Abstract: A method is provided for brazing a metal leadframe clip to an electrical resistance heating tip for an electrical resistance igniter, wherein the electrical resistance heating tip includes silicon carbide. The method includes forming a layer of SiO2/Al2O3 on a surface of the electrical resistance heating tip; applying a braze alloy paste between the layer of SiO2/Al2O3 and the metal leadframe clip; and heating the braze alloy, the metal leadframe clip and the electrical resistance heating tip to fuse the braze alloy.

Abstract: A method is provided for brazing a metal leadframe clip to an electrical resistance heating tip for an electrical resistance igniter, wherein the electrical resistance heating tip includes silicon carbide. The method includes forming a layer of SiO2/Al2O3 on a surface of the electrical resistance heating tip; applying a braze alloy paste between the layer of SiO2/Al2O3 and the metal leadframe clip; and heating the braze alloy, the metal leadframe clip and the electrical resistance heating tip to fuse the braze alloy.

Abstract: An igniter for igniting combustible gases in a hot zone, such as in a solid oxide fuel cell, comprising a subassembly including an electrical resistance heating tip comprising SiC, metal leadframe clips formed of a nickel-based superalloy and attached to the heating tip, wire leads formed of a nickel-chromium alloy and connected to the leadframe clips for supplying electric current to the heating tip, and a nickel-based braze alloy comprising palladium and cobalt for connecting the leadframe clips to the heating tip and to the wire leads; an alumina ceramic body for receiving the brazed subassembly; and a potting compound comprising zirconia for potting the subassembly into the alumina ceramic body.

Abstract: An SOFC fuel cell stack system in accordance with the invention including a recycle flow leg for recycling a portion of the anode tail gas into the inlet of an associated hydrocarbon reformer supplying reformate to the stack. The recycle leg includes a controllable pump for varying the flow rate of tail gas. Preferably, a heat exchanger is provided in the leg ahead of the pump for cooling the tail gas via heat exchange with incoming cathode air. A low-wattage electrical reheater is also preferably included between the heat exchanger and the pump to maintain the temperature of tail gas entering the pump, during conditions of low tail gas flow, at a drybulb temperature above the dewpoint of the tail gas.

Abstract: A system for removal of H2S from sulfur-containing reformate comprising a permanent canister assembly having fittings for flow of reformate therethrough and a replaceable cartridge assembly containing an H2S adsorber element and fittings for convenient, simple, and reliable mating and sealing with the permanent canister assembly. The cartridge assembly comprises a housing that may be optionally a full cylinder or a semi-cylinder. The cartridge assembly may be easily reloaded off-line for re-use of the cartridge components with a fresh adsorber element. Preferably, the adsorber element is also renewable off-line for re-use.

Abstract: An igniter for igniting combustible gases in a hot zone, such as in a solid oxide fuel cell, comprising a subassembly including an electrical resistance heating tip comprising SiC, metal leadframe clips formed of a nickel-based superalloy and attached to the heating tip, wire leads formed of a nickel-chromium alloy and connected to the leadframe clips for supplying electric current to the heating tip, and a nickel-based braze alloy comprising palladium and cobalt for connecting the leadframe clips to the heating tip and to the wire leads; an alumina ceramic body for receiving the brazed subassembly; and a potting compound comprising zirconia for potting the subassembly into the alumina ceramic body.

Abstract: A system for removal of H2S from sulfur-containing reformate comprising a permanent canister assembly having fittings for flow of reformate therethrough and a replaceable cartridge assembly containing an H2S adsorber element and fittings for convenient, simple, and reliable mating and sealing with the permanent canister assembly. The cartridge assembly comprises a housing that may be optionally a full cylinder or a semi-cylinder. The cartridge assembly may be easily reloaded off-line for re-use of the cartridge components with a fresh adsorber element. Preferably, the adsorber element is also renewable off-line for re-use.

Abstract: In an SOFC stack system, a reformer supplies reformate to the stack. An anode tail gas portion is recycled into the reformer. An inline flowmeter indicates an apparent recycle flow rate. A map of anode tail gas composition as a function of fuel utilization efficiency U, reformer oxygen/carbon ratio O:C, and recycle percentage R is generated on a laboratory test bed at various recycle rates and fuel utilization rates. Compositions are sent through a flowmeter and a Coriolus mass flowmeter provide a Coriolus flow and sensor voltage function across the various compositions and flow rates to create an average curve and an average (reference) voltage at a given flow. A scale factor Z is calculated and used to determine a scaled sensor voltage X for use in an average flow polynomial curve fit equation to calculate tail gas mass flow rate at any flow value indicated by the flow meter.

Abstract: An outwardly-opening fuel injector including a conical valve seat and conical valve head having nominally identical cone angles and mating lengths along the conical frustum between about 0.25 mm and about 0.30 mm. One of either the seat surface or the head surface is provided with an annular undercut to limit the length of mating contact to the desired range. The mating lengths and seal areas remain constant with use because the undercut prevents further changes in mating length. The resulting seal area prevents recession of the head into the seat with use, and therefore the valve stroke is predictable and constant. Further, the undercut provides a sharp corner in the fuel flow path downstream of the seal area, which increases the turbulent kinetic energy of fuel being discharged as a spray cone.

Abstract: A fuel injector is provided which includes a director, such as a ball, mounted downstream of the fuel injection port. When the valve is actuated, fuel exits the injection port. Fuel adheres to the ball until it reaches the equator of the ball. At the equator, the fuel begins to separate from the ball and forms a sheeted, cone-shaped configuration. When used with poppet valve injectors, the present invention preferably includes a wall manifold above the ball. Air from an air source, such as from the engine vacuum is introduced through the wall. Air travels through an air distribution chamber at a ninety degree angle to the direction of fuel flow. The air stream is directed to the ball's equator. This blast of air causes the fuel to atomize to a droplet size in the range of 3 to 6 microns SMD. When the invention is used with solenoid actuated fuel injectors, a ball is mounted downstream of the director plate. In this case, an air housing carries air from an air source to an air blast chamber.

Abstract: A pressure atomizer includes a body having a central axis, and defining a chamber. The body further defines a connecting passage that fluidly connects the chamber to an exterior of the body. The connecting passage has an inside surface. A substantially cylindrical separator collar is disposed concentrically within the connecting passage, and includes an inside surface and an outside surface. At least a portion of the outside surface is disposed a predetermined distance from the inside surface of the connecting passage to thereby define an outer fluid passageway. The outer fluid passageway extends from the chamber to a first exit point. A pintle is disposed substantially concentrically within the separator collar. The pintle includes an outside surface that is disposed a predetermined distance from the inside surface of the separator collar to thereby define an inner fluid passageway. The inner fluid passageway extends from the chamber to a second exit point.

Abstract: A pressure atomizer includes a silicon plate having a top surface and a bottom surface. A portion of the top surface defines a turbulent chamber. The turbulent chamber is peripherally bounded by the top surface of the plate. The turbulent chamber is recessed a predetermined depth relative to the top surface. The silicon plate further defines at least one flow orifice. Each flow orifice extends from the bottom surface of the silicon plate to intersect with and open into the turbulent chamber. Each flow orifice is in fluid communication with the turbulent chamber.

Abstract: An actuator (10) for a fuel injector having a dual coil solenoid. The solenoid coils (14, 16) are connected in parallel and have windings that are wound in opposite directions. The actuator (10) of the present invention defines three air gap surfaces (22, 24, 26), one of which (24) is located in the space shared between the two coils (14, 16). The shared air gap surface (24) has a high flux density due to the additive nature of the magnetic forces between the oppositely wound coils (4, 16). The dual-coil solenoid of the actuator (10) of the present invention creates a very high force and a low inductive load which results in fast injector response times.

Abstract: An electromagnetic fuel injector has an upper, middle and lower body. A solenoid and guide tube are mounted within the middle body. A plug is mounted within the guide tube. The armature moves from its lower position when the solenoid is not energized to its upper position. There are two air gaps which are closed when the armature moves to its upper position, one between the armature and a stop shoulder on the middle body and the other between the armature and the plug. During assembly, the plug is inserted partially into the guide tube. Next, the armature is inserted into the guide tube. The armature is pushed upward until it contacts a stop on the middle body. The armature and the plug then stop moving. Because the plug is in a tight fitting relationship with the upper body, it remains in place when the armature is moved back to its lower position. This positions the plug such that the two air gaps are equal. The second air gap is positioned between the top and bottom of the solenoid.