A fuel cell device having an exterior surface defining an interior ceramic support structure. An active zone is along a first portion of the length for undergoing a fuel cell reaction, and at least one non-active end region is along an end portion extending away from the active zone without being he
A fuel cell device having an exterior surface defining an interior ceramic support structure. An active zone is along a first portion of the length for undergoing a fuel cell reaction, and at least one non-active end region is along an end portion extending away from the active zone without being heated. Fuel and oxidizer passages extend within the interior support structure from respective first and second inlets in the non-active end region to the active zone. The active zone has an anode associated with each of the fuel passages and a cathode associated with each of the oxidizer passages in opposing relation to a respective one of the anodes with an electrolyte therebetween. A plurality of ceramic support members in spaced-apart positions are provided throughout each one of the plurality of fuel and oxidizer passages that physically holds open the passages to prevent collapse.
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1. A solid oxide fuel cell device comprising: an elongate ceramic substrate having an exterior surface defining an interior solid ceramic support structure, an active zone along a first portion of the length for undergoing a fuel cell reaction when supplied with heat, fuel and oxidizer, and at least
1. A solid oxide fuel cell device comprising: an elongate ceramic substrate having an exterior surface defining an interior solid ceramic support structure, an active zone along a first portion of the length for undergoing a fuel cell reaction when supplied with heat, fuel and oxidizer, and at least one non-active end region along a second portion of the length extending away from the active zone without being heated to dissipate heat and to thereby remain at a lower temperature than the active zone when the active zone is supplied with heat;a plurality of fuel passages extending within the interior solid ceramic support structure of the elongate ceramic substrate from one or more first inlets in the at least one non-active end region to the active zone, and each of the plurality of fuel passages having an anode associated therewith in the active zone;a plurality of oxidizer passages extending within the interior solid ceramic support structure of the elongate ceramic substrate from one or more second inlets in the at least one non-active end region to the active zone, each of the plurality of oxidation passages having a cathode associated therewith in the active zone positioned in opposing relation to the respective one of the anodes, wherein the at least one non-active end region lack anodes and cathodes in opposing relation so as to be incapable of undergoing a fuel cell reaction;an electrolyte disposed between each of the opposing anodes and cathodes within the interior solid ceramic support structure in the active zone, the electrolyte being monolithic with the interior solid ceramic support structure; anda plurality of ceramic support members in spaced-apart positions throughout each one of the plurality of fuel and oxidizer passages that physically holds open the passages to prevent collapse. 2. The fuel cell device of claim 1 wherein elongate ceramic substrate has a length that is the greatest dimension whereby the elongate ceramic substrate exhibits thermal expansion along a dominant axis that is coextensive with the length. 3. The fuel cell device of claim 1 wherein the plurality of ceramic support members include randomly positioned ceramic spherical particles. 4. The fuel cell device of claim 1 wherein the at least one non-active end region includes opposing non-active end regions with the active zone intermediate therebetween, and wherein the one or more first inlets reside in one of the opposing non-active end regions and the one or more second inlets reside in the other one of the opposing non-active end regions. 5. The fuel cell device of claim 1 wherein at least one anode includes an exposed anode portion at the exterior surface of the elongate ceramic substrate in the at least one non-active end region, and at least one cathode includes an exposed cathode portion at the exterior surface of the elongate ceramic substrate in the at least one non-active end region, the device further comprising: a first metallic contact pad applied to the exterior surface in the at least one non-active end region in electrical contact with the exposed anode portion, and a first voltage connection between the first metallic contact pad and a negative voltage node; anda second metallic contact pad applied to the exterior surface in the at least one non-active end region in electrical contact with the exposed cathode portion, and a second voltage connection between the second metallic contact pad and a positive voltage node. 6. The fuel cell device of claim 1 wherein each anode includes an exposed anode portion at the exterior surface of the elongate ceramic substrate, and each cathode includes an exposed cathode portion at the exterior surface of the elongate ceramic substrate, the device further comprising: a plurality of metallization areas applied to the exterior surface in electrical contact with one or more exposed anode portions and/or exposed cathode portions to form exterior parallel and/or series electrical connections. 7. The fuel cell device of claim 1, wherein the anodes each include a non-opposed anode section not in opposing relation to a respective cathode, and the cathodes each include a non-opposed cathode section not in opposing relation to a respective anode;wherein the non-opposed anode sections are electrically interconnected within the interior solid ceramic support structure of the elongate ceramic substrate by electrically conductive anode via connections, and the non-opposed cathode sections are electrically interconnected within the interior solid ceramic support structure of the elongate ceramic substrate by electrically conductive cathode via connections; andwherein one of the anodes includes an exposed anode portion at the exterior surface of the elongate ceramic substrate in the at least one non-active end region, and one of the cathodes includes an exposed cathode portion at the exterior surface of the elongate ceramic substrate in the at least one non-active end region, the device further comprising:a first metallic contact pad applied to the exterior surface in the at least one non-active end region in electrical contact with the exposed anode portion, and a first voltage connection between the first metallic contact pad and a negative voltage node; anda second metallic contact pad applied to the exterior surface in the at least one non-active end region in electrical contact with the exposed cathode portion, and a second voltage connection between the second metallic contact pad and a positive voltage node. 8. The fuel cell device of claim 1 wherein the plurality of fuel passages includes a first fuel passage and one or more second fuel passages, and the plurality of oxidizer passages includes a first oxidizer passage and one or more second oxidizer passages, and wherein the second fuel passages alternate with the second oxidizer passages between the first fuel passage and the first oxidizer passage. 9. The fuel cell device of claim 8 wherein the anode associated with the first fuel passage is disposed at a surface of the first fuel passage nearest an adjacent second oxidizer passage, the cathode associated with the first oxidizer passage is disposed at a surface of the first oxidizer passage nearest an adjacent second fuel passage, the anode associated with each of the second fuel passages includes anodes on each of opposing surfaces of the second fuel passage adjacent first and/or second oxidizer passages, and the cathode associated with each of the second oxidizer passages includes cathodes on each of opposing surfaces of the second oxidizer passage adjacent first and/or second fuel passages. 10. The fuel cell device of claim 1 further comprising a fuel supply coupled to the one or more first inlets in the at least one non-active end region in fluid communication with the plurality of fuel passages for supplying a fuel flow into the fuel passages, and an air supply coupled to the one or more second inlets in the at least one non-active end region in fluid communication with the plurality of oxidizer passages for supplying an air flow into the oxidizer passages. 11. The fuel cell device of claim 1 wherein the intermediate portion further comprises a pre-heat zone within the interior solid ceramic support structure between the at least one non-active end region and the active zone, and wherein the pre-heat zones lack an anode and a cathode in opposing relation therein. 12. The fuel cell device of claim 11 wherein at least one anode extends from within the interior solid ceramic support structure to an exposed anode portion at the exterior surface in the active zone and a first exterior metallization extends from the exposed anode portion at the exterior surface in the active zone to the exterior surface in the at least one non-active end region, and at least one cathode extends from within the interior solid ceramic support structure to an exposed cathode portion at the exterior surface in the active zone and a second exterior metallization extends from the exposed cathode portion at the exterior surface in the active zone to the exterior surface in the at least one non-active end region. 13. The fuel cell device of claim 11 wherein the fuel passages and the oxidizer passages each further comprise a pre-heat chamber within the interior solid ceramic support structure in the at least one non-active end region and extending at least partially into the pre-heat zone wherein each pre-heat chamber has a greater volume than a volume of the respective fuel and oxidizer passage in the active zone. 14. The fuel cell device of claim 1 further comprising: a heat source positioned adjacent the first portion to supply heat to the active zone; andan insulating region between the heat source and the at least one non-active end region adapted to maintain the at least one non-active end region at the lower temperature than the active zone. 15. A solid oxide fuel cell system comprising: a hot zone chamber;a plurality of the solid oxide fuel cell devices of claim 1, each positioned with the first portion in the hot zone chamber and the at least one non-active end region extending outside the hot zone chamber;a heat source coupled to the hot zone chamber and adapted to supply heat to the active zones within the hot zone chamber;a fuel supply coupled outside the hot zone chamber to the first inlets in fluid communication with the fuel passages for supplying a fuel flow into the fuel passages; andan air supply coupled outside the hot zone chamber to the second inlets in fluid communication with the oxidizer passages for supplying an air flow into the oxidizer passages. 16. The fuel cell system of claim 15 wherein each anode includes an exposed anode portion at the exterior surface of the elongate ceramic substrate in the at least one non-active end region, and each cathode includes an exposed cathode portion at the exterior surface of the elongate ceramic substrate in the at least one non-active end region, the system further comprising: a negative voltage connection to the exterior surface in the at least one non-active end region in electrical contact with at least one of the exposed anode portions; anda positive voltage connection to the exterior surface in the at least one non-active end region in electrical contact with at least one of the exposed cathode portions. 17. The fuel cell system of claim 15 wherein, in each device, the anodes extend from within the interior solid ceramic support structure to an exposed anode portion at the exterior surface in the active zone and a first exterior metallization extends from the exposed anode portion at the exterior surface in the active zone in the hot zone chamber to the exterior surface in the at least one non-active end region outside the hot zone chamber, and the cathodes extend from within the interior solid ceramic support structure to an exposed cathode portion at the exterior surface in the active zone and a second exterior metallization extends from the exposed cathode portion at the exterior surface in the active zone in the hot zone chamber to the exterior surface in the at least one non-active end region outside the hot zone chamber.
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