Abstract: A manufacturing line includes a tape of green material that is directed through a furnace so that the furnace burns off organic binder material and then partially sinters the tape without the use of a setter board. Sintered articles resulting from the manufacturing line may be thin with relatively large surface areas; and, while substantially unpolished, have few sintering-induced surface defects. Tension may be applied to the partially sintered tape as it passes through a second furnace on the manufacturing line to shape resulting sintered articles.

Abstract: A method for making a cordierite filter article, including: firing an extruded green body batch composition according to: a first temperature ramping from ambient temperature up to a first soaking temperature; a first soaking at a temperature of at least 1255° C. for at least 2 hours; a second temperature ramping from the first soak temperature down to a second soak temperature; and a second soaking at a temperature of at least 1250° C. and at least 5° C. below the first soaking temperature, as defined herein.

Abstract: A method for making a thin, free-standing ceramic sheet may include drawing a carrier film proximate a casting head and across a casting bed of a tape caster at a rate from about 2 cm/min to about 500 cm/min. Depositing a thin film of ceramic slip less than about 150 ?m on the carrier film with the casting head. The ceramic slip may comprises a ceramic powder with an ultimate crystallite size of less than about 10 ?m dispersed in a fluid vehicle such that the ceramic slip has a ceramic solids fraction of greater than about 20% by volume. The deposited ceramic slip may be dried on the carrier film thereby forming a green ceramic sheet on the carrier film. After the green ceramic sheet is dried, the green ceramic sheet may be sintered.

Abstract: A method for making a cordierite filter article, including: firing an extruded green body batch composition according to: a first temperature ramping from ambient temperature up to a first soaking temperature; a first soaking at a temperature of at least 1255° C. for at least 2 hours; a second temperature ramping from the first soak temperature down to a second soak temperature; and a second soaking at a temperature of at least 1250° C. and at least 5° C. below the first soaking temperature, as defined herein.

Abstract: A solid oxide fuel cell comprising a thin ceramic electrolyte sheet having an increased street width is disclosed. Also disclosed are solid oxide fuel cells comprising: a substantially flat ceramic electrolyte sheet, a substantially flat ceramic electrolyte sheet having a seal area of greater thickness than the active area of the electrolyte sheet, a ceramic electrolyte sheet that overhangs the seal area, a ceramic electrolyte sheet and at least one substantially flat border material, and a border material having a non-linear edge. Methods of making a solid oxide fuel cell in accordance with the disclosed embodiments are also disclosed. Also disclosed are methods of making a solid oxide fuel cell wherein the seal has a uniform thickness, wherein the seal is heated to remove a volatile component prior to sealing, and wherein the distance between the frame and the ceramic electrolyte sheet of the device is constant.

Abstract: The present invention provides structures and methods that utilize fuel reformation to assist in thermal management of a channel-less SOFC at the device cell and/or stack assembly level. At the device level, passive and/or active control of unreformed fuel, or a mixture of reformed and unreformed fuel, is used to inject fuel in a distributed manner along the anode chamber of the channel-less SOFC. The injected fuel can be controlled in its composition, pressure, velocities, and/or flow rates. Additionally, present invention provides thermal management across a plurality of fuel cells in a stack assembly by actively controlling fuel composition, pressure, velocities, and/or flow rates provided to fuel inlets of the fuel cells.

Abstract: A method for making a thin, free-standing ceramic sheet may include drawing a carrier film proximate a casting head and across a casting bed of a tape caster at a rate from about 2 cm/min to about 500 cm/min. Depositing a thin film of ceramic slip less than about 150 ?m on the carrier film with the casting head. The ceramic slip may comprises a ceramic powder with an ultimate crystallite size of less than about 10 ?m dispersed in a fluid vehicle such that the ceramic slip has a ceramic solids fraction of greater than about 20% by volume. The deposited ceramic slip may be dried on the carrier film thereby forming a green ceramic sheet on the carrier film. After the green ceramic sheet is dried, the green ceramic sheet may be sintered.

Abstract: Disclosed are solid oxide fuel cell systems, and methods for reducing temperature distribution across electrolytes within solid oxide fuel cells (SOFC), and increasing overall system efficiency. In one embodiment, the SOFCs include preheating channels that are interposed between electrolyte electrode assemblies within SOFCs, to provide internal heat exchange. The fuel and/or air entering the SOFC can be preheated in the preheating channels, thereby reducing or eliminating the need for an external preheating system. The preheating channels also provide barriers between each electrolyte electrode assembly, which aids in isolating damage within a single fuel cell.

Abstract: The invention is directed to insulating compositions for use in solid oxide fuel cells. Such compositions can be used to prevent seal damage and increase the electrical and ion efficiency.

Abstract: Disclosed are seals and seal structures for use in electrochemical devices such as solid oxide fuel cell devices. Exemplary seal structures are configured such that at least a portion of the interface between the seal and electrolyte sheet deviates from planarity by extending either (i) upwardly and inwardly (ii) or downwardly and inwardly, toward the active portion of the electrolyte sheet surface where one or more device electrodes are deposited. By angling the seal portion of the electrolyte sheet, the sharpness of any resulting bends or deformations that may occur during use can be reduced, thus reducing the likelihood of any cracks forming in the typically high stress regions of the electrolyte sheet. Further, preferably at least a portion of the electrolyte sheet contacting the seal composition, the seal-electrolyte interface may deviate from planarity by at least 0.

Abstract: An electrolyte sheet comprising two major surfaces, the electrolyte sheet including regions of differing compositions, so that (i) at least one of these regions has at least 1.5 times higher ionic conductivity than at least one other region; (ii) wherein the at least one other region has 20% more tetragonal phase zirconia per volume than the least one region with higher ionic conductivity; and (iii) when viewed in cross-section taken through said major surfaces at least one of the regions exhibits a non-uniform thickness.

Abstract: A stress reducing mounting for an electrolyte sheet assembly in a solid electrolyte fuel cell is provided that includes a support frame or manifold having an inner edge portion that supports a peripheral portion of the sheet assembly, a seal that affixes an edge of the peripheral portion to the frame or manifold, and a stress reducer disposed around the peripheral portion of the electrolyte sheet and the frame or manifold that reduces tensile stress in the peripheral portion of the electrolyte sheet when the peripheral portion is bent by pressure differentials or thermal differential expansion. The stress reducer is at least one of a convex curved surface on the inner edge portion of the frame or manifold that makes area contact with the peripheral portion when it bends in response to a pressure differential or thermal differential expansion, and a stiffening structure on the sheet peripheral portion that renders the ceramic sheet material forming the peripheral portion more resistant to bending.

Abstract: According to one embodiment t of the present invention a method of manufacturing metal-to-ceramic seals comprising the steps of: (a) providing a ferric stainless steel part selected from the group consisting of high temperature stainless steels and high temperature superalloy; (b) providing a ceramic part; (c) providing a braze material in between the ferric stainless steel part and said ceramic part, the braze containing Ag and metal oxide wetting agents; and (d) heating said ferric stainless steel part, braze material, and ceramic part in an oxidizing atmosphere.

Abstract: The invention is directed to highly crystalline, frit-sintered glass-ceramic materials and seals made using them that are suitable for solid oxide fuel cell applications. The seals have a coefficient of thermal expansion in the range of 70-130×10?7° C., preferably 85-115×10?7° C. The glass-ceramic materials have a crystalline component and a glass component, the crystalline component being >50% of the glass-ceramic and the glass component being <50%. In one preferred embodiment the crystalline component is >75%. Regarding the crystalline component only, >50% of the crystals in the crystalline component of the glass-ceramic has a structure selected from the structural groups represented by walstromite, cyclowollastonite, ?-(Ca,Sr)SiO3, kalsilite, kaliophilite and wollastonite (the primary crystalline phase) and the remaining <50% of the crystalline component is at least one secondary crystalline phase.

Abstract: The invention is directed to highly crystalline, frit-sintered glass-ceramic materials and seals made using them that are suitable for solid oxide fuel cell applications. The seals have a coefficient of thermal expansion in the range of 70-130×10?7° C., preferably 85-115×10?7° C. The glass-ceramic materials have a crystalline component and a glass component, the crystalline component being >50% of the glass-ceramic and the glass component being <50%. In one preferred embodiment the crystalline component is >75%. Regarding the crystalline component only, >50% of the crystals in the crystalline component of the glass-ceramic has a structure selected from the structural groups represented by walstromite, cyclowollastonite, ?-(Ca,Sr)SiO3, kalsilite, kaliophilite and wollastonite (the primary crystalline phase) and the remaining <50% of the crystalline component is at least one secondary crystalline phase.

Abstract: The invention is directed to highly crystalline, frit-sintered glass-ceramic materials and seals made using them that are suitable for solid oxide fuel cell applications. The seals have a coefficient of thermal expansion in the range of 70-130×10?7° C., preferably 85-115×10?7° C. The glass-ceramic materials have a crystalline component and a glass component, the crystalline component being>50% of the glass-ceramic and the glass component being<50%. In one preferred embodiment the crystalline component is >75%. Regarding the crystalline component only,>50% of the crystals in the crystalline component of the glass-ceramic has a structure selected from the structural groups represented by walstromite, cyclowollastonite, ?-(Ca,Sr)SiO3, kalsilite, kaliophilite and wollastonite (the primary crystalline phase) and the remaining <50% of the crystalline component is at least one secondary crystalline phase.

Abstract: A solid oxide fuel cell comprising a thin ceramic electrolyte sheet having an increased street width is disclosed. Also disclosed are solid oxide fuel cells comprising: a substantially flat ceramic electrolyte sheet, a substantially flat ceramic electrolyte sheet having a seal area of greater thickness than the active area of the electrolyte sheet, a ceramic electrolyte sheet that overhangs the seal area, a ceramic electrolyte sheet and at least one substantially flat border material, and a border material having a non-linear edge. Methods of making a solid oxide fuel cell in accordance with the disclosed embodiments are also disclosed. Also disclosed are methods of making a solid oxide fuel cell wherein the seal has a uniform thickness, wherein the seal is heated to remove a volatile component prior to sealing, and wherein the distance between the frame and the ceramic electrolyte sheet of the device is constant.

Abstract: The invention is directed to highly crystalline, frit-sintered glass-ceramic materials and seals made using them that are suitable for solid oxide fuel cell applications. The seals have a coefficient of thermal expansion in the range of 70-130×10?7° C., preferably 85-115×10?7° C. The glass-ceramic materials have a crystalline component and a glass component, the crystalline component being >50% of the glass-ceramic and the glass component being <50%. In one preferred embodiment the crystalline component is >75%. Regarding the crystalline component only, >50% of the crystals in the crystalline component of the glass-ceramic has a structure selected from the structural groups represented by walstromite, cyclowollastonite, ?-(Ca,Sr)SiO3, kalsilite, kaliophilite and wollastonite (the primary crystalline phase) and the remaining <50% of the crystalline component is at least one secondary crystalline phase.

Abstract: An electrolyte sheet comprising two major surfaces, the electrolyte sheet including regions of differing compositions, so that (i) at least one of these regions has at least 1.5 times higher ionic conductivity than at least one other region; (ii) wherein the at least one other region has 20% more tetragonal phase zirconia per volume than the least one region with higher ionic conductivity; and (iii) when viewed in cross-section taken through said major surfaces at least one of the regions exhibits a non-uniform thickness.

Abstract: A portable solid oxide fuel cell assembly comprising: (i) at least one multi-cell device formed at least in part by a compliant electrolyte sheet; (ii) a frame module supporting the device, said frame module providing air and fuel to the device, the frame forming, in conjunction with the device at least one of: a single fuel chamber, a single air chamber adjacent to the active area of the at least one multi-cell device; wherein said at least one multi-cell device generates more than 5V of electricity and has a maximum dimension of no more than 0.5 meter.