Abstract: A direct carbon fuel cell having an anode electrode of carbon particles pre-wetted with carbonate, a cathode electrode, and an electrolyte layer disposed between the anode electrode and the cathode electrode and containing a molten carbonate. The fuel cell includes a wicking feature whereby excess carbonate produced during the operation of the fuel cell is removed. The use of carbonate pre-wetted carbon particles as the anode provides a network of empty voids, facilitating the removal of CO2 gas from the cell, thereby enhancing fuel cell performance.

Abstract: A method for separation of molecular hydrogen from a gaseous mixture containing the molecular hydrogen, which method employs a dense mixed oxide ion/electronic/hydrogen atom conducting membrane or separator having a feed side and a permeate side that enables two mechanisms for hydrogen separation—ambi-polar conduction and hydrogen atom conduction. In this method, at least a portion of the molecular hydrogen is converted on the feed side of the membrane to hydrogen atoms, which hydrogen atoms are conducted through the membrane to the permeate side thereof where they are converted back to molecular hydrogen. The permeate side of the membrane is contacted with steam, forming water and/or steam on the feed side of the membrane and additional molecular hydrogen on the permeate side of the separator.

Abstract: A hydrogen-selective membrane material having a dense inner membrane layer composed of a Group VB alloy and no Pd disposed between two porous outer membrane support layers composed of the same Group VB alloy and no Pd or other noble metal, the amount of the Group VB alloy being greater than about 90 atomic % of each layer.

Abstract: A direct carbon fuel cell having an anode electrode of carbon particles pre-wetted with carbonate, a cathode electrode, and an electrolyte layer disposed between the anode electrode and the cathode electrode and containing a molten carbonate. The fuel cell includes a wicking feature whereby excess carbonate produced during the operation of the fuel cell is removed. The use of carbonate pre-wetted carbon particles as the anode provides a network of empty voids, facilitating the removal of CO2 gas from the cell, thereby enhancing fuel cell performance.

Abstract: A sealant composition for use in sealing solid oxide fuel cells is provided which comprises a glass component which comprises a mixture of alkali-free inorganic oxides, and an optional filler component dispersed in the glass component, said filler component being up to 40% by weight of the composition. The glass component can include, on a mole basis, 20 to 50% BaO, 1 to 10% Y2O3, 5 to 20% B2O3, 10 to 30% SiO2, 3 to 35% MgO, 2 to 20% CaO, 1 to 10% ZnO, and 0 to 5% ZrO2, and exemplary filler components include zirconia, alumina, barium titanate, strontium titanate, and combinations thereof.

Abstract: A process for producing nano size powders comprising the steps of mixing an aqueous continuous phase comprising at least one metal cation salt with a hydrophilic organic polymeric disperse phase, forming a metal cation salt/polymer gel, and heat treating the gel at a temperature sufficient to drive off water and organics within the gel, leaving as a residue a nanometer particle-size powder.

Abstract: Methods of making fuel cell electrodes in which the pores of an electrically conductive metal substrate are filled with a slurry containing particles of the same or a different electrically conductive metal. The liquid phase of the slurry is removed, leaving the particles of conductive material in the pores of the substrate; and the conductive metal(s) making up the substrate and the metal particles supplied from the slurry are converted to oxide.

Abstract: A method for producing a ribbed electrode for a fuel cell including the steps of depositing a suspension of a powdered electrode metal onto the face of a substantially flat porous electrode metal substrate, forming a plurality of raised structures on the face of the electrode, and sintering the electrode.

Abstract: Fuel cells, fuel cell components, and other electrochemical devices and components fabricated by plasma spraying. Devices such as fuel cells may be made by plasma spraying and then assembling individual components or by plasma spraying components on other components to form a laminate.

Abstract: Fuel cell cathodes formed by the oxidation of a porous, fiber reinforced, green structure and methods of fabricating cathodes of the character just described.

Abstract: A composite active electrolyte-matrix tape, single laminated active electrolyte-matrix tapes laminate, single electrolyte matrix/cathode tapes laminate, and single composite active electrolyte-matrix/cathode tapes laminate, all in the form of a single flexible sheet for use as fuel cells components, and process for producing same in situ. These components reduce the number of components necessarily handled in fuel cell assembly. The composite active electrolyte-matrix tape provides a major portion or all of the active electrolyte required by the entire cell for operation. The electrolyte matrix/cathode tapes laminate provides a supported electrolyte matrix structure resistant to cracking and fracture. Active electrolyte may also be added to either the electrolyte matrix, to the cathode, or to both tapes in the electrolyte matrix/cathode laminate to provide a major portion or all of the active electrolyte for cell operation. The invention is suited for molten alkali metal carbonates fuel cells.

Abstract: A process for producing metal oxide dispersion-strengthened anodes for use in fuel cells in which a metal alloy powder comprising at least one metal powder and at least one metal oxide forming phase is formed into a "green" cohesive structure. The "green" cohesive structure is heated in a sintering furnace resulting in simultaneous sintering and internal oxidizing of the oxide forming phase within the "green" cohesive structure, forming an oxide dispersion-strengthened structure. To promote simultaneous sintering of the "green" cohesive structure and internal oxidation of the oxide forming phase within the "green" cohesive structure, an oxidizing agent is disposed within the "green" cohesive structure or is applied to the exterior of the cohesive structure.

Abstract: Electrolyte matrix structures for molten carbonate fuel cells which: have a fine, uniform, and controlled porosity; are stable under operating conditions; and readily meet acceptable performance levels. These structures or matrices are easily manufactured by a simple and scalable technique from a slip containing particulate LiAlO.sub.2 dispersed in an organic vehicle and an acrylic-based binder. The solvent is evaporated, leaving a flat, flexible, green structure. The green-structure is heated in a non-oxidizing atmosphere to thermally decompose and thereby remove the binder. This leaves a porous structure which is impregnated with molten carbonate by capillary action.

Abstract: A porous matrix of lithium aluminate particles for molten alkali metal carbonates electrolytes having about 5 to about 50 volume percent, based upon the volume of the solids, of electrically non-conductive, active electrolyte compatible fibers having an average diameter of about 1 to about 50 microns and an average length greater than about 5 times the average diameter. Such matrices reduce matrix cracking upon loading with molten carbonates active electrolyte and provide high surface area over long term fuel cell operation.

Abstract: Porous metal components for high temperature fuel cells which are made by integrating the heretofore employed, separate tape casting and pack cementation processes. Particles of a base metal and a master alloy are suspended in a liquid medium in which a binding agent and a halide activator are dispersed. The suspension is cast into the shape wanted in the component, typically by tape casting; and the cast structure is heated to remove the liquid medium, leaving a flexible, green cast structure commonly referred to as a tape. The green tape is so heated as to: (a) burn out the binder in the tape; (b) form an alloy of the base metal and an alloying metal in the master alloy; and (c) sinter the alloy particles into a porous, coherent metal structure.

Abstract: An assembly of fuel cell components comprising a matrix tape having an active area and a peripheral wet seal area, an anode and/or a cathode in contact with a face of the matrix tape, the anode and cathode extending beyond a periphery of the active area of the matrix tape and contacting the peripheral wet seal area, and a portion of the peripheral wet seal area forming a frame around the anode and cathode to prevent gas crossover between the electrodes during cell operation and to prevent oxidation of the edges of the electrodes.

Abstract: Methods of fabricating anodes for high temperature fuel cell in which an alloy powder with a major phase of a base metal and a minor phase of a stabilizing, alloying metal is preformed into the shape wanted in the anode. This green structure is sintered under conditions which produce a metallic, essentially oxygen-free structure. The sintered structure is selectively oxidized in situ in a fuel cell under conditions which promote internal oxidation and a consequent increase in the stability of the anode under operating conditions where the anode is exposed to high temperatures for long periods of time.

Abstract: The present invention is directed to a method for forming porous oxide dispersion strengthened molten carbonate fuel cell anodes having improved anode creep resistance. The method comprises the steps of forming an alloy powder comprised of a base metal and an alloy metal, forming the alloy into a porous anode structure by sintering, and then placing the porous anode structure under conditions in which the base metal is reduced and the alloy metal is oxidized, thereby internally oxidizing the alloy metal to form oxide particles therein.

Abstract: Reduction of electrode metal dissolution in electrolyte between two metal electrodes of a voltaic cell by adding an electrode metal dissolution reduction agent to the electrolyte prior to operation of the cell, the electrode metal dissolution reduction agent being a sacrificial electrode metal, a metal promoting common ion effect with one of the electrode metals, seed metal particles serving as precipitation sites for an electrode metal, and combinations thereof. Reduction of the electrode metal dissolution in the electrolyte of a voltaic cell is also achieved by maintaining a partial pressure of carbon dioxide of about 0.5 to about 1.5 atmospheres in the electrolyte during operation of the cell. The method and electrolyte is particularly suited for molten carbonate fuel cells.