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 solid ceramic electrolyte may include an ion-conducting ceramic and at least one grain growth inhibitor. The ion-conducting ceramic may be a lithium metal phosphate or a derivative thereof. The grain growth inhibitor may be magnesia, titania, or both. The solid ceramic electrolyte may have an average grain size of less than about 2 microns. The grain growth inhibitor may be between about 0.5 mol. % to about 10 mol. % of the solid ceramic electrolyte.

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: An ion-conducting composite electrolyte is provided comprising path-engineered ion-conducting ceramic electrolyte particles and a solid polymeric matrix. The path-engineered particles are characterized by an anisotropic crystalline structure and the ionic conductivity of the crystalline structure in a preferred conductivity direction H associated with one of the crystal planes of the path-engineered particle is larger than the ionic conductivity of the crystalline structure in a reduced conductivity direction L associated with another of the crystal planes of the path-engineered particle. The path-engineered particles are sized and positioned in the polymeric matrix such that a majority of the path-engineered particles breach both of the opposite major faces of the matrix body and are oriented in the polymeric matrix such that the preferred conductivity direction H is more closely aligned with a minimum path length spanning a thickness of the matrix body than is the reduced conductivity direction L.

Abstract: There is disclosed a polycrystalline lithium-ion conductive membrane for a lithium-air battery that comprises at least one surface, a polycrystalline lithium-ion conductive material comprising grain boundaries, and at least one modifying phase, wherein (a) the at least one modifying phase is incorporated into the grain boundaries to form a modified polycrystalline lithium-ion conductive material comprising modified grain boundaries, (b) the at least one modifying phase is incorporated into the at least one surface to form a modified surface, or both (a) and (b). Various lithium based batteries, including lithium ion, lithium-air, and lithium-water batteries are disclosed, as well as methods for modifying the polycrystalline lithium-ion conductive membrane to allow it to be used in such battery applications.

Abstract: A flame spray pyrolysis method for making nanoscale, lithium ion-conductive ceramic powders comprises providing a precursor solution comprising chemical precursors dissolved in an organic solvent, and spraying the precursor solution into an oxidizing flame to form a nanoscale, lithium ion-conductive ceramic powder, wherein a concentration of the chemical precursors in the solvent ranges from 1 to 20 M. The precursor solution can comprise 1-20% excess lithium with respect to a stoichiometric composition of the ceramic powder. Nominal compositions of the nanoscale, ceramic powders are Li1.4Al0.4M1.6(PO4)3 where M is Ti or Ge.

Abstract: A solid ceramic electrolyte may include an ion-conducting ceramic and at least one grain growth inhibitor. The ion-conducting ceramic may be a lithium metal phosphate or a derivative thereof The grain growth inhibitor may be magnesia, titania, or both. The solid ceramic electrolyte may have an average grain size of less than about 2 microns. The grain growth inhibitor may be between about 0.5 mol. % to about 10 mol. % of the solid ceramic electrolyte.

Abstract: A flame spray pyrolysis method for making nanoscale, lithium ion-conductive ceramic powders comprises providing a precursor solution comprising chemical precursors dissolved in an organic solvent, and spraying the precursor solution into an oxidizing flame to form a nanoscale, lithium ion-conductive ceramic powder, wherein a concentration of the chemical precursors in the solvent ranges from 1 to 20 M. The precursor solution can comprise 1-20% excess lithium with respect to a stoichiometric composition of the ceramic powder. Nominal compositions of the nanoscale, ceramic powders are Li1.4Al0.4M1.6(PO4)3 where M is Ti or Ge.

Abstract: An ion-conducting composite electrolyte is provided comprising path-engineered ion-conducting ceramic electrolyte particles and a solid polymeric matrix. The path-engineered particles are characterized by an anisotropic crystalline structure and the ionic conductivity of the crystalline structure in a preferred conductivity direction H associated with one of the crystal planes of the path-engineered particle is larger than the ionic conductivity of the crystalline structure in a reduced conductivity direction L associated with another of the crystal planes of the path-engineered particle. The path-engineered particles are sized and positioned in the polymeric matrix such that a majority of the path-engineered particles breach both of the opposite major faces of the matrix body and are oriented in the polymeric matrix such that the preferred conductivity direction H is more closely aligned with a minimum path length spanning a thickness of the matrix body than is the reduced conductivity direction L.

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: According to one embodiment of the invention a fuel cell device array monolith comprises at least three planar electrolyte sheets having two sides. The electrolyte sheets are situated adjacent to one another. At least one of the electrolyte sheets is supporting a plurality of anodes situated on one side of the electrolyte sheet; and plurality of cathodes situated on the other side of the electrolyte sheet. The electrolyte sheets are arranged such that the electrolyte sheets with a plurality of cathodes and anodes is situated between the other electrolyte sheets. The at least three electrolyte sheets are joined together by sintered fit, with no metal frames or bipolar plates situated therebetween.

Abstract: A catalyst body which includes ceria:zirconia and a metal-zeolite, and is substantially free, or free, of tungsten or tungsten compounds, and methods of manufacture. The ceria and zirconia are present with a zirconia/ceria mole ratio of less than or equal to 1.0. The catalyst body is especially useful in NOx reduction applications.

Abstract: A solid oxide fuel cell device assembly comprising: (i) at least one solid oxide fuel cell device including one electrolyte sheet sandwiched between at least one pair of electrodes; and (ii) a non-steel frame fixedly attached to said at least one fuel cell device without a seal located therebetween.

Abstract: An exemplary fuel cell device assembly includes: (i) an electrolyte sheet; (ii) a plurality of cathodes disposed on one side of the electrolyte sheet; (iii) a plurality of anodes disposed on another side of the electrolyte sheet; and (iv) a frame supporting the electrolyte sheet, the frame having a plurality of channels. Preferably the cross-sectional area of the frame has channel density of at least 20/in2 and channel wall thickness of 50 mils or less.

Abstract: A solid oxide fuel cell device assembly comprising: (i) at least one solid oxide fuel cell device including one electrolyte sheet sandwiched between at least one pair of electrodes; and (ii) a non-steel frame fixedly attached to said at least one fuel cell device without a seal located therebetween.

Abstract: An exemplary method of making a fuel cell device assemblies includes the steps of: (i) providing a ceramic batch; (ii) extruding the ceramic batch through a die and a mask to form green extrudate that, in cross-section, has at least 10 cells/in2 and wall thickness of 50 mils or less; (iii) cutting the green extrudate to an appropriate length to form a green frame blank; (iv) sintering the green frame blank at a temperature of at least 1200° C., preferably at a temperature of between 1400° C. and 1600° C. for at least one hour to form a ceramic frame with a plurality of parallel channels; (v) inserting at least one fuel cell array into its designated position within the ceramic frame; and (vi) sealing the at least one fuel cell array to the frame.

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.