Abstract: The invention relates to a method making a compact chemical reactor with high aspect ratio cavities comprising the steps: forming at least one intermediate assembly, consisting of: at least one frame comprising: a process layer, a perimeter barrier and at least one low aspect ratio cavity; at least one frame comprising: a process layer, two perimeter barriers, and at least two low aspect ratio cavities disposed on a second process layer; at least one layer comprising a perimeter barrier formed on one side of a process layer with at least one low aspect ratio cavity; or combinations of (i) and (iii) joined together; joining at least two intermediate assemblies together to create a compact chemical reactor with at least one high aspect ratio cavity; and joining the compact chemical reactor with at least one high aspect ratio cavity to two reactant plenums to facilitate a transport process between the reactant plenums and the process layers.

Abstract: The fuel cell layer with a central axis includes a first and a second unit fuel cell, an oxidant plenum comprising an oxidant; and a fuel plenum comprises a fuel; and each unit fuel cell comprises: a first and second process layer; a first cavity and second cavity formed between the first and second process layer and a first process layer of an adjacent unit fuel cell; a first perimeter barrier disposed on the second process layer substantially surrounding the second cavity; a second perimeter barrier disposed on the first process layer substantially surrounding the first cavity forming a unit fuel cell comprising a front face and back face; the first cavity is in communication with the oxidant plenum; the second cavity is in communication with the fuel plenum; wherein at least one of the process layers transports ions between the first and second cavities.

Abstract: The compact chemical reactor with a central axis includes at least two unit reactors disposed adjacent to each other to form front and back sides of the compact chemical reactor; a front and back reactant plenum communicating with the front and back side respectively; at least one of the plenums comprises a reactant; and unit reactors comprising: a front cavity between front and back process layers; a back cavity between back and front process layers of adjacent unit reactors; the process layers facilitate transport processes between reactant plenums; each cavity communicates with one side of the compact chemical reactor; a front and back perimeter barrier on the back and front process layers respectfully, substantially surrounding respective cavities. At least one of the unit reactors comprise at least one frame formed from one of the process layers, at least one of the perimeter barriers, and at least one of the cavities.

Abstract: The compact chemical reactor includes one or more unit reactors, a front reactant plenum, and a back reactant plenum. Each unit reactor is made of a front and back process layer, a front and back cavity, and a front and back perimeter barrier. The resulting assemblage is configured so the front cavity is in communication with the front side of the compact chemical reactor and the back cavity is in communication with the back side of the compact chemical reactor. The process layers facilitate an exchange of reactants between the reactant plenums.

Abstract: A fuel cell layer with a fuel plenum, an oxidant, and a plurality of fuel cells, wherein each fuel cell has a porous substrate, a channel, an anode and a cathode formed in opposite channel walls, an electrolyte contacting the anode and the cathode preventing transfer of fuel to the cathode and transfer of oxidant to the anode, a coatings to prevent fuel or oxidant from entering a portion of the porous substrate, a first sealant barrier disposed on the first side and the second sealant barrier disposed on the second side, and a positive and a negative electrical connection disposed on the second side, wherein multiple fuel cells are connected and the fuel cell assembly generates a current to drive an external load.

Abstract: The invention is a multiple fuel cell layer structure with numerous fuel cell layers, each fuel cell has an anode, a cathode, a positive end and a negative end, wherein a first fuel cell layer is stacked on top of a second fuel cell layer such that the anode side of the first fuel cell and the anode side of the second fuel cell adjoin, additional fuel cell layers can then added in a like manner, at least one seal disposed between the adjacent fuel cell layers forming at least one plenum, and a positive and a negative connector is connected to the stack to an outside load such that when fuel is presented to the anode sides of the fuel cell layers and oxidant is presented to the cathode sides of the fuel cell layers current is produced to drive the outside load.

Abstract: The invention is an electrochemical cell for the separation of hydrogen and oxygen from water made of a fuel plenum with a fuel inlet, a oxidant plenum, a porous substrate, an undulating channel with walls, a support member between the walls, an anode and a cathode in the walls, an electrolyte contacting the anode and the cathode forming a barrier preventing transfer of fuel and oxidant to the cathode or to the anode, a two separate coatings on the porous substrate to prevent fuel or oxidant from entering the porous substrate, a sealant barrier to divide the two plenums, and a negative electrical and a positive electrical connection on the side of the porous substrate for flowing current from an outside source to the porous substrate.

Abstract: The invention is a fuel cell layer for connecting to an external load made of a fuel plenum, an oxidant plenum, a porous substrate connecting the fuel and oxidant plenums, and a plurality of fuel cells, wherein each cell has a distinct channel, two catalyst layers, an anode in one layer and a cathode in the other layer, an electrolyte in the channel to prevent transfer of fuel to the cathode and oxidant to the anode, two coatings on the porous substrate to prevent fuel or oxidant, sealant barriers, and a positive electrical and negative electrical connection disposed on the side of the channel.