cell end plate is also configured to act as a distribution manifold for the distribution of reactants and coolants to the fuel cell stack. Fuel cell assemblies including the fuel cell end plate and methods of assembling the fuel cell end plate are also disclosed.

Abstract: A fuel cell end plate configured to transmit substantially constant compressive forces along a surface of a fuel cell is provided. The fuel cell end plate is configured such that the compressive force is substantially constant along the surface of the fuel cell even when the surface of the fuel cell is non-parallel. The fuel cell end plate is also configured such that the surfaces of the end plate remain substantially parallel when the fuel cell end plate is in contact with a non-parallel surface of a fuel cell or fuel cell stack. The fuel cell end plate is also configured to act as a distribution manifold for the distribution of reactants and coolants to the fuel cell stack. Fuel cell assemblies including the fuel cell end plate and methods of assembling the fuel cell end plate are also disclosed.

Abstract: A fuel cell bipolar separator plate of variable length is formed from a sheet having a fixed width. The sheet is passed through a tool a predetermined distance and a pattern of ribs is formed on a central portion of the sheet with the tool to define a segment along the length of the sheet. The ribs define a fuel flow path on a first side of the sheet and an oxidant flow path on an opposed second side of the sheet. The sheet is passed through a tool a predetermined distance and the steps of forming the pattern on the sheet and passing the sheet through the tool are repeated until the sheet possesses a desired length, at which point the sheet is cut to a desired length.

Abstract: A compression assembly for use with a fuel cell stack is disclosed. The compression assembly includes opposing end plate manifolds, thermal insulation layers, cold compression plates and compression distribution plates. The compression distribution plates include a plurality of extension elements that are connected and in a manner to provide compressive force to the fuel cell stack.

Abstract: Embodiments of the present invention are directed to fuel cell enclosures separate by a dielectric joint. The dielectric joint includes a flange portion from respective housing sections. A dielectric material is positioned between the respective flanges. Removable fasteners are used to secure the flanges and housing sections together.

Abstract: A fuel cell is fitted with a current collector situated between a ribbed separator and an electrode. The current collector is comprised of a plurality of flat wires which span the peaks of the ribs of the separator. The flat wires are of sufficient thickness, width, and frequency to support the electrode against the compressive load of the fuel cell stack. The width and frequency are alterable to suppress or enhance reactant access to the electrode.

Abstract: The present invention provides an aqueous-based electrolyte slurry for molten carbonate fuel cells. The invention provides means to eliminate the potential for the preferential transport of potassium carbonate and subsequent irreversible alteration of the 62/38 molar ratio of the eutectic mixture of the lithium potassium carbonate electrolyte.

Abstract: An electrolyte delivery apparatus that includes an electrolyte reservoir, a heating device and a pressure generator is provided. The electrolyte delivery apparatus is configured to supply electrolyte to a fuel cell, such as a molten carbonate fuel cell, or fuel cell stack, and, in certain examples, to an operating fuel cell or fuel cell stack. A fuel cell assembly including the electrolyte delivery apparatus and methods of using the electrolyte delivery apparatus are also provided.

Abstract: A fuel cell bipolar separator plate of variable length is formed from a sheet having a fixed width. The sheet is passed through a tool a predetermined distance and a pattern of ribs is formed on a central portion of the sheet with the tool to define a segment along the length of the sheet. The ribs define a fuel flow path on a first side of the sheet and an oxidant flow path on an opposed second side of the sheet. The sheet is passed through a tool a predetermined distance and the steps of forming the pattern on the sheet and passing the sheet through the tool are repeated until the sheet possesses a desired length, at which point the sheet is cut to a desired length.

Abstract: A stretch-forming press for stamping continuously fed sheet metal includes a ram, a base member, and a feed mechanism configured to advance a strip of sheet metal through the stretch-forming press. A forming station has a die configured to form a desired pattern in the strip of sheet metal. A leveling station has a pair of opposed jaws slidably received in corresponding recesses of the stretch-forming press, with the jaws oriented at an angle with respect to a direction of travel for the strip of sheet metal as it passes through the leveling station.

Abstract: A stretch-forming press for stamping continuously fed sheet metal includes a ram, a base member, and a feed mechanism configured to advance a strip of sheet metal through the stretch-forming press. A forming station has a die configured to form a desired pattern in the strip of sheet metal. A leveling station has a pair of opposed jaws slidably received in corresponding recesses of the stretch-forming press, with the jaws oriented at an angle with respect to a direction of travel for the strip of sheet metal as it passes through the leveling station.

Abstract: A fuel cell end plate configured to transmit substantially constant compressive forces along a surface of a fuel cell is provided. The fuel cell end plate is configured such that the compressive force is substantially constant along the surface of the fuel cell even when the surface of the fuel cell is non-parallel. The fuel cell end plate is also configured such that the surfaces of the end plate remain substantially parallel when the fuel cell end plate is in contact with a non-parallel surface of a fuel cell or fuel cell stack. The fuel cell end plate is also configured to act as a distribution manifold for the distribution of reactants and coolants to the fuel cell stack. Fuel cell assemblies including the fuel cell end plate and methods of assembling the fuel cell end plate are also disclosed.

Abstract: A fuel cell bipolar plate includes first and second plates with ribs defining anode and cathode flow channels The plate are nested so as to define a plurality of center flow channels. First and second edge areas are formed at ends of the plates. A plurality of first internal fuel manifolds is formed in the first edge area and is in fluid communication with the center flow channels. A plurality of second internal fuel manifolds is formed in the first edge area and is in fluid communication with the anode flow channels. A turnaround plenum is formed in the second edge area and is in fluid communication with the center flow channels and the anode flow channels.

Abstract: A fuel cell apparatus includes a fuel cell stack positioned within a housing. The housing is contained entirely within a compression assembly. In certain preferred embodiments, the fuel cell stack includes a plurality of bipolar separator plates formed of a plurality of segments, the compression assembly including mating pairs of anode compression bars and cathode compression bars secured to one another and being positioned between a pair of segments.

Abstract: An aqueous binder for making an electrode is provided. The aqueous binder includes water, a polymeric alcohol, a non-polymeric alcohol, a water-soluble resin, a drying moderator, and optionally an anti-foaming agent. The aqueous binder typically includes mostly water such that minimal toxic substances are evolved when the aqueous binder is used to produce electrodes. Electrodes and fuel cells assembled using the aqueous binder are also described.

Abstract: Metallic fuel cell components that are at least partially coated with a coating comprising silane are provided. Methods of protecting a metallic fuel cell component from corrosion is provided, in which the methods comprise at least partially coating a fuel cell bipolar separator plate with a coating comprising a silane. Also included are fuel cells and fuel cell stacks comprising such metallic fuel cell components and methods for manufacturing such.

Abstract: An apparatus for auto thermal reforming hydrocarbon fuel in a fuel cell stack includes a plurality of fuel cells stacked together. Each fuel cell has an inlet manifold, and the inlet manifolds of the fuel cells are aligned with one another to form a manifold chamber. A porous wand extends through the manifold. A mixing device is positioned within the wand and is configured to carry fuel gas and oxidant through the wand.

Abstract: A fuel cell bipolar separator plate at least partially coated with a coating that is stable when in contact with or in close proximity to a proton exchange membrane and that is stable within the environment of the anode and cathode environments of the fuel cell is provided. Also included are fuel cells comprising such a fuel cell bipolar separator plate and method of manufacturing the fuel cell bipolar separator plate and the fuel cell comprising the fuel cell bipolar separator plate.