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 solid oxide fuel cell comprising a thin ceramic electrolyte sheet having an increased street width is disclosed. Also disclosed are solid oxide fuel cells comprising: a substantially flat ceramic electrolyte sheet, a substantially flat ceramic electrolyte sheet having a seal area of greater thickness than the active area of the electrolyte sheet, a ceramic electrolyte sheet that overhangs the seal area, a ceramic electrolyte sheet and at least one substantially flat border material, and a border material having a non-linear edge. Methods of making a solid oxide fuel cell in accordance with the disclosed embodiments are also disclosed. Also disclosed are methods of making a solid oxide fuel cell wherein the seal has a uniform thickness, wherein the seal is heated to remove a volatile component prior to sealing, and wherein the distance between the frame and the ceramic electrolyte sheet of the device is constant.

Abstract: The invention provides a protected metal anode architecture comprising: a metal anode layer; and an organic protection film formed over and optionally in direct contact with the metal anode layer, wherein the metal anode layer comprises a metal selected from the group consisting of an alkaline metal and an alkaline earth metal, and the organic protection film comprises a reaction product of the metal and an electron donor compound. The invention further provides a method of forming a protected metal anode architecture.

Abstract: Disclosed are composite electrodes for use in a solid oxide fuel cell devices. The electrodes are comprised of a sintered mixture of lanthanum strontium ferrite phase and yttria stabilized zirconia phase. The lanthanum strontium ferrite phase has the general formula (LaxSry)i±?(FeaMnbCoc)O3; wherein 1.O?x?0.65; 0.35?y?0.0; x+y=1.0, ?=0-0.1, a+b+c=1, and a>0.6. Also disclosed are methods of making the composite electrodes and solid oxide fuel cell devices comprising same.

Abstract: Disclosed is a segmented modular solid oxide fuel cell device having a plurality of independently controllable electrical power producing segments disposed within a common thermal environment. Also disclosed are methods for selectively operating one or more segments of the disclosed segmented modular solid oxide fuel cell device. Also disclosed are methods for performing a maintenance process on one or more segments of a segmented modular fuel cell device during fuel cell operation.

Abstract: Apparatuses and methods for determining the concentration of an analyte gas in a gas stream with a sensor are described. The analyte gas sensor may include a mass-sensitive resonator and a diffusion barrier. The mass-sensitive resonator may be coated with an absorptive material which is reactive with an analyte gas, such as NOx. The diffusion barrier may be positioned to limit a gas flow with the analyte gas towards the absorptive material, and a ratio of the diffusion time of the gas flow through the diffusion barrier to the reaction time of the analyte gas with the absorptive material may be from about 0.1 to about 100.

Abstract: According to one embodiment of the present invention a fuel cell system comprises: (i) a plurality of fuel cell packets, each packet comprising at least one fuel inlet, at least one fuel outlet, a frame, and two multi-cell fuel cell devices, the fuel cell devices situated such that an anode side of one fuel cell device faces an anode side of another fuel cell device, and the two fuel cell devices, in combination, at least partially form a fuel chamber connected to the fuel inlet and the fuel outlet; (ii) a plurality of heat exchange packets, each packet comprising at least one oxidant inlet, at least one oxidant outlet, and an internal oxidant chamber connected to the at least one oxidant inlet and the least one oxidant outlet; the heat exchange packets being parallel to and interspersed between the fuel cell packets, such that the heat exchange packets face the fuel cell packets and form, at least in part, a plurality of cathode reaction chambers between the heat exchange packets and the fuel cell packets; (

Abstract: The invention is directed to insulating compositions for use in solid oxide fuel cells. Such compositions can be used to prevent seal damage and increase the electrical and ion efficiency.

Abstract: An electrolyte sheet comprising two major surfaces, the electrolyte sheet including regions of differing compositions, so that (i) at least one of these regions has at least 1.5 times higher ionic conductivity than at least one other region; (ii) wherein the at least one other region has 20% more tetragonal phase zirconia per volume than the least one region with higher ionic conductivity; and (iii) when viewed in cross-section taken through said major surfaces at least one of the regions exhibits a non-uniform thickness.

Abstract: A stress reducing mounting for an electrolyte sheet assembly in a solid electrolyte fuel cell is provided that includes a support frame or manifold having an inner edge portion that supports a peripheral portion of the sheet assembly, a seal that affixes an edge of the peripheral portion to the frame or manifold, and a stress reducer disposed around the peripheral portion of the electrolyte sheet and the frame or manifold that reduces tensile stress in the peripheral portion of the electrolyte sheet when the peripheral portion is bent by pressure differentials or thermal differential expansion. The stress reducer is at least one of a convex curved surface on the inner edge portion of the frame or manifold that makes area contact with the peripheral portion when it bends in response to a pressure differential or thermal differential expansion, and a stiffening structure on the sheet peripheral portion that renders the ceramic sheet material forming the peripheral portion more resistant to bending.

Abstract: A solid oxide fuel cell device assembly comprising: (i) at least one solid oxide fuel cell device including one electrolyte sheet sandwiched between at least one pair of electrodes; and (ii) a non-steel frame fixedly attached to said at least one fuel cell device without a seal located therebetween.

Abstract: An exemplary fuel cell device assembly includes: (i) an electrolyte sheet; (ii) a plurality of cathodes disposed on one side of the electrolyte sheet; (iii) a plurality of anodes disposed on another side of the electrolyte sheet; and (iv) a frame supporting the electrolyte sheet, the frame having a plurality of channels. Preferably the cross-sectional area of the frame has channel density of at least 20/in2 and channel wall thickness of 50 mils or less.

Abstract: The invention is directed to highly crystalline, frit-sintered glass-ceramic materials and seals made using them that are suitable for solid oxide fuel cell applications. The seals have a coefficient of thermal expansion in the range of 70-130×10?7° C., preferably 85-115×10?7° C. The glass-ceramic materials have a crystalline component and a glass component, the crystalline component being >50% of the glass-ceramic and the glass component being <50%. In one preferred embodiment the crystalline component is >75%. Regarding the crystalline component only, >50% of the crystals in the crystalline component of the glass-ceramic has a structure selected from the structural groups represented by walstromite, cyclowollastonite, ?-(Ca,Sr)SiO3, kalsilite, kaliophilite and wollastonite (the primary crystalline phase) and the remaining <50% of the crystalline component is at least one secondary crystalline phase.

Abstract: Disclosed is a segmented modular solid oxide fuel cell device having a plurality of independently controllable electrical power producing segments disposed within a common thermal environment. Also disclosed are methods for selectively operating one or more segments of the disclosed segmented modular solid oxide fuel cell device. Also disclosed are methods for performing a maintenance process on one or more segments of a segmented modular fuel cell device during fuel cell operation.

Abstract: The invention is directed to highly crystalline, frit-sintered glass-ceramic materials and seals made using them that are suitable for solid oxide fuel cell applications. The seals have a coefficient of thermal expansion in the range of 70-130×10?7° C., preferably 85-115×10?7° C. The glass-ceramic materials have a crystalline component and a glass component, the crystalline component being >50% of the glass-ceramic and the glass component being <50%. In one preferred embodiment the crystalline component is >75%. Regarding the crystalline component only, >50% of the crystals in the crystalline component of the glass-ceramic has a structure selected from the structural groups represented by walstromite, cyclowollastonite, ?-(Ca,Sr)SiO3, kalsilite, kaliophilite and wollastonite (the primary crystalline phase) and the remaining <50% of the crystalline component is at least one secondary crystalline phase.

Abstract: The invention is directed to highly crystalline, frit-sintered glass-ceramic materials and seals made using them that are suitable for solid oxide fuel cell applications. The seals have a coefficient of thermal expansion in the range of 70-130×10?7° C., preferably 85-115×10?7° C. The glass-ceramic materials have a crystalline component and a glass component, the crystalline component being>50% of the glass-ceramic and the glass component being<50%. In one preferred embodiment the crystalline component is >75%. Regarding the crystalline component only,>50% of the crystals in the crystalline component of the glass-ceramic has a structure selected from the structural groups represented by walstromite, cyclowollastonite, ?-(Ca,Sr)SiO3, kalsilite, kaliophilite and wollastonite (the primary crystalline phase) and the remaining <50% of the crystalline component is at least one secondary crystalline phase.

Abstract: A solid oxide fuel cell device assembly comprising: (i) at least one solid oxide fuel cell device including one electrolyte sheet sandwiched between at least one pair of electrodes; and (ii) a non-steel frame fixedly attached to said at least one fuel cell device without a seal located therebetween.

Abstract: An exemplary method of making a fuel cell device assemblies includes the steps of: (i) providing a ceramic batch; (ii) extruding the ceramic batch through a die and a mask to form green extrudate that, in cross-section, has at least 10 cells/in2 and wall thickness of 50 mils or less; (iii) cutting the green extrudate to an appropriate length to form a green frame blank; (iv) sintering the green frame blank at a temperature of at least 1200° C., preferably at a temperature of between 1400° C. and 1600° C. for at least one hour to form a ceramic frame with a plurality of parallel channels; (v) inserting at least one fuel cell array into its designated position within the ceramic frame; and (vi) sealing the at least one fuel cell array to the frame.

Abstract: A solid oxide fuel cell comprising a thin ceramic electrolyte sheet having an increased street width is disclosed. Also disclosed are solid oxide fuel cells comprising: a substantially flat ceramic electrolyte sheet, a substantially flat ceramic electrolyte sheet having a seal area of greater thickness than the active area of the electrolyte sheet, a ceramic electrolyte sheet that overhangs the seal area, a ceramic electrolyte sheet and at least one substantially flat border material, and a border material having a non-linear edge. Methods of making a solid oxide fuel cell in accordance with the disclosed embodiments are also disclosed. Also disclosed are methods of making a solid oxide fuel cell wherein the seal has a uniform thickness, wherein the seal is heated to remove a volatile component prior to sealing, and wherein the distance between the frame and the ceramic electrolyte sheet of the device is constant.

Abstract: A solid oxide fuel cell that is resistant to seal delamination is disclosed. The solid oxide fuel cell comprises, either individually or in combination, a solid electrically non-conductive frame, a seal structure comprising a material capable of preventing a transfer of charge across the seal during fuel cell operation, and a seal comprising a glass frit that is substantially free of oxides of lithium, sodium, or both lithium and sodium. Methods for manufacturing a solid oxide fuel cell are also disclosed.