Abstract: The disclosure relates to ceramic lithium ion electrolyte membranes and processes for forming them. The ceramic lithium electrolyte membrane may comprise at least one ablative edge. Exemplary processes for forming the ceramic lithium ion electrolyte membranes comprise fabricating a lithium ion electrolyte sheet and cutting at least one edge of the fabricated electrolyte sheet with an ablative laser.

Abstract: A method for making a thin, free-standing ceramic sheet may include drawing a carrier film proximate a casting head and across a casting bed of a tape caster at a rate from about 2 cm/min to about 500 cm/min. Depositing a thin film of ceramic slip less than about 150 ?m on the carrier film with the casting head. The ceramic slip may comprises a ceramic powder with an ultimate crystallite size of less than about 10 ?m dispersed in a fluid vehicle such that the ceramic slip has a ceramic solids fraction of greater than about 20% by volume. The deposited ceramic slip may be dried on the carrier film thereby forming a green ceramic sheet on the carrier film. After the green ceramic sheet is dried, the green ceramic sheet may be sintered.

Abstract: The disclosure relates to ceramic lithium ion electrolyte membranes and processes for forming them. The ceramic lithium electrolyte membrane may comprise at least one ablative edge. Exemplary processes for forming the ceramic lithium ion electrolyte membranes comprise fabricating a lithium ion electrolyte sheet and cutting at least one edge of the fabricated electrolyte sheet with an ablative laser.

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 method for making a thin, free-standing ceramic sheet may include drawing a carrier film proximate a casting head and across a casting bed of a tape caster at a rate from about 2 cm/min to about 500 cm/min. Depositing a thin film of ceramic slip less than about 150 ?m on the carrier film with the casting head. The ceramic slip may comprises a ceramic powder with an ultimate crystallite size of less than about 10 ?m dispersed in a fluid vehicle such that the ceramic slip has a ceramic solids fraction of greater than about 20% by volume. The deposited ceramic slip may be dried on the carrier film thereby forming a green ceramic sheet on the carrier film. After the green ceramic sheet is dried, the green ceramic sheet may be sintered.

Abstract: According to one embodiment of the present invention an electrolyte sheet includes a body of varied thickness, the electrolyte sheet having a textured surface with multiple protruding features. The protruding features form an undercut angle with respect to the normal of the electrolyte sheet, the undercut angle being more than 0 degrees and less than 15 degrees.

Abstract: According to one embodiment of the present invention an electrolyte sheet includes a body of varied thickness, the electrolyte sheet having a textured surface with multiple protruding features. The protruding features form an undercut angle with respect to the normal of the electrolyte sheet, the undercut angle being more than 0 degrees and less than 15 degrees.