Abstract: An environmental control system includes a turbomachine and an air cycle machine that is driven by shaft power of the turbomachine. The turbomachine includes a compressor, which supplies compressed bleed air to the air cycle machine. Ambient air is compressed by the compressor, and heat of compression is removed by an air-to-air heat exchanger, which envelops the turbomachine. The cooled, compressed air is expanded in the air cycle machine to produce a stream of cooled, conditioned air. Ambient air used by the air-to-air heat exchanger to cool the compressed bleed air is drawn into the turbomachine's exhaust by an eductor.

Abstract: A unitized solid oxide fuel cell comprises a first electrically conductive interconnect operatively connected to an anode of the fuel cell, with the first interconnect having a first substantially planar portion and a first skirt portion. A second electrically conductive interconnect is operatively connected to a cathode of the fuel cell, with the second interconnect having a second substantially planar portion and a second skirt portion that is juxtaposed to the first skirt portion. A gas inlet is fixed to at least one of the first and second skirt portions while a gas outlet is fixed to at least one of the first and second skirt portions. The gas inlet and outlet can be releasably attached to a gas manifold.

Abstract: A method of fabricating solid oxide fuel cell electrodes, and in particular anodes, includes the steps of forming a microcomposite element comprising a plurality of layers of an electrically conductive tape and an electrolyte tape, with the plurality of layers forming a first electrically conductive pattern. A plurality of microcomposite subelements are created from the microcomposite element, with each microcomposite subelement having the first electrically conductive pattern. A plurality of the microcomposite subelements are juxtaposed to one another and also rotated in planes substantially parallel to one another. Thereby, a totality of the first electrically conductive patterns form a second electrically conductive pattern in the anode. Electrical conduction is established with the patterns all being in electrical contact with one another.

Abstract: A solid oxide fuel cell stack includes a plurality of solid oxide fuel cells juxtaposed to one another, with at least two of the cells having a substantially flat configuration; and each of the two cells having an anode layer, an electrolyte layer, and a cathode layer. The fuel stack also includes at least one interconnect disposed among the plurality of cells, with the interconnect being capable of providing an electrical connection between the cells, and the interconnect comprising a plurality of first extensions on a first surface of the interconnect and a plurality of second depressions on a second surface of the interconnect. The first extensions and second depressions are integrally formed with one another to provide a plurality of oxidant passageways and fuel passageways.

Abstract: A method of fabricating solid oxide fuel cell electrodes, and in particular anodes, includes the steps of forming a microcomposite element comprising a plurality of layers of an electrically conductive tape and an electrolyte tape, with the plurality of layers forming a first electrically conductive pattern. A plurality of microcomposite subelements are created from the microcomposite element, with each microcomposite subelement having the first electrically conductive pattern. A plurality of the microcomposite subelements are juxtaposed to one another and also rotated in planes substantially parallel to one another. Thereby, a totality of the first electrically conductive patterns form a second electrically conductive pattern in the anode. Electrical conduction is established with the patterns all being in electrical contact with one another.

Abstract: A method of preparing a fuel cell element includes the steps of: laminating ceramic tapes to form an unfired anode/electrolyte laminate; reducing the thickness of the anode/electrolyte laminate; sintering the anode/electrolyte laminate; laminating ceramic tapes to form an unfired cathode/interconnect laminate; reducing the thickness of the cathode/interconnect laminate; embossing a gas flow path pattern into the cathode layer of the cathode/interconnect laminate; sintering the cathode/interconnect laminate; and bonding the sintered anode/electrolyte laminate to the sintered cathode/interconnect laminate such that the electrolyte layer contacts the cathode layer. The fuel cell produced by this method has thin electrolyte and interconnect layers which result in high fuel cell outlet power.

Abstract: A fuel cell is made by preparing a first unfired anode ceramic tape and a second unfired electrolyte ceramic tape, with the second ceramic tape being much thinner than the first ceramic tape. The first ceramic tape and the second ceramic tape are laminated together to form an unfired anode/electrolyte laminate, which is rolled to reduce the layer thicknesses. The anode layer is embossed with a gas flow path pattern. A third unfired cathode ceramic tape and a fourth unfired interconnect ceramic tape are prepared, with the fourth ceramic tape being much thinner than the third ceramic tape. The third ceramic tape and the fourth ceramic tape are laminated together to form an unfired cathode/interconnect laminate, which is rolled to reduce the layer thicknesses. The cathode layer is embossed with a gas flow pattern. The two laminates are sintered, stacked, and bonded in the appropriate pattern to form a fuel cell element.

Abstract: A device having a thin ceramic layer therein, is made by preparing a mixture of ceramic particles, a binder, and a plasticizer, and forming the mixture into a ceramic layer. A second layer is placed adjacent to the ceramic layer to form a composite layered structure. The thickness of the composite layered structure is reduced, preferably by rolling, until the ceramic layer portion of the composite layered structure has a preselected small thickness. If desired, the thickness of the ceramic layer can be reduced to an arbitrarily small value by stacking the reduced composite layered structures (or one of the layered structures with another structure) and repeating the reducing operation on the stack. The ceramic layer having the preselected thickness is assembled into a device. Devices that can be prepared by this approach include, for example, multilayer capacitors, solid oxide fuel cells, and solid-electrolyte electrochemical storage cells.

Abstract: A fuel cell comprises an anode, a cathode, a solid electrolyte disposed between the anode and the cathode, and interconnect means for providing an electrical connection located adjacent to either the cathode or the anode but not adjacent to the solid electrolyte. The interconnect means includes an interconnect layer having a composition of (i) a mixture of an electrical conductor and a ceramic matrix material that is sinterable in an oxidizing atmosphere at a temperature of less than about 1500.degree. C., (ii) a mixture of a lanthanum chromite-based ceramic and a yttrium chromite-based ceramic, or (iii) a yttrium chromite-based ceramic of the form Y.sub.w-x-y Ca.sub.x Zr.sub.y Cr.sub.v-z Zn.sub.z O.sub.3 , where w is from about 0.9 to about 1.1, x is from about 0.1 to about 0.3, y is from about 0.001 to about 0.1, z is from about 0.1 to about 0.3, and v is from about 1 to about 1.2.

Abstract: A fuel cell comprises an anode, a cathode, a solid electrolyte disposed between the anode and the cathode, and interconnect means for providing an electrical connection located adjacent to either the cathode or the anode but not adjacent to the solid electrolyte. The interconnect means includes an interconnect layer having a composition of a mixture of an electrical conductor and a ceramic matrix material that is sinterable in an oxidizing atmosphere at a temperature of less than about 1500.degree. C. The interconnect means includes, a first buffer layer having a region with a composition that is intermediate between that of the anode and that of the interconnect layer, a second buffer layer having a region with a composition that is intermediate between that of the cathode and that of the interconnect layer, and the interconnect layer disposed between the first buffer layer and the second buffer layer.

Abstract: In a two-step densifying process of making a monolithic solid oxide fuel cell, a limited number of anode-electrolyte-cathode cells separated by an interconnect layer are formed and partially densified. Subsequently, the partially densified cells are stacked and further densified to form a monolithic array.

Abstract: Manifolds of a solid oxide fuel cell are integrally formed with the fuel cell's core. The fuel cell includes repetitively stacked anode, electrolyte, cathode interconnect gasket elements. The gasket elements space apart the interconnect and electrolyte elements and bound the anode and cathode elements. The interconnect, electrolyte, and gasket elements are provided with cutouts that define manifold passageways for the fuel and oxidant. The gasket elements further prevent the fuel from contacting the cathode elements and the oxidant from contacting the anode elements.

Abstract: A method for preparing an article from a powder includes the step of providing a partially consolidated mixture of a solid powder and an organic binder system. The partially consolidated mixture is contacted with a stiffening solution comprising a stiffening agent that effects at least partial cross-linking of the organic binder system, and a solvent that dissolves the stiffening agent but not the organic binder system. The binder system is thereafter removed, and the article sintered.

Abstract: The invention details a two-step densifying process, method, and apparatus for making a solid oxide ceramic fuel cell. According to the invention, a limited number of anode-electrolyte-cathode cells separated by a single or trilayer interconnect are formed and densified. Subsequently, a plurality of the densified cells are stacked and further processed to form a monolithic array.

Abstract: A monolithic solid oxide fuel cell of the type characterized by a plurality of fuel and oxidant passageways extending through the core of the fuel cell. The fuel cell is constructed only of anode, cathode, electroylte and interconnect materials. The cell is constructed using multilayer tapes formed by first roll milling four individual tapes of cathode, electrolyte, anode, and interconnect material, and then roll milling the multilayer tape from the four tapes of a single material. Passageways are formed within the cathode and anode layers by roll milling elongated organic fibers into the tapes and burning out the fibers during the binder removal, sintering process. A manufacturing process is also disclosed.

Abstract: Production of metallic aluminum by the electrolysis of Al.sub.2 S.sub.3 at 700.degree.-800.degree. C. in a chloride melt composed of one or more alkali metal chlorides, and one or more alkaline earth metal chlorides and/or aluminum chloride to provide improved operating characteristics of the process.