Abstract: A camshaft phaser includes an input member; an output member defining an advance chamber and a retard chamber with the input member; a supply passage; a vent passage; and a valve spool within the output member which is moveable between a first and second position. The first position prevents communication between the advance chamber and the vent passage, prevents communication between the retard chamber and the vent passage, and allows oil to flow from one of the advance chamber and the retard chamber to the other of the advance chamber and the retard chamber. The second position provides communication between the vent passage and one of the advance chamber and the retard chamber, prevents communication between the vent passage and the other of the advance chamber and the retard chamber, and provides communication between the supply passage and the other of the advance chamber and the retard chamber.

Abstract: A method of manufacturing a solid oxide fuel cell stack having an electrically conductive interconnect, including the steps of: (a) providing a first fuel cell and a second fuel cell, (b) providing a substrate having an iron-chromium alloy, (c) depositing a layer of metallic cobalt over a portion of substrate surface, (d) subjecting the layer of metallic cobalt to reducing conditions, (e) then exposing the remaining portion of the layer of metallic cobalt to oxidizing conditions for a predetermined time and temperature, such that the surface portion of the layer of metallic cobalt is oxidized to cobalt oxide, thereby forming the electrically conductive interconnect having a layer of metallic cobalt sandwiched between a surface layer of cobalt oxide and the layer of cobalt-iron-chromium alloy, and (f) sandwiching the substrate between the first and second fuel cells.

Abstract: A method of manufacturing a solid oxide fuel cell stack having an electrically conductive interconnect, including the steps of: (a) providing a first fuel cell and a second fuel cell, (b) providing a substrate having an iron-chromium alloy, (c) depositing a layer of metallic cobalt over a portion of substrate surface, (d) subjecting the layer of metallic cobalt to reducing conditions, (e) then exposing the remaining portion of the layer of metallic cobalt to oxidizing conditions for a predetermined time and temperature, such that the surface portion of the layer of metallic cobalt is oxidized to cobalt oxide, thereby forming the electrically conductive interconnect having a layer of metallic cobalt sandwiched between a surface layer of cobalt oxide and the layer of cobalt-iron-chromium alloy, and (f) sandwiching the substrate between the first and second fuel cells.

Abstract: A fuel cell stack assembly includes a fuel cell stack wherein a plurality of fuel cell cassettes is coupled together by a joining material. A spring strap is coupled to the fuel cell stack in a manner effective to apply a first compressive force to the fuel cell stack. A first load distribution plate is located intermediate the fuel cell stack and the spring strap. The first load distribution plate is configured to distribute the first compressive force over the fuel cell stack in a manner effective to normalize the first compressive force on the joining material. A diaphragm is configured to define a cavity and is configured to apply a second compressive force to the fuel cell stack dependent on a cavity pressure of oxidant within the cavity. The cavity pressure is dependent upon an oxidant pressure of oxidant provided to the fuel cell stack.

Abstract: A method is provided for adding sulfur to a solid oxide fuel cell (SOFC) stack having a Ni—YSZ anode to prolong the life of the SOFC stack. The method includes the steps of providing a reformate stream essentially free of sulfur compounds, feeding the reformate stream to the SOFC stack, and adding a predetermined amount of a sulfur compound into the reformate stream upstream of the SOFC stack. The predetermined amount of the sulfur compound is effective to prolong the life of the Ni—YSZ anode by retarding the formation of carbon onto the Ni—YSZ anode and the coarsening of the granular microstructure of the Ni—YSZ anode, while minimizing the degradation of power output of the SOFC stack within a predetermined limit.

Abstract: A solid oxide fuel cell (SOFC) stack having a glass seal sandwiched between the sealing surfaces of adjacent cassettes, in which at least one cassette includes means for interlocking the glass seal onto the sealing surface of the cassette for improved adhesion and durability of the glass seal. The at least one cassette includes a plurality of perforations configured to receive and lock onto a portion of the glass seal. At least one of the perforations includes a through-hole having an exterior opening on the sealing surface and an interior opening on the interior surface of the cassette. A portion of the glass seal is received in the perforation forming a glass column in the through-hole and a flared glass end on the interior surface surrounding the interior opening. The flared glass end cooperates with the glass column to interlock the glass seal onto the cassette's sealing surface.

Abstract: A fuel cell stack assembly includes a fuel cell stack wherein a plurality of fuel cell cassettes is coupled together by a joining material. A spring strap is coupled to the fuel cell stack in a manner effective to apply a first compressive force to the fuel cell stack. A first load distribution plate is located intermediate the fuel cell stack and the spring strap. The first load distribution plate is configured to distribute the first compressive force over the fuel cell stack in a manner effective to normalize the first compressive force on the joining material. A diaphragm is configured to define a cavity and is configured to apply a second compressive force to the fuel cell stack dependent on a cavity pressure of oxidant within the cavity. The cavity pressure is dependent upon an oxidant pressure of oxidant provided to the fuel cell stack.

Abstract: A solid oxide fuel cell stack having a plurality of cassettes and a glass composite seal disposed between the sealing surfaces of adjacent cassettes, thereby joining the cassettes and providing a hermetic seal therebetween. The glass composite seal includes an alkaline earth aluminosilicate (AEAS) glass disposed about a viscous glass such that the AEAS glass retains the viscous glass in a predetermined position between the first and second sealing surfaces. The AEAS glass provides geometric stability to the glass composite seal to maintain the proper distance between the adjacent cassettes while the viscous glass provides for a compliant and self-healing seal. The glass composite seal may include fibers, powders, and/or beads of zirconium oxide, aluminum oxide, yttria-stabilized zirconia (YSZ), or mixtures thereof, to enhance the desirable properties of the glass composite seal.

Abstract: A system for adding sulfur to a reformate stream feeding a fuel cell stack, having a sulfur source for providing sulfur to the reformate stream and a metering device in fluid connection with the sulfur source and the reformate stream. The metering device injects sulfur from the sulfur source to the reformate stream at a predetermined rate, thereby providing a conditioned reformate stream to the fuel cell stack. The system provides a conditioned reformate stream having a predetermined sulfur concentration that gives an acceptable balance of minimal drop in initial power with the desired maximum stability of operation over prolonged periods for the fuel cell stack.

Abstract: A fuel cell stack is provided with a plurality of fuel cell cassettes where each fuel cell cassette has a fuel cell with an anode and cathode. The fuel cell stack includes an anode supply chimney for supplying fuel to the anode of each fuel cell cassette, an anode return chimney for removing anode exhaust from the anode of each fuel cell cassette, a cathode supply chimney for supplying oxidant to the cathode of each fuel cell cassette, and a cathode return chimney for removing cathode exhaust from the cathode of each fuel cell cassette. A first fuel cell cassette includes a flow control member disposed between the anode supply chimney and the anode return chimney or between the cathode supply chimney and the cathode return chimney such that the flow control member provides a flow restriction different from at least one other fuel cell cassettes.

Abstract: A system for adding sulfur to a fuel cell stack, having a reformer adapted to reform a hydrocarbon fuel stream containing sulfur contaminants, thereby providing a reformate stream having sulfur; a sulfur trap fluidly coupled downstream of the reformer for removing sulfur from the reformate stream, thereby providing a desulfurized reformate stream; and a metering device in fluid communication with the reformate stream upstream of the sulfur trap and with the desulfurized reformate stream downstream of the sulfur trap. The metering device is adapted to bypass a portion of the reformate stream to mix with the desulfurized reformate stream, thereby producing a conditioned reformate stream having a predetermined sulfur concentration that gives an acceptable balance of minimal drop in initial power with the desired maximum stability of operation over prolonged periods for the fuel cell stack.

Abstract: A solid oxide fuel cell stack having a plurality of cassettes and a glass composite seal disposed between the sealing surfaces of adjacent cassettes, thereby joining the cassettes and providing a hermetic seal therebetween. The glass composite seal includes an alkaline earth aluminosilicate (AEAS) glass disposed about a viscous glass such that the AEAS glass retains the viscous glass in a predetermined position between the first and second sealing surfaces. The AEAS glass provides geometric stability to the glass composite seal to maintain the proper distance between the adjacent cassettes while the viscous glass provides for a compliant and self-healing seal. The glass composite seal may include fibers, powders, and/or beads of zirconium oxide, aluminum oxide, yttria-stabilized zirconia (YSZ), or mixtures thereof, to enhance the desirable properties of the glass composite seal.

Abstract: A method for fuel cell system thermal management includes: maintaining a first zone at a first selected temperature range, maintaining a second zone at a second selected temperature range, and maintaining a third zone at a third selected temperature range. The second zone is in thermal communication with a first sensor and comprises a reformer, while the third zone is in thermal communication with a second sensor and comprises a fuel cell stack. The second selected temperature range is greater than the first selected temperature range, while the third selected temperature range is greater than the second selected temperature range.

Abstract: A method for fuel cell system thermal management includes: maintaining a first zone at a first selected temperature range, maintaining a second zone at a second selected temperature range, and maintaining a third zone at a third selected temperature range. The second zone is in thermal communication with a first sensor and comprises a reformer, while the third zone is in thermal communication with a second sensor and comprises a fuel cell stack. The second selected temperature range is greater than the first selected temperature range, while the third selected temperature range is greater than the second selected temperature range. The method may further include sensing a second zone temperature in the second zone, determining whether the second zone temperature is at the second selected temperature range, and adding a process air flow to the second zone if the second zone temperature rises above the second selected temperature range.

Abstract: A valve seat/director unit the combines the functions of an injector valve seat and a separate spray director plate into an integral unit combining both functions. The unit is a generally flat plate having an outer portion with at least one sealing rib. A central portion includes at least one endless rib forming a valve seat and surrounding a spray director including a recessed area communicating with at least one fuel spray opening. Upper surfaces of the sealing rib(s) and valve seat are preferably flat and coplanar with one another for engagement by cooperating surfaces of an injector member and a valve member, respectively.

Abstract: The waste energy recovery assembly for a fuel cell system comprises: a cathode exhaust passage in fluid communication with a mixing zone through a collection chamber; an anode exhaust passage in fluid communication with said mixing zone by way of an anode exhaust gas orifice disposed in a direction capable of forming an anode exhaust gas flow entering said mixing zone at an angle of about 45° to about 135° to a combined gas flow entering said mixing zone from said collection chamber; a thermal exchange structure in fluid communication with said mixing zone; and an exhaust gas passage in fluid communication with said thermal exchange structure.

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 electromagnetic fuel injector comprises a body having a fuel inlet and a fuel outlet and a base comprising a valve seat sealably connected to the body. A disk-shaped armature disposed at the fuel outlet for controlling the flow of fuel has an upper surface and a lower surface that comprises a sealing interface with the valve seat. A ring-shaped flexural element comprising a plurality of spaced flexural legs is in contact with the injector body and the upper surface of the armature and provides a spring bias between the body and armature upper surface. When the injector is closed, spring bias between the body and armature upper surface maintains the armature in a sealing position with the valve seat, and when the injector is open, increased spring bias between the body and armature upper surface impels the armature to return to a sealing position with the valve seat.

Abstract: A method for monitoring process gas of a solid oxide fuel cell system is disclosed. The method comprises directing a portion of process gas from a chamber of the solid oxide fuel cell system to a main plenum chamber. A portion of process gas is cooled to a measurable temperature and directed to a sensor for analyzing. A solid oxide fuel cell system is also disclosed.

Abstract: A fuel injector includes a flexural element connected to a valve armature for restricting radial movement of the armature within a fuel passage. The flexural element is flat and exerts no force on the valve when it is closed but is flexed when the valve is opened and supplements the valve spring force during closing of the valve. The flexural element also is used to set the valve stroke length equal to the element's thickness. A flat tool presses a valve ball into the armature while the ball is seated on a valve seat until the flexural element engages a seat related surface. Engagement of the tool with the flexural element fixed to the armature assures that the flexural element is in an unloaded flat position when the valve is closed and establishes the valve stroke when the valve assembly and seat are installed in the injector body.