Abstract: The present invention provides electrochemical device structures having integrated seals, and methods of fabricating them. According to various embodiments the structures include a thin, supported electrolyte film with the electrolyte sealed to the support. The perimeter of the support is self-sealed during fabrication. The perimeter can then be independently sealed to a manifold or other device, e.g., via an external seal. According to various embodiments, the external seal does not contact the electrolyte, thereby eliminating the restrictions on the sealing method and materials imposed by sealing against the electrolyte.

Abstract: Several members make up a joint in a high-temperature electrochemical device, wherein the various members perform different functions. The joint is useful for joining multiple cells (generally tubular modules) of an electrochemical device to produce a multi-cell segment-in-series stack for a solid oxide fuel cell, for instance. The joint includes sections that bond the joining members to each other; one or more seal sections that provide gas-tightness, and sections providing electrical connection and/or electrical insulation between the various joining members. A suitable joint configuration for an electrochemical device has a metal joint housing, a first porous electrode, a second porous electrode, separated from the first porous electrode by a solid electrolyte, and an insulating member disposed between the metal joint housing and the electrolyte and second electrode.

Abstract: A method is described for producing layered structures comprising a porous metal layer and a ceramic containing layer comprising wherein a porous green ceramic layer is provided, and thereafter loose metal particles are applied to the green ceramic layer before sintering. In one embodiment, the green ceramic layer, after application of the loose metal particles, is dried to drive off the solvent and cause interpenetration of the metal particles. In another embodiment loose particles can be removed from the composite such as by shaking, and the green ceramic/loose metal particles composite compressed to cause further interpenetration of the metal particles prior to sintering.

Abstract: Porous substrates and associated structures for solid-state electrochemical devices, such as solid-oxide fuel cells (SOFCs), are low-cost, mechanically strong and highly electronically conductive. Some preferred structures have a thin layer of an electrocatalytically active material (e.g., Ni-YSZ) coating a porous high-strength alloy support (e.g., SS-430) to form a porous SOFC fuel electrode. Electrode/electrolyte structures can be formed by co-firing or constrained sintering processes.

Abstract: Porous substrates and associated structures for solid-state electrochemical devices, such as solid-oxide fuel cells (SOFCs), are low-cost, mechanically strong and highly electronically conductive. Some preferred structures have a thin layer of an electrocatalytically active material (e.g., Ni—YSZ) coating a porous high-strength alloy support (e.g., SS-430) to form a porous SOFC fuel electrode. Electrode/electrolyte structures can be formed by co-firing or constrained sintering processes.

Abstract: A method of joining dissimilar materials having different ductility, involves two principal steps: Decoration of the more ductile material's surface with particles of a less ductile material to produce a composite; and, sinter-bonding the composite produced to a joining member of a less ductile material. The joining method is suitable for joining dissimilar materials that are chemically inert towards each other (e.g., metal and ceramic), while resulting in a strong bond with a sharp interface between the two materials. The joining materials may differ greatly in form or particle size. The method is applicable to various types of materials including ceramic, metal, glass, glass-ceramic, polymer, cermet, semiconductor, etc., and the materials can be in various geometrical forms, such as powders, fibers, or bulk bodies (foil, wire, plate, etc.). Composites and devices with a decorated/sintered interface are also provided.

Abstract: Porous substrates and associated structures for solid-state electrochemical devices, such as solid-oxide fuel cells (SOFCs), are low-cost, mechanically strong and highly electronically conductive. Some preferred structures have a thin layer of an electrocatalytically active material (e.g., Ni—YSZ) coating a porous high-strength alloy support (e.g., SS-430) to form a porous SOFC fuel electrode. Electrode/electrolyte structures can be formed by co-firing or constrained sintering processes.

Abstract: A fuel cell stack made of a plurality of cell units stacked and operatively connected at one end thereof. Each of the units includes a holder having at least one cell, typically provided as an SOFC membrane, to produce an electric current when fuel and oxidant are present as the result of an electrochemical reaction.

Abstract: A segmented-in-series high temperature solid-state electro-chemical device in which the cell segments are supported on a substrate comprising a porous metal layer for mechanical strength and a non-conducting porous layer for electrical insulation between cell segments is fabricated by co-sintering at least the metal substrate, insulating layer, an electrode and electrolyte. This allows for efficient manufacturing and the use of a thinner electrolyte (e.g., less than 40 microns thick) than in conventional designs, with a resulting performance improvement attributable at least in part to increased ionic conductivity. Alternative structures for the cell and interconnect repeat segments which are supported on a metallic substrate, as well as methods for producing said structures, specific compositions of the interconnect, and Al-containing compositions for the metallic substrate are described.

Abstract: The present invention provides electrochemical device structures having integrated seals, and methods of fabricating them. According to various embodiments the structures include a thin, supported electrolyte film with the electrolyte sealed to the support. The perimeter of the support is self-sealed during fabrication. The perimeter can then be independently sealed to a manifold or other device, e.g., via an external seal. According to various embodiments, the external seal does not contact the electrolyte, thereby eliminating the restrictions on the sealing method and materials imposed by sealing against the electrolyte.

Abstract: The process described herein provides a simple and cost effective method for making crack free, high density thin ceramic film. The steps involve depositing a layer of a ceramic material on a porous or dense substrate. The deposited layer is compacted and then the resultant laminate is sintered to achieve a higher density than would have been possible without the pre-firing compaction step.

Abstract: Copper-based cermets and methods of preparing them are provided. The Cu-based cermets have interpenetrating networks of copper alloy and stabilized zirconia that are in intimate contact and display high electronic connectivity through the copper alloy phase. In certain embodiments, methods of preparing the cermets involving sintering a mixture of ceramic and copper-based powders in a reducing atmosphere at a temperature above the melting point of the copper or copper alloy are provided. Also provided are electrochemical structures having the Cu-based cermet, e.g., as an anode structure or a barrier layer between an anode and a metal support. Applications of the cermet compositions and structures include use in high-operating-temperature electrochemical devices, including solid oxide fuel cells, hydrogen generators, electrochemical flow reactors, etc.

Abstract: Simple, low cost methods of manufacturing highly porous structures are provided. The methods involve building up porous structures with elements shaped to provide the desired strength, porosity and pore structure of the porous structure and then sintering the elements together to form the structure. Also provided are novel sintered porous structures made up of sintered non-spherical elements. In certain embodiments, the shaped green elements and the porous structure are simultaneously sintered. Also provided are novel sintered porous structures made up of sintered non-spherical elements.

Abstract: A pre-fabricated electrochemical device having a dense electrolyte disposed between an anode and a cathode preferably deposited as thin films is bonded to a porous electrically conductive support. A second porous electrically conductive support may be bonded to a counter electrode of the electrochemical device. Multiple electrochemical devices may be bonded in parallel to a single porous support, such as a perforated sheet to provide a planar array. Planar arrays may be arranged in a stacked interconnected array. A method of making a supported electrochemical device is disclosed wherein the method includes a step of bonding a pre-fabricated electrochemical device layer to an existing porous metal or porous metal alloy layer.

Abstract: Multiple stacks of tubular electrochemical cells having a dense electrolyte disposed between an anode and a cathode preferably deposited as thin films arranged in parallel on stamped conductive interconnect sheets or ferrules. The stack allows one or more electrochemical cell to malfunction without disabling the entire stack. Stack efficiency is enhanced through simplified gas manifolding, gas recycling, reduced operating temperature and improved heat distribution.

Abstract: Multiple stacks of tubular electrochemical cells having a dense electrolyte disposed between an anode and a cathode preferably deposited as thin films arranged in parallel on stamped conductive interconnect sheets or ferrules. The stack allows one or more electrochemical cell to malfunction without disabling the entire stack. Stack efficiency is enhanced through simplified gas manifolding, gas recycling, reduced operating temperature and improved heat distribution.

Abstract: Layered structures and associated fabrication methods that serve as the foundation for preparing high-operating-temperature electrochemical cells have a porous ceramic layer and a porous metal support or current collector layer bonded by mechanical interlocking which is provided by interpenetration of the layers and/or roughness of the metal surface. The porous layers can be infiltrated with catalytic material to produce a functioning electrochemical electrode.

Abstract: A process and apparatus for the electrolytic separation of fluorine from a mixture of gases is disclosed. Also described is the process and apparatus for the generation of fluorine from fluorine/fluoride containing solids, liquids or gases.

Abstract: Tubular objects having two or more concentric layers that have different properties are joined to one another during their manufacture primarily by compressive and friction forces generated by shrinkage during sintering and possibly mechanical interlocking. It is not necessary for the concentric tubes to display adhesive-, chemical- or sinter-bonding to each other in order to achieve a strong bond. This facilitates joining of dissimilar materials, such as ceramics and metals.

Abstract: Provided is a composite electrochemical device fabricated from highly electronically conductive materials such as metals, metal alloys, or electronically conductive ceramics. The electronic conductivity of the electrode substrate is maximized. The invention allows for an electrode with high electronic conductivity and sufficient catalytic activity to achieve high power density in ionic (electrochemical) devices such as fuel cells and electrolytic gas separation systems including oxygen generation system.