Fuel cell devices and systems are provided. In certain embodiments, the devices include a ceramic support structure having a length, a width, and a thickness with the length direction being the dominant direction of thermal expansion. A reaction zone having at least one active layer therein is space
Fuel cell devices and systems are provided. In certain embodiments, the devices include a ceramic support structure having a length, a width, and a thickness with the length direction being the dominant direction of thermal expansion. A reaction zone having at least one active layer therein is spaced from the first end and includes first and second opposing electrodes, associated active first and second gas passages, and electrolyte. The active first gas passage includes sub-passages extending in the y direction and spaced apart in the x direction. An artery flow passage extends from the first end along the length and into the reaction zone and is fluidicly coupled to the sub-passages of the active first gas passage. The thickness of the artery flow passage is greater than the thickness of the sub-passages. In other embodiments, fuel cell devices include second sub-passages for the active second gas passage and a second artery flow passage coupled thereto, and extending from either the first end or the second end into the reaction zone. In yet other embodiments, one or both electrodes of a fuel cell device are segmented.
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1. A fuel cell device comprising: a ceramic support structure having a length in an x direction from a first end to a second end, a width in a y direction from a first side to a second side, and a thickness in a z direction from a top surface to a bottom surface, wherein the length is greater than t
1. A fuel cell device comprising: a ceramic support structure having a length in an x direction from a first end to a second end, a width in a y direction from a first side to a second side, and a thickness in a z direction from a top surface to a bottom surface, wherein the length is greater than the width or thickness whereby the x direction of the ceramic support structure is a dominant direction of thermal expansion;a reaction zone along a first portion of the length configured to be exposed to a heat source to heat the reaction zone to an operating reaction temperature, and at least one cold zone along a second portion of the length configured to be shielded from the heat source to remain at a low temperature below the operating reaction temperature when the reaction zone is heated;at least one fuel passage within the ceramic support structure extending from the at least one cold zone to the reaction zone, and having an associated anode in the reaction zone within the ceramic support structure;at least one oxidizer passage within the ceramic support structure extending from the at least one cold zone to the reaction zone, and having an associated cathode in the reaction zone positioned in opposing relation to the anode within the ceramic support structure; andan electrolyte disposed between the opposing anode and cathode in the reaction zone,wherein at least one of the anode or cathode, or both, is a segmented electrode having an area and a thickness and that includes a plurality of electrode material segments in a spaced pattern in the area and separated by gaps extending to at least a portion of the thickness of the segmented electrode, andfurther comprising a current collector extending continuously over the segmented electrode in contact with each of the electrode material segments. 2. The fuel cell device of claim 1, wherein the current collector is positioned over the gaps to form voids between the electrode material segments. 3. The fuel cell device of claim 1, wherein the current collector fills the gaps between the electrode material segments. 4. The fuel cell device of claim 1, wherein the anode is the segmented electrode and the cathode is non-segmented and thicker than the anode. 5. The fuel cell device of claim 1, wherein the segmented electrode has different physical and/or material properties than the current collector. 6. The fuel cell device of claim 5, wherein the segmented electrode has a different composition than the current collector. 7. The fuel cell device of claim 6, wherein the current collector comprises a different metal element than the segmented electrode. 8. A fuel cell device comprising: a ceramic support structure having a length in an x direction from a first end to a second end, a width in a y direction from a first side to a second side, and a thickness in a z direction from a top surface to a bottom surface, wherein the length is greater than the width or thickness whereby the x direction of the ceramic support structure is a dominant direction of thermal expansion;a reaction zone along a first portion of the length configured to be exposed to a heat source to heat the reaction zone to an operating reaction temperature, and at least one cold zone along a second portion of the length configured to be shielded from the heat source to remain at a low temperature below the operating reaction temperature when the reaction zone is heated;at least one fuel passage within the ceramic support structure extending from the at least one cold zone to the reaction zone, and having an associated anode in the reaction zone within the ceramic support structure;at least one oxidizer passage within the ceramic support structure extending from the at least one cold zone to the reaction zone, and having an associated cathode in the reaction zone positioned in opposing relation to the anode within the ceramic support structure; andan electrolyte disposed between the opposing anode and cathode in the reaction zone,wherein the anode has an area in the x and y directions and a thickness in the z direction and includes a plurality of anode segments in a spaced pattern in the area separated by gaps extending to at least a portion of the thickness, andfurther comprising a current collector extending continuously in the x and y directions over the area of the anode and in contact with each of the anode segments. 9. The fuel cell device of claim 8, wherein the current collector is positioned over the gaps to form voids between the anode segments. 10. The fuel cell device of claim 8, wherein the current collector fills the gaps between the anode segments. 11. The fuel cell device of claim 8, wherein the cathode is non-segmented and thicker than the anode. 12. The fuel cell device of claim 11, wherein the anode and cathode extend to a greater width in the y direction toward both the first and second sides than the fuel and oxidizer passages. 13. The fuel cell device of claim 12, wherein the cathode extends to each of the first and side sides. 14. The fuel cell device of claim 8, wherein the anode has different physical and material properties than the current collector. 15. The fuel cell device of claim 14, wherein the anode has a different composition than the current collector. 16. The fuel cell device of claim 15, wherein the current collector comprises a different metal element than the anode. 17. A fuel cell device comprising: a ceramic support structure having a length in an x direction from a first end to a second end, a width in a y direction from a first side to a second side, and a thickness in a z direction from a top surface to a bottom surface, wherein the length is greater than the width or thickness whereby the x direction of the ceramic support structure is a dominant direction of thermal expansion;a reaction zone along a first portion of the length configured to be exposed to a heat source to heat the reaction zone to an operating reaction temperature, and at least one cold zone along a second portion of the length configured to be shielded from the heat source to remain at a low temperature below the operating reaction temperature when the reaction zone is heated;at least one fuel passage within the ceramic support structure extending from the at least one cold zone to the reaction zone;at least one oxidizer passage within the ceramic support structure extending from the at least one cold zone to the reaction zone;a segmented anode associated with the fuel passage in the reaction zone within the ceramic support structure, wherein the segmented anode has an area and a first thickness and includes a plurality of anode segments in a spaced pattern in the area separated by gaps extending to at least a portion of the first thickness;a non-segmented cathode associated with the oxidizer passage in the reaction zone and positioned in opposing relation to the segmented anode within the ceramic support structure, wherein the non-segmented cathode has a second thickness greater than the first thickness of the segmented anode;an electrolyte disposed between the opposing segmented anode and non-segmented cathode in the reaction zone; anda current collector extending continuously over the area of the segmented anode in contact with each of the anode segments, wherein the current collector has a different composition than the segmented anode. 18. The fuel cell device of claim 17, wherein the current collector is positioned over the gaps to form voids between the anode segments. 19. The fuel cell device of claim 17, wherein the current collector fills the gaps between the anode segments. 20. The fuel cell device of claim 17, wherein the segmented anode and non-segmented cathode extend to a greater width in the y direction toward both the first and second sides than the fuel and oxidizer passages. 21. The fuel cell device of claim 17, wherein the non-segmented cathode extends to each of the first and side sides. 22. The fuel cell device of claim 17, wherein the current collector comprises a different metal element than the segmented anode. 23. A fuel cell device comprising: a ceramic support structure having a length in an x direction from a first end to a second end, a width in a y direction from a first side to a second side, and a thickness in a z direction from a top surface to a bottom surface, wherein the length is greater than the width or thickness whereby the x direction of the ceramic support structure is a dominant direction of thermal expansion;a reaction zone along a first portion of the length configured to be exposed to a heat source to heat the reaction zone to an operating reaction temperature, and at least one cold zone along a second portion of the length configured to be shielded from the heat source to remain at a low temperature below the operating reaction temperature when the reaction zone is heated;at least one fuel passage within the ceramic support structure extending from the at least one cold zone to the reaction zone;at least one oxidizer passage within the ceramic support structure extending from the at least one cold zone to the reaction zone;an anode associated with the fuel passage in the reaction zone within the ceramic support structure, wherein the anode has a first area and a first thickness;a cathode associated with the oxidizer passage in the reaction zone and positioned in opposing relation to the anode within the ceramic support structure, wherein the cathode has a second area and a second thickness;an electrolyte disposed between the opposing anode and cathode in the reaction zone;wherein one or both of the anode or cathode includes a plurality of electrode segments in a spaced pattern in the respective first or second area separated by gaps extending to at least a portion of the respective first or second thickness,wherein the anode and cathode extend to a greater width in the y direction toward both the first and second sides than the fuel and oxidizer passages, andfurther comprising a current collector extending continuously over and in contact with the plurality of electrode segments, wherein the current collector has a different composition than the plurality of electrode segments that the current collector is contacting. 24. The fuel cell device of claim 23, wherein the current collector is positioned over the gaps to form voids between the anode segments. 25. The fuel cell device of claim 23, wherein the current collector fills the gaps between the anode segments.
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