Abstract: A method for separating gases within a barrier, and a metallic barrier separating the gases is provided for use in solid oxide fuel cells, or SOFC. A network of pores can vent steam formed within the barrier by the reaction of hydrogen diffusing from one side and oxygen diffusing from the other side. This venting prevents the buildup of destructive pressure within the barrier, while retaining the required gas separation and electrical conductivity properties. The invention can be applied to systems other than solid oxide fuel cells and includes barriers made of noble metals and non-noble metals.

Abstract: High temperature solid oxide fuel cells (SOFC) and fuel cell stacks incorporating metallic bipolar separators with integral edge seals are provided. The electrochemical cells include reactant manifolds and flow passages, and may have either cathode or anode supported structures. The bipolar separators are thin metallic sheets that minimize thermal expansion stress in the electrochemical cells. The tubular bead edge seals are formed as an integral part of the bipolar separator by a low-cost sheet metal stamping process.

Abstract: A bipolar fuel cell stack is provided, along with a method for two-stage internal reforming in fuel cells, in which electric power can be generated from the reaction of hydrocarbon fuel with oxidant gases in the fuel cells. The fuel cell stack can include two or more electrochemical fuel cells in thermal contact to provide direct internal reforming. The fuel is reformed and partially utilized to produce electric power in a set of first stage cells, and further utilized to generate additional electric power in a set of second stage cells. In the first stage cells, the fuel is actively mixed with products of reaction over the anode to limit fuel concentration and suppress soot formation. The first stage exhaust then passes through the second stage cells in plug flow mode to increase fuel utilization.

Abstract: The present invention includes noble metal bipolar separators and seals for solid oxide fuel cells. Controlled porosity vents steam formed within the separator by the reaction of hydrogen diffusing from one side with oxygen diffusing from the other. This venting prevents the buildup of destructive pressure within the separator while retaining the required gas separation and electronic conductivity properties. The principle of the invention applies to applications other than solid oxide fuel cells, and includes materials other than noble metals.

Abstract: The present invention is a hybrid system for generating power from hydrocarbon and alcohol fuels using a two-stage process to achieve high overall energy conversion efficiency. The first stage is a reformer and fuel cell subsystem that uses an internal combustion engine operated at an air/fuel ratio richer than stoichiometric as a partial oxidation reformer for commonly available liquid or gaseous hydrocarbon or alcohol fuels. The engine produces shaft power and a product gas mixture containing hydrogen, carbon monoxide, and traces of light hydrocarbons that is used as fuel in fuel cells to generate electric power. The second stage is a heat engine subsystem that captures heat from the reformer and fuel cell subsystem, and produces additional shaft power. In addition to efficiency, advantages include adaptability to a variety of fuels, quick system startup with immediate shaft power availability, and low emission of pollutantants.