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An electrical power generating device having a plurality of ceramic composite cells, each cell having a cathode and an anode. A thermal shell in which the ceramic composite cells are stacked or arranged in electrical series and gas parallel surrounded by shock absorbing and insulating materials, res

An electrical power generating device having a plurality of ceramic composite cells, each cell having a cathode and an anode. A thermal shell in which the ceramic composite cells are stacked or arranged in electrical series and gas parallel surrounded by shock absorbing and insulating materials, respectively, is preferably included. Also provided are an exhaust fan, thermocouple sensors, a fuel supply, a programmable computer controller with user interface, and a container supporting the assembly and having passageways for providing air ingress and egress to the device, and power output terminals for the electrical power from the device. Methods for manufacturing the ceramic composite cells are also provided, including a method for manufacturing stabilized zirconia and for use in the ceramic materials used within the ceramic composite cell.

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We claim: 1. A method for manufacturing a ceramic composite oxygen or power generating cell comprising providing a first metal member having a perimeter and a section defining a pattern of openings; applying a ceramic material to the section, firing the ceramic material to create a ceramic composit

We claim: 1. A method for manufacturing a ceramic composite oxygen or power generating cell comprising providing a first metal member having a perimeter and a section defining a pattern of openings; applying a ceramic material to the section, firing the ceramic material to create a ceramic composite body; coating at least a portion of the ceramic composite body with an electrically conductive material; firing the electrically conductive material to form an electrode layer; providing a bipolar metal member having contact portions extending outwardly in one or two directions from a plane of the bipolar metal member for engagement with the ceramic composite body; connecting the bipolar metal member to the perimeter of the first metal member of the ceramic composite body wherein a gas tight chamber is formed between said ceramic composite body and said bipolar metal member. 2. The method of claim 1, wherein the step of applying the layer of ceramic material to the pattern of openings comprises dipping. 3. The method of claim 1, wherein the bipolar metal member and the first metal member of the ceramic composite body form an output for removing exhaust generated in said fuel chamber of said cell. 4. The method of claim 1, further comprising applying an electrocatalyst layer to the ceramic material of the ceramic composite body. 5. The method of claim 1, further comprising providing a current collector between the electrode layer and the bipolar metal member. 6. The method of claim 1, further comprising sealing the ceramic composite body with seal slip coat. 7. The method of claim 1, further comprising attaching at least one metallic frame to said bipolar metal member. 8. The method of claim 1, wherein the gas tight seal is formed by welding. 9. The method of claim 1, further comprising forming three dimensional structures on the surface of the bipolar metal member. 10. The method of claim 1, wherein the three dimensional structures are formed by embossing. 11. The method of claim 1, wherein the pattern of openings is formed by photochemical etching or photolithography. 12. The method of claim 1, further comprising sealing the ceramic composite body with a seal slip coat; attaching at least one metallic frame to said bipolar metal members for supporting said bipolar member, wherein the bipolar metal member has three dimensional structures on the surface thereof and an electrical contact layer disposed on said three dimensional structures, and further wherein the metal member of said ceramic composite body has a thickness of from 0.001 to 0.008 inches. 13. The method of claim 12, further comprising providing an output for removing exhaust generated in said cell; providing a heat unit for heating said cell to a desired reaction temperature; providing a fan for supplying air; and providing at least one arm extending from the ceramic composite body. 14. The method of claim 1, wherein the pattern of openings is a hexagonal close pack cell pattern, and further wherein the first metal member has a thickness of from 0.001 to 0.008 inches. 15. The method of claim 12, further comprising: providing a fluid fuel input in an arm; providing a gas output in an arm; wherein: the fluid fuel input and the gas output are in the same or different arms. 16. The method of claim 15, further comprising applying an electrocatalyst layer to the ceramic material of the ceramic composite body. 17. The method of claim 1, further comprising disposing solid fuel between the bipolar metal member and the first metal member of the ceramic composite body. 18. The method of claim 1, further comprising applying an electrocatalyst layer to the ceramic material of the ceramic body, and further wherein the electrode layer comprises silver or a mixture of silver and a second metal selected from the group consisting of gold; platinum; palladium; iridium; and mixtures thereof; and the electrocatalyst layer is comprised of a mixture of solid electrolyte particles and transition metal oxide particles. 19. A method of manufacturing a ceramic composite oxygen or power generating cell stack comprising (a) providing at least two ceramic composite cells, a first cell and a second adjacent cell, each cell comprising: a ceramic composite body comprising a first metal member having a pattern of openings formed within a portion of the metal member and a ceramic material disposed on said pattern of openings; first and second electrically conductive porous gas permeable electrode layers on opposite surfaces of said ceramic composite body, said first electrode layer forming an anode and said second electrode layer forming a cathode; a bipolar metal member for engagement with the ceramic composite body of said first cell on one side and with the ceramic composite body of the second cell on the other side; wherein said bipolar metal member and said first metal member are interconnected at a gas tight seal surrounding said ceramic material to form a gas tight chamber and together forming an output for removing exhaust generated in said gas tight chamber of said cell; and (b) interconnecting the ceramic composite cells so that said ceramic composite cells are arranged in electrical series and gas parallel. 20. The method of claim 19, further comprising disposing said stack at least partially within a thermal shell. 21. The method of claim 20, wherein said thermal shell has a first, a second and a third concurrent metal layer. 22. The method of claim 20, further comprising surrounding said stack with insulating material before inserting said stack into the thermal shell. 23. The method of claim 19, further comprising providing at least one current collector interspaced between an electrode layer of one cell and the bipolar metal member of the adjacent cell. 24. The method of claim 19, further comprising providing a heating element to each end of the stack. 25. The method of claim 19, further comprising disposing said stack at least partially within a thermal shell; surrounding said stack with insulating materials before inserting said stack into the thermal shell; providing at least one current collector interspaced between an electrode layer of one cell and the bipolar metal member of the adjacent cell; and providing a heating element to each end of the stack. 26. The method of claim 25, wherein the cells further comprise: three dimensional structures on the surface of the bipolar metal member; ceramic composite member with seal slip coat; at least one metallic frame to said bipolar metal member, for supporting said bipolar member, wherein the metal member of said ceramic composite body has a thickness of from 0.001 to 0.008 inches. 27. The method of claim 25, wherein the cells further comprise: an output for removing exhaust generated in said cell; a heat unit for heating said cells to a desired reaction temperature; a fan for supplying air; at least one arm extending from the ceramic composite body.