Abstract: Disclosed is an exemplary test apparatus having an autoclave head, a fretting mechanism connected on a first end to a first side of the autoclave head, a load train operably connected with a first end of the fretting mechanism, an autoclave adapter connected on a first side to a second side of the autoclave head, and a force balance assembly connected to a second side of the autoclave head and configured to equalize a pressure acting on the load train. Certain exemplary embodiments include an upper plate, a plurality of upper tie rods connected to a first side of the upper plate and a second side of the autoclave adapter, a lower plate, a plurality of lower tie rods connected to the first side of the autoclave head and a first side of the lower plate, and a pressure vessel sealingly connected to the first side of the autoclave head.

Abstract: Disclosed is an exemplary test apparatus having an autoclave head, a fretting mechanism connected on a first end to a first side of the autoclave head, a load train operably connected with a first end of the fretting mechanism, an autoclave adapter connected on a first side to a second side of the autoclave head, and a force balance assembly connected to a second side of the autoclave head and configured to equalize a pressure acting on the load train. Certain exemplary embodiments include an upper plate, a plurality of upper tie rods connected to a first side of the upper plate and a second side of the autoclave adapter, a lower plate, a plurality of lower tie rods connected to the first side of the autoclave head and a first side of the lower plate, and a pressure vessel sealingly connected to the first side of the autoclave head.

Abstract: A solid oxide fuel cell module contains a plurality of integral bundle assemblies, the module containing a top portion with an inlet fuel plenum and a bottom portion receiving air inlet feed and containing a base support, the base supports dense, ceramic exhaust manifolds which are below and connect to air feed tubes located in a recuperator zone, the air feed tubes passing into the center of inverted, tubular, elongated, hollow electrically connected solid oxide fuel cells having an open end above a combustion zone into which the air feed tubes pass and a closed end near the inlet fuel plenum, where the fuel cells comprise a fuel cell stack bundle all surrounded within an outer module enclosure having top power leads to provide electrical output from the stack bundle, where the fuel cells operate in the fuel cell mode and where the base support and bottom ceramic air exhaust manifolds carry from 85% to all 100% of the weight of the stack, and each bundle assembly has its own control for vertical and horizont

Abstract: A plurality of integral bundle assemblies contain a top portion with an inlet fuel plenum and a bottom portion containing a base support, the base supports a dense, ceramic air exhaust manifold having four supporting legs, the manifold is below and connects to air feed tubes located in a recuperator zone, the air feed tubes passing into the center of inverted, tubular, elongated, hollow electrically connected solid oxide fuel cells having an open end above a combustion zone into which the air feed tubes pass and a closed end near the inlet fuel plenum, where the open end of the fuel cells rest upon and within a separate combination ceramic seal and bundle support contained in a ceramic support casting, where at least one flexible cushion ceramic band seal located between the recuperator and fuel cells protects and controls horizontal thermal expansion, and where the fuel cells operate in the fuel cell mode and where the base support and bottom ceramic air exhaust manifolds carry from 85% to all of the weight

Abstract: A solid oxide fuel cell generator is provided for electrochemically reacting a fuel gas with a flowing oxidant gas at an elevated temperature to produce power. The generator includes a generator section receiving a fuel gas and a plurality of elongated fuel cells extending through the generator section and having opposing open fuel cell ends for directing an oxidant gas between opposing plena in the generator. A sealant defines a seal on the fuel cells adjacent at least one of the fuel cell ends. The sealant is a modified lanthanum borate aluminosilicate glass composition having a minimal amount of boron oxide and silica, and in which the sealant maintains substantially constant physical characteristics throughout multiple thermal cycles.

Abstract: A solid oxide fuel cell (400) is made having a tubular, elongated, hollow, active section (445) which has a cross-section containing an air electrode (452) a fuel electrode (454) and solid oxide electrolyte (456) between them, where the fuel cell transitions into at least one inactive section (460) with a flattened parallel sided cross-section (462, 468) each cross-section having channels (472, 474, 476) in them which smoothly communicate with each other at an interface section (458).

Abstract: A fuel cell generator including a housing defining a plurality of chambers including a generator chamber having first and second generator sections. A plurality of elongated fuel cells extend through the first and second generator sections. An oxidant supply supplies oxidant to at least one of the chambers within the housing in order to provide oxidant to one end of each of the fuel cells. A fuel distribution plenum extends transversely to the elongated fuel cells and is located between the first and second generator sections. The fuel distribution plenum distributes fuel to the first and second generator sections in opposing directions within the generator chamber.

Abstract: A contact used to electrically connect High-temperature density fuel cells together is provided. The contact includes at least one hollow cord which each has at least three contact surfaces with the fuel cell, of which two contact surfaces connect neighboring anode surfaces and the third contact surface connects the interconnector of the next High-temperature density fuel cell. A method for producing a fuel cells system including high-power density fuel cells is also provided.

Abstract: A solid oxide fuel cell module contains a plurality of integral bundle assemblies, the module containing a top portion with an inlet fuel plenum and a bottom portion receiving air inlet feed and containing a base support, the base supports dense, ceramic exhaust manifolds which are below and connect to air feed tubes located in a recuperator zone, the air feed tubes passing into the center of inverted, tubular, elongated, hollow electrically connected solid oxide fuel cells having an open end above a combustion zone into which the air feed tubes pass and a closed end near the inlet fuel plenum, where the fuel cells comprise a fuel cell stack bundle all surrounded within an outer module enclosure having top power leads to provide electrical output from the stack bundle, where the fuel cells operate in the fuel cell mode and where the base support and bottom ceramic air exhaust manifolds carry from 85% to all 100% of the weight of the stack, and each bundle assembly has its own control for vertical and horizont

Abstract: A plurality of integral bundle assemblies contain a top portion with an inlet fuel plenum and a bottom portion containing a base support, the base supports a dense, ceramic air exhaust manifold having four supporting legs, the manifold is below and connects to air feed tubes located in a recuperator zone, the air feed tubes passing into the center of inverted, tubular, elongated, hollow electrically connected solid oxide fuel cells having an open end above a combustion zone into which the air feed tubes pass and a closed end near the inlet fuel plenum, where the open end of the fuel cells rest upon and within a separate combination ceramic seal and bundle support contained in a ceramic support casting, where at least one flexible cushion ceramic band seal located between the recuperator and fuel cells protects and controls horizontal thermal expansion, and where the fuel cells operate in the fuel cell mode and where the base support and bottom ceramic air exhaust manifolds carry from 85% to all of the weight

Abstract: A solid oxide fuel cell (400) is made having a tubular, elongated, hollow, active section (445) which has a cross-section containing an air electrode (452) a fuel electrode (454) and solid oxide electrolyte (456) between them, where the fuel cell transitions into at least one inactive section (460) with a flattened parallel sided cross-section (462, 468) each cross-section having channels (472, 474, 476) in them which smoothly communicate with each other at an interface section (458).

Abstract: A solid oxide fuel cell generator is provided for electrochemically reacting a fuel gas with a flowing oxidant gas at an elevated temperature to produce power. The generator includes a generator section receiving a fuel gas and a plurality of elongated fuel cells extending through the generator section and having opposing open fuel cell ends for directing an oxidant gas between opposing plena in the generator. A sealant defines a seal on the fuel cells adjacent at least one of the fuel cell ends. The sealant is a modified lanthanum borate aluminosilicate glass composition having a minimal amount of boron oxide and silica, and in which the sealant maintains substantially constant physical characteristics throughout multiple thermal cycles.

Abstract: A high temperature fuel cell generator (10) having a housing (12) containing a top air feed plenum (80), a bottom fuel inlet (54), a fuel reaction generator chamber (62) containing fuel cells (42) and a reacted fuel-reacted air combustion chamber (38) above the fuel reaction generator chamber (62), where inlet air (14) can be heated internally within the housing in at least one interior heat transfer zone/block (92) located between the reacted fuel-reacted air combustion chamber (38) and the air feed plenum (80).

Abstract: A fuel cell generator apparatus contains at least one fuel cell assembly module with at least one subassembly containing fuel cells, where the subassemblies are fueled at their base by a fuel feed injector attached to a fuel feed pre-reformer connected to fuel distribution manifolds; and where a module housing encloses the subassemblies and is in turn surrounded by a vessel having two ends providing a purge gas space between the housing and vessel; and where at least one fuel gas feed inlet, gaseous oxidant-purge gas feed inlet, and vessel exhaust gas outlet pass through the vessel; where the vessel can be used for pressurized or non-pressurized operation and is preferably tubular.

Abstract: A fuel cell generator apparatus contains at least one fuel cell subassembly module in a module housing, where the housing is surrounded by a pressure vessel such that there is an air accumulator space, where the apparatus is associated with an air compressor of a turbine/generator/air compressor system, where pressurized air from the compressor passes into the space and occupies the space and then flows to the fuel cells in the subassembly module, where the air accumulation space provides an accumulator to control any unreacted fuel gas that might flow from the module.

Abstract: A solid oxide fuel cell generator (10) contains stacks (20) of hollow, tubular axially elongated fuel cells (36) which can operate to generate electricity; a single oxidant inlet plenum (52) including a bottom enclosing member, having hole therethrough which acts as an oxidant feed tube positioning board (77); a fuel inlet plenum (11); an oxidant/fuel exhaust chamber (94); power leads (32) electrically connected to the fuel cells transverse to the axis (36′) of the fuel calls; and a plurality of oxidant feed tubes (51); all surrounded by insulation (76); where there are at least two fuel cell stacks arranged in a row next to each other, the oxidant feed tube positioning board at the bottom of the oxidant inlet plenum is a laminate of layers of porous alumino-silicate ceramic fibers bonded with a ceramic alumina binder and dense woven ceramic (78) impregnated with ceramic adhesive (79), and wherein the insulation constitutes, primarily, bulk ceramic fibers.

Abstract: A fuel cell generator apparatus contains at least one fuel cell subassembly module in a module housing, where the housing is surrounded by a pressure vessel such that there is an air accumulator space, where the apparatus is associated with an air compressor of a turbine/generator/air compressor system, where pressurized air from the compressor passes into the space and occupies the space and then flows to the fuel cells in the subassembly module, where the air accumulation space provides an accumulator to control any unreacted fuel gas that might flow from the module.

Abstract: A fuel cell generator apparatus contains at least one fuel cell assembly module with at least one subassembly containing fuel cells, where the subassemblies are fueled at their base by a fuel feed injector attached to a fuel feed pre-reformer connected to fuel distribution manifolds; and where a module housing encloses the subassemblies and is in turn surrounded by a vessel having two ends providing a purge gas space between the housing and vessel; and where at least one fuel gas feed inlet, gaseous oxidant-purge gas feed inlet, and vessel exhaust gas outlet pass through the vessel; where the vessel can be used for pressurized or non-pressurized operation and is preferably tubular.

Abstract: A solid oxide fuel cell generator (10) contains stacks (20) of hollow, tubular axially elongated fuel cells (36) which can operate to generate electricity; a single oxidant inlet plenum (52) including a bottom enclosing member, having holes therethrough which acts as an oxidant feed tube positioning board (77); a fuel inlet plenum (11); an oxidant/fuel exhaust chamber (94); power leads (32) electrically connected to the fuel cells transverse to the axis (36′) of the fuel calls; and a plurality of oxidant feed tubes (51); all surrounded by insulation (76); where there are at least two fuel cell stacks arranged in a row next to each other, the oxidant feed tube positioning board at the bottom of the oxidant inlet plenum is a laminate of layers of porous alumino-silicate ceramic fibers bonded with a ceramic alumina binder and dense woven ceramic (78) impregnated with ceramic adhesive (79), and wherein the insulation constitutes, primarily, bulk ceramic fibers.

Abstract: A solid oxide fuel assembly is made, wherein rows (14, 24) of fuel cells (16, 18, 20, 26, 28, 30), each having an outer interconnection (36) and an outer electrode (32), are disposed next to each other with corrugated, electrically conducting expanded metal mesh (22) between each row of cells, the corrugated mesh (22) having top crown portions (40) and bottom shoulder portions (42), where the top crown portion (40) contacts outer interconnections (36) of the fuel cells (16, 18, 20) in a first row (14), and the bottom shoulder portions (42) contacts outer electrodes (32) of the fuel cells in a second row (24), said mesh electrically connecting each row of fuel cells, and where there are no metal felt connections between any fuel cells.