Abstract: Methods of sealing a bipolar plate supported solid oxide fuel cell with a sealed anode compartment are provided. The solid oxide fuel cell includes a cathode, an electrolyte, and an anode, which are supported on a metallic bipolar plate assembly including gas flow fields and the gas impermeable bipolar plate. The electrolyte and anode are sealed into an anode compartment with a metal perimeter seal. An improved method of sealing is provided by extending the metal seal around the entire perimeter of the cell between an electrolyte and the bipolar plate to form the anode compartment. During a single-step high temperature sintering process the metal seal bonds to the edges of the electrolyte and anode layers, the metal foam flow field and the bipolar plate to form a gastight containment.

Abstract: Methods of sealing a bipolar plate supported solid oxide fuel cell with a sealed anode compartment are provided. The solid oxide fuel cell includes a cathode, an electrolyte, and an anode, which are supported on a metallic bipolar plate assembly including gas flow fields and the gas impermeable bipolar plate. The electrolyte and anode are sealed into an anode compartment with a metal perimeter seal. An improved method of sealing is provided by extending the metal seal around the entire perimeter of the cell between an electrolyte and the bipolar plate to form the anode compartment. During a single-step high temperature sintering process the metal seal bonds to the edges of the electrolyte and anode layers, the metal foam flow field and the bipolar plate to form a gastight containment.

Abstract: A bipolar plate supported solid oxide fuel cell with a sealed anode compartment is provided. The solid oxide fuel cell includes a cathode, an electrolyte, and an anode, which are supported on a metallic bipolar plate assembly including gas flow fields and the gas impermeable bipolar plate. The electrolyte and anode are sealed into an anode compartment with a metal perimeter seal. An improved method of sealing is provided by extending the metal seal around the entire perimeter of the cell between an electrolyte and the bipolar plate to form the anode compartment. During a single-step high temperature sintering process the metal seal bonds to the edges of the electrolyte and anode layers, the metal foam flow field and the bipolar plate to form a gastight containment.

Abstract: A method for preparing compositionally graded metallic plates and compositionally graded metallic plates suitable for use as interconnects for solid oxide fuel cells are provided. The method of the invention, utilizing powder metallurgy, enables making metallic plates of generally any desired composition to meet the corrosion requirements of fuel cells and other applications, and enables making metallic plates of graded composition from one surface of the plate to the other. A powder of the desired alloy composition is obtained, then solvents, dispersants, a plasticizer and an organic binder are added to form a slip. The slip is then formed into a layer on a desired substrate that can be flat or textured. Once dried, the layer is removed from the substrate and the binder is burned out. The layer is sintered in a reducing atmosphere at a set temperature for a predefined duration specific to the materials used and the desired final properties.

Abstract: A method for preparing compositionally graded metallic plates and compositionally graded metallic plates suitable for use as interconnects for solid oxide fuel cells are provided. The method of the invention, utilizing powder metallurgy, enables making metallic plates of generally any desired composition to meet the corrosion requirements of fuel cells and other applications, and enables making metallic plates of graded composition from one surface of the plate to the other. A powder of the desired alloy composition is obtained, then solvents, dispersants, a plasticizer and an organic binder are added to form a slip. The slip is then formed into a layer on a desired substrate that can be flat or textured. Once dried, the layer is removed from the substrate and the binder is burned out. The layer is sintered in a reducing atmosphere at a set temperature for a predefined duration specific to the materials used and the desired final properties.

Abstract: A solid oxide fuel cell (SOFC) repeat unit includes an oxide electrolyte, an anode, a metallic fuel flow field, a metallic interconnect, and a metallic air flow field. The multilayer laminate is made by casting tapes of the different functional layers, laminating the tapes together and sintering the laminate in a reducing atmosphere. Solid oxide fuel cell stacks are made by applying a cathode layer, bonding the unit into a gas manifold plate, and then stacking the cells together. This process leads to superior mechanical properties in the SOFC due to the toughness of the supporting metallic layers. It also reduces contact resistances in stacking the cells since there is only one physical contact plane for each repeat unit.