Abstract: A fuel cell assembly having manifold means for providing fuel and air to, and removing spent fuel and air from, flow passageways across the anodes and cathodes in a fuel cell stack. The sizes and proportions of the supply and return manifolds are optimized, and the total cross-sectional area of the return manifold is about twice the cross-sectional area of the supply manifold. The pressure drop in the manifolds is less than about one-quarter of the total pressure drop across the anode and cathode passageways in the stack, which ratio may be attained by adjusting the thickness of the anode and cathode spacers and/or the size of the chimneys. Widthwise uniformity of flow across the anodes and cathodes is improved by forming each of the manifolds as a plurality of smaller, parallel flow conduits.

Abstract: A solid oxide fuel cell is disclosed. The solid oxide fuel cell comprises an electrolyte disposed between and in ionic communication with a first electrode and a second electrode to form an electrochemical cell. At least one spacer is disposed in contact with the electrochemical cell. A mat is disposed adjacent to the spacer. A method for making a solid oxide fuel cell is also disclosed.

Abstract: A gas treatment system and method for using the same is disclosed. The gas treatment system, comprises: a non-thermal plasma reactor; and a catalyst composition disposed within said non-thermal plasma reactor, said catalyst composition comprising a MZr4(PO4)6, wherein M is a metal selected from the group consisting of platinum, palladium, ruthenium, silver, rhodium, osmium, iridium, and combinations comprising at least one of said foregoing metals. The process comprises exposing said gas to a plasma field and to the catalyst composition.

Abstract: A method of starting a solid oxide fuel cell system is disclosed. The method comprises pressurizing a main plenum to a first pressure. The main plenum comprises a first supply of fuel, blowers, and air control valves. The first supply of fuel and a first supply of air are directed to a preheated micro-reformer. A heated pre-reformate is created in the micro-reformer and discharged from the micro-reformer to a main reformer. The main reformer is preheated with the heated pre-reformate. A second supply of fuel and a second supply of air are introduced to the main reformer. A heated main reformate is created in the main reformer and directed to a waste energy recovery assembly. A cathode supply is heated in the waste energy recovery system and then directed to a solid oxide fuel cell stack in order to heat the solid oxide fuel cell stack. Methods of transitioning, operating, shutting down, and maintaining in standby mode are also disclosed.

Abstract: A thermal energy management system for solid oxide fuel cells includes a monolithic small cell extrusion type heat exchanger coupled to an SOFC stack. In operation, a flow of air having a selected temperature is passed through the heat exchanger cells and thermal energy flowing into and out of the SOFC stack is managed primarily by radiation coupling between the SOFC stack and the heat exchanger. The system further provides management of the temperature distribution around the SOFC to meet outer skin temperature design targets and to control the inlet gas temperatures for the SOFC. The system provides a compact, efficient method for SOFC thermal energy management and is particularly well suited for transportation applications.

Abstract: An ion sensor glow plug assembly includes a metal shell for attachment to a cylinder head of a compression ignition engine. The ion sensor glow plug assembly also includes a center terminal at least partially disposed in the metal shell and connected to a source of power to create a heating circuit. The ion sensor glow plug assembly includes a metal glow sheath disposed at least partially in the metal shell and about the center terminal. The ion sensor glow plug assembly further includes an insulator disposed about the metal glow sheath and at least partially in the metal shell and extending axially into a glow area of the metal glow sheath to clean off soot on the insulator by glowing.

Abstract: A compact integrated thermal management and fuel reformation system and method includes a thermally insulated wall forming an envelope having an interior chamber housing, a solid oxide fuel cell stack and a mixed mode heat exchanger. A recuperator having interior walls that are color graded to provide temperature zones effecting a positive temperature gradient in the direction of the solid oxide fuel cell stack is disposed within the chamber and close coupled to the fuel cell stack for absorbing radiation therefrom. The recuperator further heats the partially preheated oxidant gas and partially or fully reforms incoming fuel gas. Manifolds having oxidant and fuel channels for conducting reformed fuel and heated oxidant from the recuperator to fuel cell oxidant and fuel inlets are arranged to maximize fuel flow at the portions of each fuel cell adjacent the recuperator and to maximize oxidant flow near central portions of each fuel cell. A method for providing a tailored anode fuel stream is also provided.

Abstract: A base manifold for a modular solid oxide fuel cell assembly comprises a plurality of receiving areas for receiving a plurality of solid oxide fuel cell stacks; a fuel inlet passageway disposed between a manifold fuel inlet port and a plurality of stack fuel inlet ports; an oxidant inlet passageway disposed between a manifold oxidant inlet port and a plurality of stack oxidant inlet ports; a fuel outlet passageway disposed between a plurality of stack fuel outlet ports and a manifold fuel outlet port; and an oxidant outlet passageway disposed between a plurality of stack oxidant outlet ports and a manifold oxidant outlet port.

Abstract: An ion sensor glow plug assembly includes a shell for attachment to a cylinder head of a compression ignition engine and having a passageway extending axially therethrough. The ion sensor glow plug assembly also includes a center terminal disposed at least partially in the passageway of the shell and connected to a source of power to create a heating circuit. The ion sensor glow plug assembly includes a glow sheath disposed at least partially in the passageway of the shell and about the center wire to create an ion sensing circuit. The ion sensor glow plug assembly further includes a coating disposed about a portion of the glow sheath between the glow sheath and the shell to isolate the shell from the glow sheath and extending axially into a glow area of the glow sheath to clean off soot on the glow sheath by glowing.

Abstract: A solid oxide fuel cell is disclosed. The solid oxide fuel cell comprises an electrolyte disposed between and in ionic communication with a first electrode and a second electrode to form an electrochemical cell. At least one spacer is disposed in contact with the electrochemical cell. A mat is disposed adjacent to the spacer. A method for making a solid oxide fuel cell is also disclosed.

Abstract: A method of starting a solid oxide fuel cell system is disclosed. The method comprises pressurizing a main plenum to a first pressure. The main plenum comprises a first supply of fuel, blowers, and air control valves. The first supply of fuel and a first supply of air are directed to a preheated micro-reformer. A heated pre-reformate is created in the micro-reformer and discharged from the micro-reformer to a main reformer. The main reformer is preheated with the heated pre-reformate. A second supply of fuel and a second supply of air are introduced to the main reformer. A heated main reformate is created in the main reformer and directed to a waste energy recovery assembly. A cathode supply is heated in the waste energy recovery system and then directed to a solid oxide fuel cell stack in order to heat the solid oxide fuel cell stack. Methods of transitioning, operating, shutting down, and maintaining in standby mode are also disclosed.

Abstract: An ion sensor glow plug assembly includes a shell for attachment to a cylinder head of a compression ignition engine and having a passageway extending axially therethrough. The ion sensor glow plug assembly also includes a center terminal disposed at least partially in the passageway of the shell and connected to a source of power to create a heating circuit. The ion sensor glow plug assembly includes a glow sheath disposed at least partially is the passageway of the shell and about the center terminal to create an ion sensing circuit. The ion sensor glow plug assembly further includes an insulator disposed at least partially in the passageway of the shell and about a portion of the glow sheath and extending axially therefrom to clean off soot on the glow sheath. The ion sensor glow plug assembly includes a coating disposed about a portion of the glow sheath between the glow sheath and the shell to isolate the shell from the glow sheath.

Abstract: An ion sensor glow plug assembly includes a metal shell for attachment to a cylinder head of a compression ignition engine. The ion sensor glow plug assembly also includes a center terminal at least partially disposed in the metal shell and connected to a source of power to create a heating circuit. The ion sensor glow plug assembly includes a metal glow sheath disposed at least partially in the metal shell and about the center terminal. The ion sensor glow plug assembly further includes an insulative seal disposed at least partially around the metal glow sheath to isolate the metal shell from the metal glow sheath to create an ion sensing circuit.

Abstract: An ion sensor glow plug assembly includes a shell for attachment to a cylinder head of a compression ignition engine and having a passageway extending axially therethrough. The ion sensor glow plug assembly also includes a center terminal disposed at least partially in the passageway of the shell and connected to a source of power to create a heating circuit. The ion sensor glow plug assembly includes a glow sheath disposed at least partially in the passageway of the shell and about the center wire to create an ion sensing circuit. The ion sensor glow plug assembly further includes a coating disposed about a portion of the glow sheath between the glow sheath and the shell to isolate the shell from the glow sheath.