A composition for use in forming a fuel cell matrix includes a support material, an electrolyte material, and an additive material that includes a plurality of flakes having an average length in a range of 5 to 40 micrometers and an average thickness of less than 1 micrometer.

A composition for use in forming a fuel cell matrix includes a support material, an electrolyte material, and an additive material that includes a plurality of flakes having an average length in a range of 5 to 40 micrometers and an average thickness of less than 1 micrometer.

A fuel cell matrix for use in a molten carbonate fuel cell comprising a support material and an additive material formed into a porous body, and an electrolyte material disposed in pores of the porous body, wherein the additive material is in a shape of a flake and has an average thickness of less than 1 m.

A fuel cell matrix for use in a molten carbonate fuel cell comprising a support material and an additive material formed into a porous body, and an electrolyte material disposed in pores of the porous body, wherein the additive material is in a shape of a flake and has an average thickness of less than 1 m.

A binder solution for an electrolyte matrix for use with molten carbonate fuel cells is provided. The binder solution includes a first polymer with a molecular weight of less than about 150,000 and a second binder with a molecular weight of greater than about 200,000. The binder solution produces an electrolyte matrix with improved flexibility, matrix particle packing density, strength, and pore structure.

A reinforced electrolyte matrix for a molten carbonate fuel cell includes a porous ceramic matrix, a molten carbonate salt provided in the porous ceramic matrix, and at least one reinforcing structure comprised of at least one of yttrium, zirconium, cerium or oxides thereof. The reinforcing structure does not react with the molten carbonate salt. The reinforced electrolyte matrix separates a porous anode and a porous cathode in the molten carbonate fuel cell.

A reinforced electrolyte matrix for a molten carbonate fuel cell includes a porous ceramic matrix, a molten carbonate salt provided in the porous ceramic matrix, and at least one reinforcing structure comprised of at least one of yttrium, zirconium, cerium or oxides thereof. The reinforcing structure does not react with the molten carbonate salt. The reinforced electrolyte matrix separates a porous anode and a porous cathode in the molten carbonate fuel cell.

An electrolyte matrix for use with molten carbonate fuel cells having an enhanced stability and lifetime is provided. The electrolyte matrix includes lithium aluminate as a support material and a coarsening inhibitor. The coarsening inhibitor may be in the form of discrete particles or a dopant present in the support material. The coarsening inhibitor may include MnO.sub.2, Mn.sub.2O.sub.3, TiO.sub.2, ZrO.sub.2, Fe.sub.2O.sub.3, LiFe.sub.2O.sub.3, or mixtures thereof. The coarsening inhibitor prevents the formation of large pores in the electrolyte matrix during operation of the fuel cell, increasing the performance and the service lifetime of the electrolyte matrix.

An electrolyte matrix for use with molten carbonate fuel cells having an enhanced stability and lifetime is provided. The electrolyte matrix includes lithium aluminate as a support material and a coarsening inhibitor. The coarsening inhibitor may be in the form of discrete particles or a dopant present in the support material. The coarsening inhibitor may include MnO.sub.2, Mn.sub.2O.sub.3, TiO.sub.2, ZrO.sub.2, Fe.sub.2O.sub.3, LiFe.sub.2O.sub.3, or mixtures thereof. The coarsening inhibitor prevents the formation of large pores in the electrolyte matrix during operation of the fuel cell, increasing the performance and the service lifetime of the electrolyte matrix.

A rechargeable electrochemical battery cell includes a molten carbonate salt electrolyte whose anion transports oxygen between a metal electrode and an air electrode on opposite sides of the electrolyte, where the molten salt electrolyte is retained inside voids of a porous electrolyte supporting structure sandwiched by the electrodes, and the molten salt includes carbonate including at least one of the alkaline carbonate including Li.sub.2Co.sub.2, NA.sub.2CO.sub.2, and K.sub.2CO.sub.2, having a melting point between 400 C. and 800 C.