Abstract: A joint for use in electrochemical devices, such as solid oxide fuel cells (SOFCs), oxygen separators, and hydrogen separators, that will maintain a hermetic seal at operating temperatures of greater than 600° C., despite repeated thermal cycling excess of 600° C. in a hostile operating environment where one side of the joint is continuously exposed to an oxidizing atmosphere and the other side is continuously exposed to a wet reducing gas. The joint is formed of a metal part, a ceramic part, and a flexible gasket. The flexible gasket is metal, but is thinner and more flexible than the metal part.

Abstract: A modular fuel cell cassette for use in assembling a fuel cell stack comprising a metal separator plate and a metal cell-mounting plate joined at their edges to form a hollow cassette. A fuel cell subassembly is attached to the mounting plate and extends through an opening in the mounting plate. The plates include openings to form chimney manifolds for supply and exhaust of fuel gas to the anode and air to the cathode. A conductive interconnect element extends from the fuel cell subassembly to make contact with the next cassette in a stack. The anode openings in the mounting plate and separator plate are separated by spacer rings such that the cassette is incompressible. A fuel cell stack comprises a plurality of cassettes, the mounting plate of one cassette being attached to, and insulated from, the separator plate of the next-adjacent cassette by a dielectric seal surrounding the interconnect.

Abstract: A seal formed between a metal part and a second part that will remain gas tight in high temperature operating environments which experience frequent thermal cycling, which is particularly useful as an insulating joint in solid oxide fuel cells. A first metal part is attached to a reinforcing material. A glass forming material in the positioned in between the first metal part and the second part, and a seal is formed between the first metal part and the second part by heating the glass to a temperature suitable to melt the glass forming materials. The glass encapsulates and bonds at least a portion of the reinforcing material, thereby adding tremendous strength to the overall seal. A ceramic material may be added to the glass forming materials, to assist in forming an insulating barrier between the first metal part and the second part and to regulating the viscosity of the glass during the heating step.

Abstract: A seal formed between a metal part and a second part that will remain gas tight in high temperature operating environments which experience frequent thermal cycling, which is particularly useful as an insulating joint in solid oxide fuel cells. A first metal part is attached to an reinforcing material. A glass forming material in the positioned in between the first metal part and the second part, and a seal is formed between the first metal part and the second part by heating the glass to a temperature suitable to melt the glass forming materials. The glass encapsulates and bonds at least a portion of the reinforcing material, thereby adding tremendous strength to the overall seal. A ceramic material may be added to the glass forming materials, to assist in forming an insulating barrier between the first metal part and the second part and to regulating the viscosity of the glass during the heating step.