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.