Abstract: The materials of adjoining porous metal substrate (12), oxide (14), and Pd-alloy membrane (16) layers of a composite, H2—separation palladium membrane (10) have respective thermal expansion coefficients (TEC) which differ from one another so little as to resist failure by TEC mismatch from thermal cycling. TEC differences (20, 22) of less than 3 ?m/(m.k) between materials of adjacent layers are achieved by a composite system of a 446 stainless steel substrate, an oxide layer of 4 wt % yittria-zirconia, and a 77 wt % Pd-23 wt % Ag or 60 wt % Pd-40 wt % Cu, membrane, having TECs of 11, 11, and 13.9 ?m/(m.k), respectively. The Intermediate oxide layer comprises particles forming pores having an average pore sizeless than 5 microns, and preferably less than about 3 microns, in thickness.

Abstract: A metallic, rigidized foil support structure (11) supports a cell (14) of a solid oxide fuel cell (10). The support structure (11) includes a separator sheet (18), a support sheet (16) having perforations (26) configured to communicate a fluid, and a porous layer (20) positioned between the separator sheet (18) and the support sheet (16). The porous layer (20) provides support and reinforcement to the support structure (11) as well as an electrical connection between the support sheet (16) and the separator sheet (18). Fuel flows through the porous layer (20).

Abstract: A concentrated solar energy system includes a photovoltaic cell, an optical concentrator, a heat removal system, and means for providing thermal contact between the photovoltaic cell and the heat removal system. The optical concentrator is configured to direct concentrated solar energy to the photovoltaic cell such that the photovoltaic cell generates electricity and heat. The heat removal system removes heat from the photovoltaic cell. The means for providing thermal contact provides an effective thermal conductivity per unit length between the photovoltaic cell and the heat removal system of greater than about 50 kilowatts per square meter per degree Celsius.

Abstract: A power system for an aircraft includes a solid oxide fuel cell system which generates electric power for the aircraft and an exhaust stream; and a heat exchanger for transferring heat from the exhaust stream of the solid oxide fuel cell to a heat requiring system or component of the aircraft. The heat can be transferred to fuel for the primary engine of the aircraft. Further, the same fuel can be used to power both the primary engine and the SOFC. A heat exchanger is positioned to cool reformate before feeding to the fuel cell. SOFC exhaust is treated and used as inerting gas. Finally, oxidant to the SOFC can be obtained from the aircraft cabin, or exterior, or both.

Abstract: A fuel cell stack includes a plurality of fuel cells each having an anode layer, an electrolyte layer, and a cathode layer, the fuel cells each having a first effective thermal expansion coefficient; a plurality of bipolar plates positioned between adjacent fuel cells having an anode interconnect, a separator plate, and a cathode interconnect, the bipolar plates being positioned between adjacent fuel cells, wherein the anode interconnect is in electrical communication with the anode layer of one adjacent fuel cell, wherein the cathode interconnect is in electrical communication with the cathode layer of another adjacent fuel cell, and wherein at least one interconnect of the cathode interconnect and the anode interconnect has a second thermal expansion coefficient and is adapted to reduce strain between the at least one interconnect and an adjacent fuel cell due to differences between the first and second thermal expansion coefficients over repeated thermal cycles.

Abstract: A fuel cell stack formed of repeating cell units is provided wherein each cell unit includes a fuel cell having an anode side and a cathode side; an anode side frame; a cathode side frame; a bipolar plate having an anode side interconnect adjacent to the anode side frame and a cathode side interconnect adjacent to a cathode side frame of an adjacent cell unit; a cathode side seal between the fuel cell and the cathode side frame; and an anode side seal between the fuel cell and the anode side frame, wherein at least one of the anode side interconnect, cathode side interconnect, anode side seal and cathode side seal are compliant.

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% Y2P3, 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: Method and equipment for converting hydrocarbon fuel to a mixture of hydrogen and carbon monoxide through catalytic partial oxidation. Thermal management of the process in the pre-reaction and post reaction zones of the reactor enhance yields and reduces carbon deposition.

Abstract: Method and equipment for converting hydrocarbon fuel to a mixture of hydrogen and carbon monoxide through catalytic partial oxidation. The catalysts can include a combination of both an oxidation catalyst and a steam reforming catalyst, though no water is used in the process and catalyst contact time is short. Thermal management of the process in the pre-reaction and post reaction zones of the reactor enhance yields and reduce carbon deposition.

Abstract: An interconnect for a solid oxide fuel cell includes a compliant superstructure having a first portion defining a separator plate contact zone and a second portion defining an electrode contact zone, wherein the super structure is porous. In one embodiment, the superstructure is defined by a plurality of compliant substructures provided in a first direction and a plurality of compliant substructures provided in second direction to define a woven structure.

Abstract: A seal assembly for a solid oxide fuel cell stack, includes at least two fuel cell stack components having opposed surfaces and a seal member disposed between the surfaces, wherein the seal member is a compliant seal member that is mechanically compliant in both in-plane and out-of-plane directions relative to the surfaces. The seal member is advantageously formed of one or more substantially continuous fibers. Further, preferred materials for the seal member are provided which advantageously allow for a desired level of impermeability while preventing contamination of the fuel cell stack.

Abstract: A fuel cell stack includes a plurality of fuel cells each having an anode layer, an electrolyte layer, and a cathode layer, the fuel cells each having a first effective thermal expansion coefficient; a plurality of bipolar plates positioned between adjacent fuel cells having an anode interconnect, a separator plate, and a cathode interconnect, the bipolar plates being positioned between adjacent fuel cells, wherein the anode interconnect is in electrical communication with the anode layer of one adjacent fuel cell, wherein the cathode interconnect is in electrical communication with the cathode layer of another adjacent fuel cell, and wherein at least one interconnect of the cathode interconnect and the anode interconnect has a second thermal expansion coefficient and is adapted to reduce strain between the at least one interconnect and an adjacent fuel cell due to differences between the first and second thermal expansion coefficients over repeated thermal cycles.

Abstract: A sealless, planar fuel cell stack system, including a continuous bottom plate, a first permeable or interconnect layer, a continuous cell, a second permeable or interconnect layer, a continuous top plate, a fuel supply member, and an oxidant gas supply member, is provided. The fuel cell system of the present invention does not require glass-based sealants to seal its planar components. In the present system, the continuous cell of the system is supported by the first permeable layer. The second permeable layer is supported by the continuous cell. The fuel supply member supplies fuel into the first permeable layer. The fuel supply member extends between an outer edge and a center region of the first permeable layer and allows distribution of the fuel in a radial fashion. Further, the fuel supply member is connected to an external fuel manifold adjacent the outer edge. The oxidant gas supply member supplies oxidant gas into the second permeable layer.

Abstract: A parallel electrical connector between a first fuel cell stack having a first conducting plate and a second fuel cell stack having a second conducting plate includes a connector element affixed to the first and second conducting plates. The connector element is positioned adjacent a first open face of the first fuel cell stack and a second open face of the second fuel cell stack, wherein the first and second open faces are juxtaposed to one another. Also, the connector element is positioned substantially parallel to at least one of the first and second conducting plates. It is also configured to substantially match a configuration of at least one of the first and second conducting plates. Series-parallel connection is provided at the cell or higher cell level for two or more stacks.

Abstract: A composite sealant for in-situ sealing a fuel cell stack is provided. A paste of the sealant mixture is initially formed by mixing a glass precursor powder and a reacting filler material. The sealant mixture paste is applied to selected sealing locations of the fuel cell stack. The sealant mixture paste is then transformed into a composite sealant material to seal the selected sealing locations by heat treatment in air to about 900° C. The composite sealant material comprises a glass matrix phase and a reinforcing phase including a plurality of interlocked elongated single crystal grains. The reacting fillers modify the CTE and significantly improve the gap filling capacity of the composite sealant material and provide superior pressure containment capability at elevated temperatures.

Abstract: A radial planar fuel cell stack comprises an internal manifold having a first interior cavity and a second interior cavity. A plurality of single cells having an anode layer, a cathode layer, and an electrolyte layer therebetween are disposed about the manifold. A manifold bracket operatively fixes the manifold to at least one of the single cells. The manifold bracket describes a channel in communication with at least one of the first and second interior cavities. A porous element is disposed in the channel and ensures uniform distribution of gases over 360°.

Abstract: A sealant for a solid oxide fuel cell comprises a glass material that acts as a matrix, with the glass material being present between about 40 to 90 wt. %. A gap-filler material is also in the sealant and selected from the group consisting of a metal material and a ceramic material, with the gap-filler material being present between about 10 to 60 wt. %. The sealant can seal a gap as large as about 3 mm.

Abstract: A method of processing sulfur-containing heavy hydrocarbon fuels in the substantial absence of steam through catalytic partial oxidation is described. The process comprises the steps of vaporizing a heavy hydrocarbon fuel and bringing the vaporized fuel and oxidizer mixture in contact with a noble metal catalyst supported on an open channel structure. The hydrocarbon fuel is considered to be a liquid hydrocarbon having at least six carbon atoms and a sulfur content of at least 50 ppm. The feed, containing only the vaporized fuel and oxygen in the oxidizer mixture, is subsequently routed through a reactor containing a noble metal catalyst (typically Rh/Alumina) at contact times of not more than about 500 milliseconds and a LHSV of not less than about 0.5 h−1. The feed is partially oxidized by a catalytic reaction occurring at a temperature of no less than about 1050° C.

Abstract: A ceramic body based on barium and strontium titanates has a composition defined essentially by the formula Ba.sub.1-x Sr.sub.x TiO.sub.3, where x ranges from 0 to 1. The ceramic body is chemically and dimensionally stable in solid oxide fuel cell (SOFC) operation environments, which encounter oxidizing and reducing atmospheres at temperatures as high as 1,000.degree. C. In addition, the ceramic of which the body is comprised can be tailored to yield a ceramic in which the thermal expansion coefficient (CTE) is adjusted between 11.3.times.10.sup.-6 /.degree.C. and 12.4.times.10.sup.-6 /.degree.C. to match the CTE of the other SOFC materials, thereby avoiding the adverse effects of thermal stress. These features make the ceramic body especially suited for use as manifolds in SOFC stacks, or other non-electrical structural components, such as the inflow and outflow gas manifold materials, the stack housing, or other support structure or spacers in the stack, and the like.

Abstract: A silicon nitride sintered body has a composition consisting essentially of 80 to 93% by weight .beta. silicon nitride, 7 to 20% by weight grain boundary phases consisting essentially of (i) at least two rare earth elements, wherein yttrium is considered a rare earth, and strontium which, calculated as SrO, is 0.5 to 5% by weight, and (ii) at least two of Si, N, O and C; and (c) silicon carbide particulate present in the amount of about 5 to 35 parts by weight per 100 parts by weight of components (a) and (b), said SiC being substantially homogeneously dispersed within said sintered body. Such a ceramic has high strength and long term durability, and is especially suited for industrial applications such as components for gas turbine and automotive engines.