Abstract: A fuel cell system having an air quality sensor suite includes a fuel cell having an anode and a cathode, a fuel source providing a fuel flow, a fuel flow rate sensor having a fuel flow rate sensor output, a fuel flow control device, a fuel oxidizer flow conduit, a first mixing region coupled to the fuel source and the fuel oxidizer flow conduit, an anode chamber coupled to the anode, a combustion oxidizer flow conduit, a second mixing region coupled to the combustion oxidizer flow conduit, and at least one oxidizer flow rate sensor having an oxidizer flow rate sensor output. The system further includes at least one oxidizer pump, an air quality sensor having an air quality sensor output, and a control system coupled to the fuel flow rate sensor output, the oxidizer flow rate sensor output, and the air quality sensor output.

Abstract: The method for bonding a first substrate to a second substrate includes dispensing a paste directly onto a first substrate, the paste including a glass powder, a thermoplastic, and a first solvent, evaporating the first solvent to form a thickened paste, placing a second substrate on the thickened paste to form a stack, applying to the stack a force sufficient to cause deformation of the thickened paste, and heating the stack to a bonding temperature above a glass transition temperature of the glass powder so as to cause removal of the thermoplastic from the thickened paste and to form a glass joint between the first and second substrates.

Abstract: A fuel cell system having protection from water vapor condensation is disclosed. The system includes a fuel cell having an input port configured to receive an input gas and a liquid water transient accumulation chamber coupled to the input port. The chamber is configured to accumulate condensed water vapor from the input gas. The chamber includes a water-capture element configured to retain liquid water therein. The system further includes a first thermal pathway coupled to the chamber and also coupled to the fuel cell, so that the chamber is heated by heat from the fuel cell, when the fuel cell is operating in a steady state, in a manner that causes the liquid water accumulated in the chamber to be evaporated by the heat.

Abstract: A fuel cell system having a fuel cell generator and a fuel cartridge that is removably attachable to the fuel cell generator is disclosed. The fuel cartridge includes a housing having a port, a normally closed valve disposed in the housing that gates fuel emerging from the port, the valve having a poppet that modulates opening of the valve, the poppet having a control surface. The fuel cell generator has a moveable pintle coupled to the poppet, and the moveable pintle is operative over a range of motion which causes the poppet to move between a closed state and at least one open state.

Abstract: A method of bonding a first substrate to a second substrate includes providing a glass, applying the glass in a layer between the first and second substrates to form an assembly, and heating the assembly to a bonding temperature above a glass transition temperature of the devitrifying glass, selected to cause the glass to bond the first substrate to the second substrate. The devitrifying glass has constituents that include various amounts of group A in a molar concentration of 70-95%, group B in a molar concentration of 5-20%, group C in a molar concentration of 1-20%, group D in a molar concentration of 0-6%; and group E in a molar concentration of 0-10%. The group A, B, C, D and E groups are disclosed herein.

Abstract: A portable fuel cell system includes a fuel cell having a plurality of flow inputs and a power output, a temperature sensor configured to measure operating temperature of the fuel cell, a power output sensor coupled to the fuel cell and configured to measure a power parameter related to fuel cell power output, a controllable power converter, coupled to the power output of the fuel cell, that transfers power from the fuel cell to the fuel cell system, and a flow control device coupled to a first flow input and configured to control a first one of the flow inputs into the fuel cell. The system further includes a fuel cell system controller, coupled to the fuel cell, the power output, the temperature sensor, the power output sensor, the controllable power converter, and the flow control device.

Abstract: A portable fuel cell system and related method are disclosed. The system includes a fuel cell having an anode port through which passes an anode gas, a cathode port through which passes a cathode gas, and an exhaust port through which passes an exhaust gas. The system further includes a pump having a pump inlet and a pump outlet, wherein the pump inlet is coupled to the exhaust port of the fuel cell. The pump is configured to draw the anode gas into the anode port, to draw the cathode gas into the cathode port, and to draw the exhaust gas out of the exhaust port.

Abstract: A fuel cell system for providing power to a load, and having a safety mode, is disclosed. The system includes a fuel cell configured to convert fuel to electrical power and coupled so as to provide electrical power at a fuel cell power output, a system power port having a power connection and a data connection, configured to be reversibly coupled to the load, a power connection controller, coupled to the fuel cell power output and to the system power port, and configured to enable and disable the power connection, and a fuel cell system controller coupled to the fuel cell, the data connection and the power connection controller. The fuel cell system controller has a normal mode and a safety mode. A user selection determines whether the fuel cell system controller is in the normal mode or the safety mode. If the load has a smart power port, the data connection is configured to communicate over the smart power port.

Abstract: A portable fuel cell system includes a fuel cell having a fluid path, a pump having a pumping chamber disposed in the fluid path and a mechanical input, an electric motor having a power signal input and having an oscillatory mechanical output coupled to the mechanical input, the mechanical output having unwanted vibration primarily at a first drive frequency of a power signal, a spring and mass assembly coupled to the mechanical output so as to vibrate out of phase with, and to reduce the unwanted vibration of, the mechanical output at the drive frequency, a vibration transducer physically coupled to the mechanical output and having a vibration transducer signal output, and an electrical control system having an input coupled to receive the vibration transducer signal output and having a control output coupled to the power signal input.

Abstract: Fuel cells having an efficient means of thermal insulation such that all of the components requiring high temperature operation are contained within a single housing and whereby such thermal insulation is disposed exterior to such housing.

Abstract: A structure including a support defining an opening, and a tensilely stressed thin-film membrane disposed to occlude the opening, the membrane contacting at least a portion of the support. The stressed membrane includes a material having a characteristic crack spacing greater than one-half of a minimum dimension of the membrane and less than ten times the minimum dimension. A structure including a support defining a opening having a minimum opening dimension, and a compressively stressed thin-film membrane disposed to occlude the opening, the membrane contacting at least a portion of the support. The stressed membrane includes a membrane material having a critical aspect ratio for buckling that is greater than a ratio of one-half of the minimum opening dimension to a thickness of the membrane, and the critical aspect ratio for buckling is less than a ratio of ten times the minimum opening dimension to the thickness of the membrane.

Abstract: The invention relates to a fuel cell apparatus that includes a housing. The housing defines a substantially isothermal zone which integrates a fuel cell and a tail gas burner with the isothermal zone. The fuel cell and the tail gas burner are in thermal communication and share a common wall. In one embodiment, the housing further integrates a fuel reformer, where the fuel reformer is in thermal communication with the fuel cell. In one embodiment, the fuel cell and the tail gas burner can be arranged to produce a power density greater than or equal to about 2 W/cc. The fuel cell preferably is a solid oxide fuel cell.

Abstract: Fuel cells having an efficient means of thermal insulation such that all of the components requiring high temperature operation are contained within a single housing and whereby such thermal insulation is disposed exterior to such housing.

Abstract: Presented herein is a fuel cell assembly, including a reformer housing, a reformer region within the reformer housing for producing hydrogen, a vacuum housing for containing the reformer housing, a low-pressure insulating region between the reformer housing and the vacuum housing for providing thermal insulation, radiation shields disposed about the reformer region for providing radiation insulation, and at least one proton-exchange-membrane fuel cell in fluid communication with the reformer region. The vacuum housing may define a volume of less than about 30 cubic centimeters. The fuel cell assembly may produce less than about 100 watts of power. Also disclosed are related methods for reforming fuel.

Abstract: The invention, in various embodiments, provides planar fuel cell stack of a plurality of fuel cells, comprising an anode layer including a first anode and a second anode, an electrolyte layer, a cathode layer including a first cathode and a second cathode, and at least one interconnect at least partially disposed within the electrolyte layer, and electrically and mechanically coupling the first anode and the second cathode. In various embodiments, structural supports are provided, the fuel cells are sized to be portable, and are manufactured to produce desired power densities and/or voltages.

Abstract: A structure including a support defining an opening, and a tensilely stressed thin-film membrane disposed to occlude the opening, the membrane contacting at least a portion of the support. The stressed membrane includes a material having a characteristic crack spacing greater than one-half of a minimum dimension of the membrane and less than ten times the minimum dimension. A structure including a support defining a opening having a minimum opening dimension, and a compressively stressed thin-film membrane disposed to occlude the opening, the membrane contacting at least a portion of the support. The stressed membrane includes a membrane material having a critical aspect ratio for buckling that is greater than a ratio of one-half of the minimum opening dimension to a thickness of the membrane, and the critical aspect ratio for buckling is less than a ratio of ten times the minimum opening dimension to the thickness of the membrane.

Abstract: An iterative process of depositing on a solid electrolyte a coating of unconnected particles composed of an ionically conductive material. A liquid solution is also applied. The liquid solution includes an inorganic component. The deposited liquid is heated to a temperature sufficient to evaporate or otherwise remove some or all of the volatile components of the liquid solution. Typically the temperature is below 1000° and often at about 850° C. The effect of heating the solution is to cause ion conducting material in the solution to adhere to the surface of the existing ion conducting particles and form connections between these particles. This is understood to create an ion conducting skeletal support structure. Within the intrestices of this skeletal support structure, the step of heating is also understood to result in the deposition of the inorganic component that will begin to form a electron conducting structure.

Abstract: Presented herein is a fuel cell assembly, including a reformer housing, a reformer region within the reformer housing for producing hydrogen, a vacuum housing for containing the reformer housing, a low-pressure insulating region between the reformer housing and the vacuum housing for providing thermal insulation, radiation shields disposed about the reformer region for providing radiation insulation, and at least one proton-exchange-membrane fuel cell in fluid communication with the reformer region. The vacuum housing may define a volume of less than about 30 cubic centimeters. The fuel cell assembly may produce less than about 100 watts of power. Also disclosed are related methods for reforming fuel.

Abstract: The invention, in various embodiments, provides planar fuel cell stack of a plurality of fuel cells, comprising an anode layer including a first anode and a second anode, an electrolyte layer, a cathode layer including a first cathode and a second cathode, and at least one interconnect at least partially disposed within the electrolyte layer, and electrically and mechanically coupling the first anode and the second cathode. In various embodiments, structural supports are provided, the fuel cells are sized to be portable, and are manufactured to produce desired power densities and/or voltages.

Abstract: Fuel cells having an efficient means of thermal insulation such that all of the components requiring high temperature operation are contained within a single housing and whereby such thermal insulation is disposed exterior to such housing.