A flow-through redox galvanic cell and a battery is described, where each flow-through galvanic cell is separated into two parts by a metal foil serving as a bi-electrode in contact with two solutions having different redox potentials. Voltage due to redox processes is formed through the foil, and two traditional electrodes (cathode and anode) in each cell are not necessary anymore. The cells in a battery should be in electric contact with each other via ion-selective membranes. The battery is easy to recharge, and it is smaller, lighter, safer and cheaper than known redox-flow batteries. It may be used as a reserve source of energy in electric grids and households. It also may be used in electric cars, and it is especially attractive for use near the seashore and on sea ships.

A flow-through redox galvanic cell and a battery is described, where each flow-through galvanic cell is separated into two parts by a metal foil serving as a bi-electrode in contact with two solutions having different redox potentials. Voltage due to redox processes is formed through the foil, and two traditional electrodes (cathode and anode) in each cell are not necessary anymore. The cells in a battery should be in electric contact with each other via ion-selective membranes. The battery is easy to recharge, and it is smaller, lighter, safer and cheaper than known redox-flow batteries. It may be used as a reserve source of energy in electric grids and households. It also may be used in electric cars, and it is especially attractive for use near the seashore and on sea ships.

Methods and systems are provided for manufacturing a membrane separator for a redox flow battery. In one example, the membrane separator is fabricate by a calendering process. The membrane separator may be configured with a polymer network to provide selectivity for ion transport across the membrane separator. The membrane separator may be further adapted with an integrated spacer in contact with a negative electrolyte.

Methods and systems are provided for manufacturing a membrane separator for a redox flow battery. In one example, the membrane separator is fabricate by a calendering process. The membrane separator may be configured with a polymer network to provide selectivity for ion transport across the membrane separator. The membrane separator may be further adapted with an integrated spacer in contact with a negative electrolyte.

A method of making an interconnect for a solid oxide fuel cell stack includes providing a chromium alloy interconnect and providing a nickel mesh in contact with a fuel side of the interconnect. Formation of a chromium oxide layer is reduced or avoided in locations between the nickel mesh and the fuel side of the interconnect. A CrNi alloy or a CrFeNi alloy is located at least in the fuel side of the interconnect under the nickel mesh.

A novel method to produce thin films spatially disposed on desired areas of workpieces is disclosed. Examples of include the formation of a yttria stabilized zirconia (YSZ) film formed on a desired portion of a stainless steel interconnect for solid oxide fuel cells by Atomic Layer Deposition (ALD). A number of methods to produce the spatially disposed YSZ film structures are described including polymeric and silicone rubber masks. The thin film structures have utility for preventing the reaction of glasses with metals, in particular alkali-earth containing glasses with ferritic stainless steels, allowing high temperature bonding of these materials.

A novel method to produce thin films spatially disposed on desired areas of workpieces is disclosed. Examples of include the formation of a yttria stabilized zirconia (YSZ) film formed on a desired portion of a stainless steel interconnect for solid oxide fuel cells by Atomic Layer Deposition (ALD). A number of methods to produce the spatially disposed YSZ film structures are described including polymeric and silicone rubber masks. The thin film structures have utility for preventing the reaction of glasses with metals, in particular alkali-earth containing glasses with ferritic stainless steels, allowing high temperature bonding of these materials.

An object of the present disclosure is to provide a fuel cell separator having a low contact resistance due to a tin oxide film and having an excellent corrosion resistance. An embodiment is a method for manufacturing a fuel cell separator including a stainless steel substrate. The method includes forming the tin oxide film on a surface of the stainless steel substrate; and attaching phosphoric acid or phosphate to at least a defective portion in the tin oxide film.

An object of the present disclosure is to provide a fuel cell separator having a low contact resistance due to a tin oxide film and having an excellent corrosion resistance. An embodiment is a method for manufacturing a fuel cell separator including a stainless steel substrate. The method includes forming the tin oxide film on a surface of the stainless steel substrate; and attaching phosphoric acid or phosphate to at least a defective portion in the tin oxide film.

A metal sheet for separators of polymer electrolyte fuel cells comprises: a substrate made of metal; and a surface-coating layer with which a surface of the substrate is coated, with a strike layer in between, wherein a coating ratio of the strike layer on the substrate is 2% to 70%, the strike layer is distributed in a form of islands, and a maximum diameter of the islands of the strike layer as coating portions is 1.00 m or less and is not greater than a thickness of the surface-coating layer.