A monolithic fuel cell device is provided by forming anode and cathode layers by dispensing paste of anode or cathode material around pluralities of spaced-apart removable physical structures to at least partially surround the structures with the anode or cathode material and then drying the paste.
A monolithic fuel cell device is provided by forming anode and cathode layers by dispensing paste of anode or cathode material around pluralities of spaced-apart removable physical structures to at least partially surround the structures with the anode or cathode material and then drying the paste. An electrolyte layer is provided in a multi-layer stack between the cathode layer and the anode layer thereby forming an active cell portion. The multi-layer stack is laminated, and then the physical structures are pulled out to reveal spaced-apart active passages formed through each of the anode layer and cathode layer. Finally, the laminated stack is sintered to form an active cell comprising the spaced apart active passages embedded in and supported by the sintered anode material and sintered cathode material.
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1. A method of making a monolithic fuel cell device, comprising: forming an anode layer by dispensing a first paste of anode material around a first plurality of spaced-apart removable physical structures to at least partially surround each of the first plurality of spaced-apart removable physical s
1. A method of making a monolithic fuel cell device, comprising: forming an anode layer by dispensing a first paste of anode material around a first plurality of spaced-apart removable physical structures to at least partially surround each of the first plurality of spaced-apart removable physical structures with the anode material and drying the first paste;forming a cathode layer by dispensing a second paste of cathode material around a second plurality of spaced-apart removable physical structures to at least partially surround each of the second plurality of spaced-apart removable physical structures with the cathode material and drying the second paste;positioning an electrolyte layer in a multi-layer stack between the cathode layer and the anode layer, wherein an active cell portion of the multi-layer stack is formed by the anode layer in opposing relation to the cathode layer with the electrolyte layer therebetween;laminating the multi-layer stack;pulling the first and second plurality of removable physical structures out of the laminated multi-layer stack to reveal spaced-apart active passages formed through each of the anode layer and the cathode layer; andsintering the laminated multi-layer stack to form an active cell comprising the spaced apart active passages embedded in and supported by the sintered anode material and sintered cathode material,wherein forming one or both of the anode layer and cathode layer includes dispensing the first or second paste with a varying composition in the thickness direction of the removable physical structures, wherein the variation in composition is selected from amount of porosity, size of pores, chemical composition, relative electrical conductivity, relative ionic conductivity, bonding properties, ratio of anode or cathode material to ceramic material, or a combination thereof, and wherein the varying composition includes a graded porosity with the porosity decreasing in a thickness direction away from the electrolyte layer. 2. The method of claim 1, further comprising dispensing a third paste of ceramic material around the first and second plurality of spaced-apart removable physical structures adjacent to the anode and cathode materials to at least partially surround each of the first and second plurality of spaced-apart removable physical structures with the ceramic material and drying the third paste to form a passive support portion adjacent the active cell portion in the multi-layer stack, wherein the sintering further forms a passive support structure comprising spaced apart passive passages embedded in and supported by the sintered ceramic material and that transition integrally to the active passages within the active cell. 3. A method of making a monolithic fuel cell device, comprising: forming an anode layer by dispensing a first paste of anode material around a first plurality of spaced-apart removable physical structures to at least partially surround each of the first plurality of spaced-apart removable physical structures with the anode material and drying the first paste;forming a cathode layer by dispensing a second paste of cathode material around a second plurality of spaced-apart removable physical structures to at least partially surround each of the second plurality of spaced-apart removable physical structures with the cathode material and drying the second paste;positioning an electrolyte layer in a multi-layer stack between the cathode layer and the anode layer, wherein an active cell portion of the multi-layer stack is formed by the anode layer in opposing relation to the cathode layer with the electrolyte layer therebetween;laminating the multi-layer stack;pulling the first and second plurality of removable physical structures out of the laminated multi-layer stack to reveal spaced-apart active passages formed through each of the anode layer and the cathode layer; andsintering the laminated multi-layer stack to form an active cell comprising the spaced apart active passages embedded in and supported by the sintered anode material and sintered cathode material,wherein forming one or both of the anode layer and cathode layer includes forming a multi-layer electrode structure having at least a first sub-layer of porous anode or cathode paste material and a second sub-layer of non-porous anode or cathode paste material dispensed over the first sub-layer, wherein the positioning of the electrolyte layer is adjacent the first sub-layer, andwherein the first sub-layer is dispensed around one side of the respective first or second plurality of spaced-apart removable physical structures and the second sub-layer is dispensed around the opposing side of the respective first or second plurality of spaced-apart removable physical structures such that, after sintering, the spaced apart active passages are partially embedded in and supported by the sintered porous anode or cathode material on one side and partially embedded in and supported by the sintered non-porous anode or cathode material on the opposing side. 4. A method of making a monolithic fuel cell device, comprising: forming an anode layer by dispensing a first paste of anode material around a first plurality of spaced-apart removable physical structures to at least partially surround each of the first plurality of spaced-apart removable physical structures with the anode material and drying the first paste;forming a cathode layer by dispensing a second paste of cathode material around a second plurality of spaced-apart removable physical structures to at least partially surround each of the second plurality of spaced-apart removable physical structures with the cathode material and drying the second paste;positioning an electrolyte layer in a multi-layer stack between the cathode layer and the anode layer, wherein an active cell portion of the multi-layer stack is formed by the anode layer in opposing relation to the cathode layer with the electrolyte layer therebetween;laminating the multi-layer stack;pulling the first and second plurality of removable physical structures out of the laminated multi-layer stack to reveal spaced-apart active passages formed through each of the anode layer and the cathode layer; andsintering the laminated multi-layer stack to form an active cell comprising the spaced apart active passages embedded in and supported by the sintered anode material and sintered cathode material,wherein forming one or both of the anode layer and cathode layer includes forming a multi-layer electrode structure having a plurality of sub-layers each with a differing porosity, with the multi-layer electrode structure decreasing in porosity in a thickness direction away from the electrolyte layer. 5. A method of making a monolithic fuel cell device, comprising: forming an anode layer by dispensing a first paste of anode material around a first plurality of spaced-apart removable physical structures to at least partially surround each of the first plurality of spaced-apart removable physical structures with the anode material and drying the first paste;forming a cathode layer by dispensing a second paste of cathode material around a second plurality of spaced-apart removable physical structures to at least partially surround each of the second plurality of spaced-apart removable physical structures with the cathode material and drying the second paste;positioning an electrolyte layer in a multi-layer stack between the cathode layer and the anode layer, wherein an active cell portion of the multi-layer stack is formed by the anode layer in opposing relation to the cathode layer with the electrolyte layer therebetween;laminating the multi-layer stack;pulling the first and second plurality of removable physical structures out of the laminated multi-layer stack to reveal spaced-apart active passages formed through each of the anode layer and the cathode layer; andsintering the laminated multi-layer stack to form an active cell comprising the spaced apart active passages embedded in and supported by the sintered anode material and sintered cathode material,wherein forming one or both of the anode layer and cathode layer includes dispensing the first or second paste with a varying composition in the length direction of the removable physical structures. 6. The method of claim 5 wherein the varying composition includes alternating length portions of anode or cathode material and ceramic material for creation of a series fuel cell travelling in the length direction. 7. A method of making a monolithic fuel cell device, comprising: forming an anode layer by dispensing a first paste of anode material around a first plurality of spaced-apart removable physical structures to at least partially surround each of the first plurality of spaced-apart removable physical structures with the anode material and drying the first paste;forming a cathode layer by dispensing a second paste of cathode material around a second plurality of spaced-apart removable physical structures to at least partially surround each of the second plurality of spaced-apart removable physical structures with the cathode material and drying the second paste;positioning an electrolyte layer in a multi-layer stack between the cathode layer and the anode layer, wherein an active cell portion of the multi-layer stack is formed by the anode layer in opposing relation to the cathode layer with the electrolyte layer therebetween;laminating the multi-layer stack;pulling the first and second plurality of removable physical structures out of the laminated multi-layer stack to reveal spaced-apart active passages formed through each of the anode layer and the cathode layer; andsintering the laminated multi-layer stack to form an active cell comprising the spaced apart active passages embedded in and supported by the sintered anode material and sintered cathode material,further comprising forming a ceramic support layer over the active cell portion and providing exposed conductive portions extending through the ceramic support layer, and repeating the steps of forming the anode and cathode layers and positioning the electrolyte therebetween to vertically stack additional active cell portions with the anode layer of one active cell portion adjacent the cathode layer of the next vertically adjacent active cell portion, with the ceramic support layer between the vertically adjacent active cell portions with the exposed conductive portion electrically connecting the active cell portions in series. 8. The method of claim 7, wherein the exposed conductive portions are formed by providing spaced via holes through the ceramic support layer and filing the via holes with conductive material. 9. The method of claim 7, wherein the exposed conductive portions are formed by providing two ceramic support layers having spaced via holes formed therein and coating one side of each of the two ceramic support layers with a conductive material and placing the coated sides in contact with each other with the via holes of one ceramic support layer offset from the via holes of the other ceramic support layer. 10. A method of making a monolithic fuel cell device, comprising: forming an anode layer by dispensing a first paste of anode material around a first plurality of removable physical structures to at least partially surround each of the first plurality of removable physical structures with the anode material and drying the first paste;forming a cathode layer by dispensing a second paste of cathode material around a second plurality of removable physical structures to at least partially surround each of the second plurality of removable physical structures with the cathode material and drying the second paste, wherein the each of the first and second plurality of removable physical structures have an elongate length and are positioned in the respective anode and cathode layer in parallel in the length direction and physically spaced apart from each other in a direction transverse to the length direction;positioning an electrolyte layer in a multi-layer stack between the cathode layer and the anode layer, wherein an active cell portion of the multi-layer stack is formed by the anode layer in opposing relation to the cathode layer with the electrolyte layer therebetween;dispensing a third paste of ceramic material around the first and second plurality of removable physical structures adjacent to the anode and cathode materials to surround each of the first and second plurality of removable physical structures with the ceramic material and drying the third paste to form a passive support portion adjacent the active cell portion in the multi-layer stack;laminating the multi-layer stack;pulling the first and second plurality of removable physical structures out of the laminated multi-layer stack to reveal spaced-apart passages formed in the passive support portion and transitioning through each of the anode layer and the cathode layer in the active cell portion; andsintering the laminated multi-layer stack to form an active cell with an adjacent ceramic passive support structure with the spaced-apart passages embedded in and supported by the sintered ceramic material, anode material and cathode material. 11. The method of claim 10, wherein the removable physical structures of the first and/or second plurality are straight in the length direction within the active cell portion and are curved for at least a portion of the passive support portion to exit the passive support portion of the multi-layer stack in a direction transverse to the length direction. 12. The method of claim 10, wherein the third paste is dispensed around the first and second plurality of removable physical structures adjacent each of the opposing length-wise sides of the active cell portion to form first and second passive support portions lengthwise before and after the active cell portion, respectively, whereby the spaced-apart passages in each of the anode layer and cathode layer formed after the sintering are coupled to an inlet in a first passive support structure, extend through the active cell, and are coupled to an outlet in a second passive support structure. 13. The method of claim 12, wherein the removable physical structures of the first plurality are straight in the length direction within the active cell portion and the first passive support portion, and are curved for at least a portion of the second passive support portion to form the outlet for the anode layer in the second passive support structure in a direction transverse to the length direction; and wherein the removable physical structures of the second plurality are straight in the length direction within the active cell portion and the second passive support portion, and are curved for at least a portion of the first passive support portion to form the outlet for the cathode layer in the first passive support portion in a direction transverse to the length direction. 14. The method of claim 12 wherein the first and/or second plurality of removable physical structures are curved between the inlet and outlet. 15. The method of claim 10, wherein the third paste is dispensed around the first and second plurality of removable physical structures adjacent each of the opposing length-wise sides of the active cell portion to form first and second passive support portions lengthwise before and after the active cell portion, respectively, and wherein the anode layer and the cathode layer include at least first and second sub-layers, where a first portion of the respective first or second plurality of removable physical structures extend within the first or second passive support portion and the first sub-layer and a second portion of the respective first or second plurality of removable physical structures extend within the other of the first or second passive support portion and the second sub-layer, whereby the spaced-apart passages in each of the first sub-layers of the anode layer and cathode layer formed after the sintering are coupled to an inlet in one of a first or second passive support structure and extend through the active cell, and the spaced-apart passages in each of the second sub-layers of the anode layer and cathode layer formed after the sintering extend from the active cell to an outlet in the other of a first or second passive support structure. 16. The method of claim 15, wherein the second portions of the first and second plurality of removable physical structures are curved for at least a portion of the length extending within the first or second passive support portion to form the outlet in a direction transverse to the length direction.
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