Abstract: Flow cell systems are provided. Example flow cell systems can include an H+/H2 half-cell and a counterpart Fe3+/Fe2+ or V5+/V4+ half-cell. Flow cell systems can also include a half-cell in fluid communication with an electrolyte regeneration chamber. Embodiments of these flow cells systems can be configured to produce hydrogen through electrolysis. Flow cell battery systems are also disclosed. Example flow cell battery systems can include an H+/H2 analyte; and a counterpart Fe3+/Fe2+ or V5+/V4+ catholyte. Processes for generating hydrogen are also disclosed. Example processes can include generating protons from a Fe3+/Fe2+ or V5+/V4+ electrolyte solution; and reacting the protons with H2O to form H2.

Abstract: A glass ceramic composition for sealing adjacent metal cassettes in an SOFC stack. The seal composition comprises an alumina-silicate glass ceramic matrix or a matrix of Zr2 and a ceramic fiber aggregate and non-fibrous zirconia dispersed in the matrix. Preferably, the fiber is selected from the group consisting of zirconium oxide fiber, alumina fiber, and combinations thereof. Preferably, the fiber is present at 1-60 weight percent with respect to the weight of glass ceramic, preferably about 30 weight percent. Preferably, the zirconia fiber is stabilized by up to about 10% yttria. Alumina fiber may substitute for a portion of the zirconia fiber. Preferably, the non-fibrous zirconia is present at about 5 weight percent and is also stabilized.

Abstract: A method for forming an anode supported electrochemical device, such as a SOFC, is disclosed. A thin layer of electrolyte 310 is supported on an anode layer comprised of an active anode layer 320 and a bulk anode layer 340. The bulk anode layer includes silicon carbide 340 in an amount between about 0.5 and 10% by weight. A cathode layer on an opposing side of the electrolyte completes the cell. The presence of the silicon carbide 340 in the supporting anode layer 340 has been found to reduce room temperature camber due to thermal expansion coefficient mismatches.

Abstract: An anode supported electrochemical device, such as a SOFC, is disclosed. A thin layer of electrolyte 310 is supported on an anode layer comprised of an active anode layer 320 and a bulk anode layer 340. The bulk anode layer includes silicon carbide 340 in an amount between about 0.5 and 10% by weight. A cathode layer on an opposing side of the electrolyte completes the cell. The presence of the silicon carbide 340 in the supporting anode layer 340 has been found to reduce room temperature camber due to thermal expansion coefficient mismatches.

Abstract: Islanding in metal layers on a dielectric material can be reduced by using a wetting agent between the metal layer and the dielectric material. One embodiment of the present invention encompasses a method comprising the steps of depositing a ceria layer on the dielectric material and depositing the metal layer on the ceria layer, wherein the ceria layer is the wetting agent for the metal layer. Another embodiment encompasses a multi-layer ceramic capacitor comprising a repeat layer having a base metal electrode formed on a ceria layer, which is deposited on a dielectric layer.

Abstract: A modular fuel cell cassette for use in assembling a fuel cell stack comprising a metal separator plate and a metal cell-mounting plate joined at their edges to form a hollow cassette. A fuel cell subassembly is attached to the mounting plate and extends through an opening in the mounting plate. The plates include openings to form chimney manifolds for supply and exhaust of fuel gas to the anode and air to the cathode. A conductive interconnect element extends from the fuel cell subassembly to make contact with the next cassette in a stack. The anode openings in the mounting plate and separator plate are separated by spacer rings such that the cassette is incompressible. A fuel cell stack comprises a plurality of cassettes, the mounting plate of one cassette being attached to, and insulated from, the separator plate of the next-adjacent cassette by a dielectric seal surrounding the interconnect.

Abstract: A seal formed between a metal part and a second part that will remain gas tight in high temperature operating environments which experience frequent thermal cycling, which is particularly useful as an insulating joint in solid oxide fuel cells. A first metal part is attached to an reinforcing material. A glass forming material in the positioned in between the first metal part and the second part, and a seal is formed between the first metal part and the second part by heating the glass to a temperature suitable to melt the glass forming materials. The glass encapsulates and bonds at least a portion of the reinforcing material, thereby adding tremendous strength to the overall seal. A ceramic material may be added to the glass forming materials, to assist in forming an insulating barrier between the first metal part and the second part and to regulating the viscosity of the glass during the heating step.

Abstract: A seal formed between a metal part and a second part that will remain gas tight in high temperature operating environments which experience frequent thermal cycling, which is particularly useful as an insulating joint in solid oxide fuel cells. A first metal part is attached to a reinforcing material. A glass forming material in the positioned in between the first metal part and the second part, and a seal is formed between the first metal part and the second part by heating the glass to a temperature suitable to melt the glass forming materials. The glass encapsulates and bonds at least a portion of the reinforcing material, thereby adding tremendous strength to the overall seal. A ceramic material may be added to the glass forming materials, to assist in forming an insulating barrier between the first metal part and the second part and to regulating the viscosity of the glass during the heating step.

Abstract: In one embodiment, the method of producing a ceramic assembly includes: disposing an electrode precursor on an electrolyte precursor having an electrolyte sintering shrinkage, disposing a stabilizer precursor having a stabilizer sintering shrinkage on the electrode precursor on a side opposite the electrolyte precursor to form a precursor assembly, and sintering the precursor assembly to form the ceramic assembly comprising a stabilizer layer, electrode, and electrolyte. The difference between the electrolyte sintering shrinkage and the stabilizer sintering shrinkage is less than or equal to ±1% and a surface of the ceramic assembly has less than or equal to about 5.0 degrees camber, as measured from the horizontal plane.

Abstract: A ceramic membrane element for an oxygen separator is formed from a ceramic material represented by the structure: A1-xA′xB1-yB′yO3-z where A is a lanthanide element; A′ is a suitable lanthanide element dopant; B is selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, zinc and mixtures thereof; B′ is copper; x is between 0.4 and 0.8; y is between 0.1 and 0.9; and z is>0 (and determined by stoichiometry). When B includes cobalt in an amount greater than 0.1, the included iron content is less than 0.05. The membrane element selectively transports oxygen ions therethrough at a relatively low temperature, with a flux detected at about 600° C. This enables the oxygen separator to be operated at lower temperatures than convention separators that frequently have operating temperatures in excess of 900° C. Mechanical stability may be enhanced by the addition of a second phase to the ceramic.