Abstract: A separator plate for an internally manifolded fuel cell stack comprising a centrally disposed active region, a peripheral seal region, and forming at least one pair of perforations substantially geometrically disposed on opposite sides of the centrally disposed active region. The peripheral seal region comprises a peripheral seal structure on each face of the separator plate completely around the periphery of each said face. A manifold seal region in each face completely encloses each perforations, the manifold seal region comprising conduits on one of said faces for communication of a gas between the centrally disposed active region and at least the one pair of perforations. The separator plate is comprised of one sheet of a material suitable for use as a separator plate, preferably a pressed sheet metal.

Abstract: A separator plate for fuel cell stack comprising a multiple-step peripheral wet seal structure and a multiple-step manifold wet seal structure which utilizes lateral and vertical material displacement resulting from the application of cell clamping forces to provide improved fuel cell and stack reactant gas sealing.

Abstract: A process for manufacture of molten carbonate fuel cell matrices in which an aluminate precursor material and a lithium salt are mixed in an aqueous or organic solvent, resulting in formation of a suspension, the suspension is heated to a temperature less than a boiling of the solvent, resulting in formation of a slurry comprising a lithium aluminate precursor material, at least one casting additive is added to the slurry, the slurry is formed into a desired shape, the desired shape is dried or cured to yield a green molten carbonate fuel cell structure, and the green molten carbonate fuel cell structure is heated after assembly into a molten carbonate fuel cell to the molten carbonate fuel cell operating temperature, resulting in transformation of the lithium aluminate precursor material to lithium aluminate.

Abstract: A fuel cell stack system comprises a plurality of fuel cell sub-stacks, each of which comprises a plurality of individual fuel cell units. A separator plate separates the fuel cell units between an anode of one fuel cell unit and a cathode of an adjacent fuel cell unit. A single separator plate separates corresponding fuel cell units in each fuel cell sub-stack. The edges of the separator plate extend substantially beyond the periphery of each fuel cell sub-stack forming oxidant flow paths between adjacent separator plates extending from the separator plate edges to the center of the separator plate from which oxidant is then distributed to each of the fuel cell units. By virtue of heat transfer from the extended edges of the separator plate to the oxidant, the heat generated by the fuel cell can be controlled.

Abstract: A carrier for conveying components of a fuel cell to be sintered through a sintering furnace. The carrier comprises a metal sheet coated with a water-based carbon paint, the water-based carbon paint comprising water, powdered graphite, an organic binder, a wetting agent, a dispersing agent and a defoaming agent.

Abstract: A hybrid internal/external manifolded fuel cell stack comprising a plurality of fuel cell units, each of which comprises an anode and a cathode and an electrolyte in contact on one side with an electrolyte facing face of the anode and in contact on the opposite side with an electrolyte facing face of the cathode. A separator plate separates each of the fuel cell units between an anode and cathode forming an anode chamber between the anode facing face of the separator plate and the anode and forming a cathode chamber between the opposite cathode facing face of the separator plate and the cathode of an adjacent fuel cell unit. The anode chamber is in gas communication with a fuel gas supply and outlet provided through internal manifolds whereas the cathode chamber is in gas communication with an oxidant gas supply and outlet provided through external manifolds.

Abstract: A fuel cell stack power bus system which includes a plurality of current collectors mounted to the peripheral edge portion of a fuel cell stack end plate. The current collectors form lapped connections with a layered power bus which can be easily positioned to extend from any side of a fuel cell stack and which has improved heat transfer characteristics.

Abstract: A one-piece separator plate suitable for use in a fuel cell stack comprising a single pressed metal plate having a peripheral raised seal region on a face of said pressed metal plate and a corresponding peripheral recessed seal region on the opposite face thereof, the corresponding peripheral recessed seal region forming a peripheral channel on said opposite face of the pressed metal plate. A peripheral insert ring is disposed in the peripheral channel, which insert ring and said peripheral raised seal region form seals between the faces of the pressed metal plate and an adjacent active cell component.

Abstract: A carrier for conveying components of a fuel cell to be sintered through a sintering furnace. The carrier comprises a metal sheet coated with a carbon-based paint, the carbon-based paint comprising an organic binder. The carbon-based paint may be an alcohol or a solvent-based paint or a water-based paint.

Abstract: A fuel cell electrolyte with an electrochemically inactive matrix, an electrochemically active electrolyte, and a substantially gas impervious metallic foil in the central region of the thickness of the electrolyte extending around its periphery over at least a portion of the fuel cell peripheral seal area and into the electrolyte active area reducing gas crossover between the anode and cathode chambers. The gas impervious metallic foil may extend beyond the periphery of the electrolyte into the fuel cell peripheral seal area and have a resilient gasket on each side forming the fuel cell peripheral seal with seal structures extending from separator plates, thereby eliminating conventional electrolyte wet seals. The seal structures according to this invention are also suitable for sealing internal manifolds in fuel cell stacks.

Abstract: A cell separator plate for separating fuel cell units in fuel cell stacks, the separator plate having a peripheral seal structure extending from each face completely around its periphery and a electrolyte seal structure extending from each face and having a generally flat face spaced inwardly from the separator plate peripheral seal structure and extending completely around the separator plate forming a separator plate/electrolyte seal with an adjacent electrolyte under cell operating conditions, and a peripheral compartment between the separator plate/electrolyte seal and separator plate peripheral seal between adjacent separator plates. The peripheral compartment may contain active electrolyte which may be wicked into the electrolyte matrix through edges of the matrix directly exposed to the peripheral compartment. The peripheral compartment may contain an inert gas to ensure active electrolyte containment within the electrolyte matrix.

Abstract: A clamping force equalizer for use in a generally rectangular fuel cell stack comprising two sheets of flexible metal sealed together at their edges and an electrically conductive material disposed between said sheets of flexible metal, said electrically conductive material being in a liquid state at a fuel cell operating material. The clamping force equalizer in accordance with this invention has a length and a width equivalent to the length and width of a horizontal plane of the fuel cell stack such that equalization of the clamping force applied to the fuel cell stack occurs over the entire horizontal plane of the fuel cell stack.