Abstract: Flexible ceramic sheets with enhanced strain tolerance for electrochemical applications such as solid oxide fuel cell electrolytes incorporate a surface indentation pattern providing a strain tolerance of not less than 0.5% in any direction in the sheet plane, being made from flexible green ceramic sheet comprising a ceramic powder and a thermoplastic organic binder by heating and reshaping the green sheet to form a multi-directional surface corrugation pattern therein, followed by firing to sinter the ceramic powder to a flexible ceramic sheet having a multi-directional surface corrugation pattern.

Abstract: Solid oxide fuel cell assemblies comprise packets of multi-cell-sheet devices based on compliant solid oxide electrolyte sheets that form a fuel chamber and support anodes interiorly and cathodes exteriorly of the chamber that can be electrically interconnected to provide a compact, high voltage power-generating unit; added frames can support the oxide sheets and incorporate fuel supply and air supply conduits or manifolds permitting stacking of the assemblies into fuel cell stacks of any required size and power-generating capacity.

Abstract: A honeycomb structure for a diesel engine or an automotive engine where the wall thickness is varied in a controlled manner from the front surface to the back of the honeycomb. One example is grading the web thickness continuously from thin webs on the front of the DPF to thick webs on the back of the DPF. Another example is to make a two layer honeycomb with thinner walls and/or perhaps even lower cell density on the upstream side of the honeycomb. This provides a lower thermal mass front while retaining the thicker webs and higher thermal mass at the back of the honeycomb. The honeycomb structure has a thermal mass or heat capacity ranging from above 8.5×10−3cal/cubic cm-K to below 0.25 cal/cubic cm-K along an axis from the inlet end to the outlet end.

Abstract: The present invention relates to an electrolyte structure coated on at least one surface with a roughened interfacial nano-crystalline layer. Another aspect of the present invention is a solid oxide fuel cell which includes a positive air electrode, a negative fuel electrode, an electrolyte structure interposed between the positive air electrode and negative fuel electrode, and a roughened interfacial nano-crystalline layer interposed between the electrolyte structure and at least one of the positive air electrode and negative fuel electrode. The present invention also relates to methods of making the coated electrolyte and solid oxide fuel cell.

Abstract: The present invention relates to a fuel cell apparatus which includes arrays of positive air electrodes and negative fuel electrodes with via interconnections disposed on an electrolyte sheet; optional electrode designs include symmetric electrodes comprising a conductive silver alloy metal phase and a thermally stabilizing ceramic phase, the latter providing low interface resistance and matching thermal properties.

Abstract: A ceramic filter for trapping and combusting diesel exhaust particulates offering improved configurations that are significantly more resistant to thermal cracking and melting damage comprises a honeycomb filter body composed of porous ceramic material and including a plurality of parallel cell channels traversing the body from a frontal inlet end to an outlet end thereof, a portion of the cell channels are plugged in a non-checkered pattern, and the remaining cell channels are plugged in a checkered pattern. In one embodiment the honeycomb filter body has a section of non-checkered and a section of checkered plugging at the frontal inlet end. In another embodiment the honeycomb filter body has a plurality of cell channels internal plugs. In another embodiment the honeycomb filter body has a plurality of partial cell channels which extend partially from the frontal inlet end into the honeycomb filter body, and are unplugged at the frontal inlet end.

Abstract: Flexible ceramic sheets with enhanced strain tolerance for electrochemical applications such as solid oxide fuel cell electrolytes incorporate a surface indentation pattern providing a strain tolerance of not less than 0.5% in any direction in the sheet plane, being made from flexible green ceramic sheet comprising a ceramic powder and a thermoplastic organic binder by heating and reshaping the green sheet to form a multidirectional surface corrugation pattern therein, followed by firing to sinter the ceramic powder to a flexible ceramic sheet having a multi-directional surface corrugation pattern.

Abstract: The present invention relates to electrode/electrolyte assemblies for solid oxide fuel cells (SOFCs) comprising a thin electrolyte sheet interposed between opposite electrodes, and wherein the positive air electrode (cathode) and negative fuel electrode (anode) are composed of similar electronically conductive metal phases and stabilizing ceramic phases, and wherein the anode exhibits both good oxidation resistance and good catalytic activity toward fuel oxidation.

Abstract: The present invention relates to a compliant fuel cell apparatus which includes arrays of positive air electrodes and negative fuel electrodes with via interconnections disposed on a thin compliant electrolyte sheet; optional electrode designs include symmetric electrodes comprising a conductive silver alloy metal phase and a thermally stabilizing ceramic phase, the latter providing low interface resistance and matching thermal properties, with the resulting fuel cells remaining sufficiently compliant to demonstrate good resistance to thermal shock damage.

Abstract: Fuel cell designs incorporating non-planar inorganic electrolyte membranes offer improved mechanical and thermal shock resistance for mobile power generation systems, e.g., for high temperature fuel cell applications using liquid fuel (diesel and gasoline) and air for automobile power plants and other power systems requiring only intermittent high-temperature fuel cell operation.

Abstract: The invention is directed at an engine exhaust system comprising: (1) a main catalyst located downstream from engine; (2) a honeycomb adsorber structure having an inlet and outlet end disposed in a housing and located downstream from the main catalyst, the honeycomb structure having a first substantially unobstructed flow region (a by-pass port) having an inlet face, and a second more obstructed flow region adjacent the first region (plurality of channels) having a second inlet face, the inlet face of the first region located upstream that of the inlet face of the second region; (3) a fluidics apparatus disposed in the housing and comprising a diverter body located upstream and proximate to the inlet face of the first region, a diversion fluid source conduit for directing the diversion fluid, proximate the diverter body; and, (4) a burn-off catalyst located downstream of the honeycomb adsorber.

Abstract: The invention is directed at an exhaust system exhibiting an increased flow uniformity under diversion conditions comprising: (1) a honeycomb structure having an inlet and outlet end disposed in a housing located in an exhaust gas stream and downstream from an engine, and having a first substantially unobstructed flow region, and a second more obstructed flow region adjacent the first region, both providing a flow path for the exhaust gases in the exhaust gas stream; and, (2) a fluidics apparatus disposed in the exhaust stream comprising a diverter body located proximate to the first region, a diversion fluid source, a conduit for directing the diversion fluid toward the diverter body and an exhaust flow divergent device.

Abstract: The present disclosure is directed to a novel honeycomb substrate, an extrusion die apparatus for forming the novel substrate, as well as a method for extruding the honeycomb structure. This inventive honeycomb structure possesses a matrix of straight cell walls defining a plurality of straight flow cells running generally parallel to the axis of extrusion, as well as a matrix of cross-directional or corrugated cell walls defining a plurality of flow channels some of which may be at an angle, preferably perpendicular to the axis of extrusion or to the straight flow channels. The extrusion die apparatus is generally comprised of primary and secondary feed holes and associated discharge slots and, preferably a device for causing buckling of the extrudate which exits the primary slots.

Abstract: The instant invention is directed at an in-line engine exhaust system comprised of the following: (1) a first close-coupled catalyzed structure located in the exhaust stream, the catalyzed structure having an inlet and an outlet end disposed in a housing, a lightoff temperature, and comprising a first substantially unobstructed flow region, and a second more obstructed flow region abutting the first region, the first region being disposed to provide a substantially unobstructed flow path for exhaust gases in the exhaust gas stream; and, (2) a flow diverter connected to a secondary air source and disposed in the housing for diverting the exhaust gases away from the first region. Furthermore, the exhaust system may be provided with a second catalyzed structure located in the exhaust gas stream downstream from the housing. Also disclosed herein is a method of treating a hydrocarbon-containing engine exhaust steam utilizing the aforementioned inventive exhaust system.

Abstract: Thin inorganic sintered structures having strength and flexibility sufficient to permit bending without breakage in at least one direction to a radius of curvature of less than 20 centimeters, methods for making them, and products incorporating them, are described. Preferred sintered ceramic structures according to the invention can comprise zirconias, titanias, aluminas, silicas, rare earth metal oxides, alkaline oxides, alkaline earth metal oxides and first, second, and third transition series metal oxides and combinations thereof and therebetween. Sintered metal structures can also be provided.

Abstract: The present invention is directed to a novel method for extruding a honeycomb structure. The method comprises the use of an extrusion die with primary and secondary feed holes and associated discharge slots, wherein extruded material exits the primary discharge slots at a faster rate than the secondary discharge slots. The faster moving extruded material buckles and forms a corrugated layer in between the two secondary extruded layers. The secondary extruded layers form straight cells. The material to be extruded maybe ceramic, plastic or metal.

Abstract: The present invention is directed to an in-line engine exhaust system. In general, the exhaust system is comprised of the following: (1) a honeycomb structure having an inlet and outlet end disposed in a housing and located in an exhaust gas stream downstream from an engine and possessing a first substantially unobstructed flow region, a second more obstructed flow region adjacent the first region; and, (2) a fluidics apparatus disposed in the exhaust stream proximate to the first region for creating a negative flow zone within the first region, which in turn results in diverting a portion of the exhaust gases away from the first region. More specifically, the fluidics apparatus includes a source diversion fluid, typically air, a conduit for delivering the diversion fluid and a diverter body for diverting the diversion fluid.

Abstract: A engine exhaust system is disclosed for reducing the amount of hydrocarbons emitted during engine start-up (cold-start), before the catalytic converter has attained its effective operating temperature. The system includes a flow diverter, in particular a secondary air jet adapted to direct substantially all of the engine exhaust through a molecular sieve structure during cold-start, and to direct the engine exhaust stream directly from the light-off catalyst to the burnoff catalyst, bypassing the molecular sieve structure after light-off.

Abstract: Flow-through fluid heaters useful, e.g., for the preheating of exhaust gas streams prior to catalytic treatment thereof, are made by bonding an electrically conductive metallic film or foil to at least one pre-sintered flexible ceramic foil substrate to provide a flexible, electrically conductive ceramic/metallic heating element, that element then being formed into a crimped sheet or base sheet for incorporation into a honeycomb structure which includes a plurality of open channels extending from one surface of the structure to another surface of the structure, formed by one or more contacting combinations of crimped sheet and base sheet. Catalytic coatings may be applied to the preheaters to provide a heater/converter with very rapid light-off characteristics.

Abstract: A method of forming complex shapes from soft solvent-containing batches and maintaining the integrity of such formed bodies. The formed bodies are made self-supporting immediately after forming or soon thereafter by contacting the shaped body with a drying or hardening liquid in which the solvent is soluble. A method is also disclosed for simultaneously drying a formed body and creating or increasing the porosity of the body by adding solid particles which are soluble in the drying liquid.