Abstract: An energy storage device is provided that includes a separator having a first surface and a second surface. The first surface defines at least a portion of a cathodic chamber, and the second surface defines an anodic chamber. The cathodic chamber includes an alkali metal halide that forms an ion that is capable of conducting through the separator. The anodic chamber has a volume that is filled with a consumable fluid. The amount of the consumable fluid is greater than 90 percent by volume of the anodic chamber volume. Furthermore, the consumable fluid is reactive with an ionic species of the alkali metal halide. A method of sealing the energy storage device is also provided.

Abstract: Disclosed herein are a system and a method for the production of hydrogen. The system advantageously combines an independent high temperature heat source with a solid oxide electrolyzer cell and a heat exchanger located between the cathode inlet and the cathode outlet. The heat exchanger is used to extract heat from the molecular components such as hydrogen derived from the electrolysis. A portion of the hydrogen generated in the solid oxide electrolyzer cell is recombined with steam and recycled to the solid oxide electrolyzer cell. The oxygen generated on the anode side is swept with compressed air and used to drive a gas turbine that is in operative communication with a generator. Electricity generated by the generator is used to drive the electrolysis in the solid oxide electrolyzer cell.

Abstract: A system and method for operating a fuel cell, including reacting a fuel with an oxidant within the fuel cell to produce electricity and reaction products comprising steam. The fuel is fed through the fuel cell, wherein a concentration of the steam increases in the first direction through the fuel cell. The direction of fuel-flow through the fuel cell is altered or reversed upon satisfying a condition, thereby altering the concentration gradient of steam in the fuel cell and providing for removal of carbon deposition with the fuel cell. Such reversal of fuel flow may also provide an exhaust from the fuel cell that can regenerate an external or adjacent hydrocarbon reformer.

Abstract: An energy storage device is provided that includes a separator having a first surface and a second surface. The first surface defines at least a portion of a cathodic chamber, and the second surface defines an anodic chamber. The cathodic chamber includes an alkali metal halide that forms an ion that is capable of conducting through the separator. The anodic chamber has a volume that is filled with a consumable fluid. The amount of the consumable fluid is greater than 90 percent by volume of the anodic chamber volume. Furthermore, the consumable fluid is reactive with an ionic species of the alkali metal halide. A method of sealing the energy storage device is also provided.

Abstract: A method of making an electrode structure is provided. The method includes disposing an electrocatalytic material on an electrode, applying heat to the electrocatalytic material to form a volatile oxide of the electrocatalytic material, and applying a voltage to the electrode to reduce the volatile oxide to provide a number of nano-sized electrocatalytic particles on or proximate to a triple phase boundary, where the number of nano-sized electrocatalytic particles is greater on or proximate to the triple phase boundary than in an area that is not on or proximate to the triple phase boundary, and where the triple phase boundary is disposed on the electrode.

Abstract: An electrolyzer assembly comprises at least one electrolyzer cell including at least two electrodes and an electrolyte interposed therebetween. The electrolyzer assembly further comprises an interconnect structure in intimate contact with at least one of the two electrodes or the electrolyte. The interconnect structure includes at least one flow channel initially defined by a removable sacrificial material, wherein the interconnect structure is configured to provide support for the electrodes and the electrolyte.

Abstract: A fuel cell assembly includes at least one fuel cell including at least two electrodes and an electrolyte. An interconnect structure includes at least one flow channel initially defined by a removable sacrificial material. A method of forming the fuel cell assembly includes the steps of providing the interconnect structure having at least one flow channel, depositing the sacrificial material into the flow channel, depositing an electrode or an electrode/electrolyte material upon the interconnect structure and the sacrificial material, and processing the fuel cell so as to remove the sacrificial material.

Abstract: Disclosed herein are a system and a method for the production of hydrogen. The system advantageously combines an independent high temperature heat source with a solid oxide electrolyzer cell and a heat exchanger located between the cathode inlet and the cathode outlet. The heat exchanger is used to extract heat from the molecular components such as hydrogen derived from the electrolysis. A portion of the hydrogen generated in the solid oxide electrolyzer cell is recombined with steam and recycled to the solid oxide electrolyzer cell. The oxygen generated on the anode side is swept with compressed air and used to drive a gas turbine that is in operative communication with a generator. Electricity generated by the generator is used to drive the electrolysis in the solid oxide electrolyzer cell.

Abstract: Disclosed herein are a system and a method for the production of hydrogen. The system advantageously combines an independent high temperature heat source with a solid oxide electrolyzer cell and a heat exchanger. The heat exchanger is used to extract heat from the molecular components such as hydrogen derived from the electrolysis. A portion of the hydrogen generated in the solid oxide electrolyzer cell is recombined with steam and recycled to the solid oxide electrolyzer cell. The oxygen generated on the anode side is swept with compressed air and used to drive a gas turbine that is in operative communication with a generator. Electricity generated by the generator is used to drive the electrolysis in the solid oxide electrolyzer cell.

Abstract: Chemical vapor deposition is performed using a plurality of expanding thermal plasma generating means to produce a coating on a substrate, such as a thermoplastic and especially a polycarbonate substrate. The substrate is preferably moved past the generating means. Included are methods which coat both sides of the substrate or which employ multiple sets of generating means, either in a single deposition chamber or in a plurality of chambers for deposition of successive coatings. The substrate surfaces spaced from the axes of the generating means are preferably heated to promote coating uniformity.

Abstract: A method for manufacturing a fuel cell assembly, and a fuel cell assembly produced by the method, are provided, with the method comprising providing at least one fuel cell unit, wherein providing the at least one fuel cell unit comprises providing at least one substrate; and disposing at least one fuel cell component layer on the at least one substrate, the at least one component layer comprising at least one of an interconnect, an anode, a cathode, and an electrolyte; wherein disposing comprises depositing the at least one component layer using an expanding-thermal-plasma coating apparatus.

Abstract: A fuel cell assembly includes at least one fuel cell including at least two electrodes and an electrolyte. An interconnect structure includes at least one flow channel initially defined by a removable sacrificial material. A method of forming the fuel cell assembly includes the steps of providing the interconnect structure having at least one flow channel, depositing the sacrificial material into the flow channel, depositing an electrode or an electrode/electrolyte material upon the interconnect structure and the sacrificial material, and processing the fuel cell so as to remove the sacrificial material.

Abstract: A method for manufacturing a fuel cell assembly, and a fuel cell assembly produced by the method, are provided, with the method comprising providing at least one fuel cell unit, wherein providing the at least one fuel cell unit comprises providing at least one substrate; and disposing at least one fuel cell component layer on the at least one substrate, the at least one component layer comprising at least one of an interconnect, an anode, a cathode, and an electrolyte; wherein disposing comprises depositing the at least one component layer using an expanding-thermal-plasma coating apparatus.

Abstract: Chemical vapor deposition is performed using a plurality of expanding thermal plasma generating means to produce a coating on a substrate, such as a thermoplastic and especially a polycarbonate substrate. The substrate is preferably moved past the generating means. Included are methods which coat both sides of the substrate or which employ multiple sets of generating means, either in a single deposition chamber or in a plurality of chambers for deposition of successive coatings. The substrate surfaces spaced from the axes of the generating means are preferably heated to promote coating uniformity.

Abstract: Chemical vapor deposition is performed using a plurality of expanding thermal plasma generating means to produce a coating on a substrate, such as a thermoplastic and especially a polycarbonate substrate. The substrate is preferably moved past the generating means. Included are methods which coat both sides of the substrate or which employ multiple sets of generating means, either in a single deposition chamber or in a plurality of chambers for deposition of successive coatings. The substrate surfaces spaced from the axes of the generating means are preferably heated to promote coating uniformity.