Abstract: 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. A reaction zone positioned along a portion of the length is configured to be heated to an operating reaction temperature, and has at least one active layer therein comprising an electrolyte separating first and second opposing electrodes, and active first and second gas passages adjacent the respective first and second electrodes. At least one cold zone positioned from the first end along another portion of the length is configured to remain below the operating reaction temperature. An artery flow passage extends from the first end along the length through the cold zone and into the reaction zone and is fluidicly coupled to the active first gas passage, which extends from the artery flow passage toward at least one side. The thickness of the artery flow passage is greater than the thickness of the active first gas passage.

Abstract: The present invention relates to a fuel cell system. A hot zone chamber has a wall thickness T and a heat source coupled thereto. An elongate fuel cell device is positioned with a first lengthwise portion within the hot zone chamber, a second lengthwise portion outside the hot zone chamber, and a third lengthwise portion of length T within the chamber wall. The third portion has a maximum dimension L in a plane transverse to the length where T?½L.

Abstract: A fuel cell device including an elongate ceramic substrate having an exterior surface defining an interior ceramic support structure and having a length that is at least 5 times greater than the width and the thickness so as to exhibit thermal expansion along a dominant axis coextensive with the length. The substrate has an active zone and at least one non-active end region. The active zone has an anode and a cathode in opposing relation with an electrolyte therebetween and the non-active end region lacks the anode and cathode in opposing relation and extends away from the active zone to dissipate heat. The electrolyte, anode and cathode extend within the interior ceramic support structure, the anode and cathode each have an electrical pathway extending from within the interior ceramic support structure to the exterior surface in the non-active end region, and the electrolyte is a ceramic co-fired with the interior ceramic support structure.

Abstract: The invention provides tubular solid oxide fuel cell devices and a fuel cell system incorporating a plurality of the fuel devices, each device including an elongate tube having a reaction zone for heating to an operating reaction temperature, and at least one cold zone that remains at a low temperature below the operating reaction temperature when the reaction zone is heated. An electrolyte is disposed between anodes and cathodes in the reaction zone, and the anode and cathode each have an electrical pathway extending to an exterior surface in a cold zone for electrical connection at low temperature. In one embodiment, the tubular device is a spiral rolled structure, and in another embodiment, the tubular device is a concentrically arranged device. The system further includes the devices positioned with their reaction zones in a hot zone chamber and their cold zones extending outside the hot zone chamber.

Abstract: 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. A reaction zone positioned along a portion of the length is configured to be heated to an operating reaction temperature, and has at least one active layer therein comprising an electrolyte separating first and second opposing electrodes, and active first and second gas passages adjacent the respective first and second electrodes. At least one cold zone positioned from the first end along another portion of the length is configured to remain below the operating reaction temperature. An artery flow passage extends from the first end along the length through the cold zone and into the reaction zone and is fluidicly coupled to the active first gas passage, which extends from the artery flow passage toward at least one side. The thickness of the artery flow passage is greater than the thickness of the active first gas passage.

Abstract: Fuel cell devices and fuel cell systems are provided. In certain embodiments, the fuel cell devices may include one or more active layers containing active cells that are connected electrically in series. In certain embodiments, the fuel cell devices include an elongate ceramic support structure the length of which is the greatest dimension such that the coefficient of thermal expansion has only one dominant axis coextensive with the length. In certain embodiments, a reaction zone is positioned along a first portion of the length for heating to a reaction temperature, and at least one cold zone is positioned along a second portion of the length for operating below the reaction temperature. There are one or more gas passages, each having an associated anode or cathode.

Abstract: The invention relates to fuel cell devices and systems, and methods of using and making fuel cell devices and systems. The fuel cell devices include an elongate ceramic substrate, such as a rectangular or tubular substrate, the length of which is the greatest dimension such that thermal expansion is exhibited along a dominant axis that is coextensive with the length. A reaction zone is positioned along a first portion of the length for heating to an operating reaction temperature, and at least one cold zone is positioned along a second portion of the length for operating at a temperature below the operating reaction temperature. There are one or more fuel passages and one or more oxidizer passages extending within an interior solid support structure of the elongate substrate, each having an associated anode and cathode, respectively, which are separated by an electrolyte. The passages include a neck-down point.

Abstract: The invention provides tubular solid oxide fuel cell devices and a fuel cell system incorporating a plurality of the fuel devices, each device including an elongate tube having a reaction zone for heating to an operating reaction temperature, and at least one cold zone that remains at a low temperature below the operating reaction temperature when the reaction zone is heated. An electrolyte is disposed between anodes and cathodes in the reaction zone, and the anode and cathode each have an electrical pathway extending to an exterior surface in a cold zone for electrical connection at low temperature. In one embodiment, the tubular device is a spiral rolled structure, and in another embodiment, the tubular device is a concentrically arranged device. The system further includes the devices positioned with their reaction zones in a hot zone chamber and their cold zones extending outside the hot zone chamber.

Abstract: The present invention relates to a method of making fuel cell devices. A stack structure is formed having plural ceramic layers, anode layers, cathode layers, and sacrificial layers, where the sacrificial layers are sized to provide internal gas passages. Removable structures are placed in contact with the sacrificial layers and extend to an edge. After laminating the stacked structure, the removable structures are pulled out to form bake-out paths that facilitate removal of the sacrificial material during a heating step, which paths are later sealed.

Abstract: A fuel cell device including an elongate ceramic substrate having an exterior surface defining an interior ceramic support structure having non-active end regions and an active zone therebetween that includes electrodes in opposing relation with an electrolyte therebetween for undergoing a fuel cell reaction when supplied with heat, fuel and oxidizer. The electrolyte is a ceramic co-fired with the interior ceramic support structure. The end regions lack opposing electrodes and extend away from the active zone to dissipate heat. Gas inlets are positioned in the end regions with respective outlets in either the active zone or opposite end region, and elongate passages are coupled therebetween at least partially extending in opposing relation through the active zone. The electrodes are positioned adjacent the gas passages in the active zone and are electrically connected to exterior contact surfaces on the exterior surface of the end regions for external connection to voltage nodes.

Abstract: A capacitor device mountable on a plane of a substrate includes an electrically conductive bottom plate adapted to be mounted substantially parallel to, and in electrical contact at the plane of the substrate and a first multilayer capacitor having substantially parallel first and second electrode plates oriented substantially perpendicular to the bottom plate with the first electrode plates being electrically connected to the bottom plate. An electrically conductive top lead frame overlaps with, and is electrically isolated from, the bottom plate. The top lead frame electrically connected to the second electrode plates and adapted to be electrically connected at the plane of the substrate. The bottom lead frame may have a corrugated shape, where the corrugated shape provides compliance between the first multilayer capacitor and the substrate. A portion of the top lead frame may contact at least a portion of a side of the first multilayer capacitor.

Abstract: The present invention relates to fuel cell devices and fuel cell systems, methods of using fuel cell devices and systems, and methods of making fuel cell devices. According to certain embodiments, the fuel cell devices may include an elongate substrate, such as a rectangular or tubular substrate, the length of which is the greatest dimension such that the coefficient of thermal expansion has only one dominant axis that is coextensive with the length. In addition, or in accordance with other certain embodiments, a reaction zone is positioned along a first portion of the length for heating to an operating reaction temperature, and at least one cold zone is positioned along a second portion of the length for operating at a temperature below the operating reaction temperature. There are one or more fuel passages in the elongate substrate, each having an associate anode, and one or more oxidizer passages in the elongate substrate, each having an associate cathode.

Abstract: The invention relates to a method of making fuel cell devices. Anode and cathode layers are applied on respective first and opposing second sides of a first portion of a first green ceramic layer, and a second green ceramic layer of thickness approximately equal to that of the anode and cathode layers is applied on a second portion of each of the first and second sides of the first green ceramic layer. A sacrificial layer is applied over each of the anode, cathode and second green ceramic layers, and a third green ceramic layer is applied over the sacrificial layers. The layered structure is heated to sinter all the layers and burn out the sacrificial layers. A pair of gas passages is thus formed with a thick sintered ceramic therebetween as a passive supporting portion and an anode, thin electrolyte and cathode therebetween as an active portion of the device.

Abstract: A fuel cell device including an elongate ceramic substrate having an exterior surface defining an interior ceramic support structure having non-active end regions and an active zone therebetween that includes electrodes in opposing relation with an electrolyte therebetween for undergoing a fuel cell reaction when supplied with heat, fuel and oxidizer. The electrolyte is a ceramic co-fired with the interior ceramic support structure. The end regions lack opposing electrodes and extend away from the active zone to dissipate heat. Gas inlets are positioned in the end regions with respective outlets in either the active zone or opposite end region, and elongate passages are coupled therebetween at least partially extending in opposing relation through the active zone. The electrodes are positioned adjacent the gas passages in the active zone and are electrically connected to exterior contact surfaces on the exterior surface of the end regions for external connection to voltage nodes.

Abstract: Fuel cell devices and fuel cell systems, methods of using same, and methods of making same are provided. In certain embodiments, the fuel cell devices may include one or more active layers containing active cells that are connected electrically in parallel and/or series. In certain embodiments, the fuel cell devices include an elongate ceramic support structure the length of which is the greatest dimension such that the coefficient of thermal expansion has only one dominant axis coextensive with the length. In certain embodiments, a reaction zone is positioned along a first portion of the length for heating to a reaction temperature, and at least one cold zone is positioned along a second portion of the length for operating below the reaction temperature. There are one or more gas passages, each having an associated anode or cathode. In some embodiments, ceramic end tubes are permanently attached to the ceramic support structure to supply gases to the passages.

Abstract: A method of making a fuel cell device comprises forming a green stacked structure to provide an internal active section of intervening green layers of ceramic material separating anode layers from cathode layers and sacrificial layers of organic material adjacent each of the anode and cathode layers opposite the intervening green layers, and a non-active section of the green layers substantially surrounding the active section. The sacrificial layers are sized to provide internal gas passages in the active section for feeding gases to the internal anodes and cathodes, and the sacrificial layers are coupled to edges of the structure to couple each of the internal gas passages to an inlet and an outlet of the device. The green stacked structure is heated to bake out the organic material to form the passages and to sinter together the green layers in the active and non-active sections.

Abstract: The present invention relates to a fuel cell system. A hot zone chamber has a wall thickness T and a heat source coupled thereto. An elongate fuel cell device is positioned with a first lengthwise portion within the hot zone chamber, a second lengthwise portion outside the hot zone chamber, and a third lengthwise portion of length T within the chamber wall. The third portion has a maximum dimension L in a plane transverse to the length where T?½ L.

Abstract: The invention relates to fuel cell devices and systems, and methods of using and making fuel cell devices and systems. The fuel cell devices include an elongate ceramic substrate, such as a rectangular or tubular substrate, the length of which is the greatest dimension such that thermal expansion is exhibited along a dominant axis that is coextensive with the length. A reaction zone is positioned along a first portion of the length for heating to an operating reaction temperature, and at least one cold zone is positioned along a second portion of the length for operating at a temperature below the operating reaction temperature. There are one or more fuel passages and one or more oxidizer passages extending within an interior solid support structure of the elongate substrate, each having an associated anode and cathode, respectively, which are separated by an electrolyte. The passages include a neck-down point.

Abstract: The invention relates to a method of making fuel cell devices. Anode and cathode layers are applied on respective first and opposing second sides of a first portion of a first green ceramic layer, and a second green ceramic layer of thickness approximately equal to that of the anode and cathode layers is applied on a second portion of each of the first and second sides of the first green ceramic layer. A sacrificial layer is applied over each of the anode, cathode and second green ceramic layers, and a third green ceramic layer is applied over the sacrificial layers. The layered structure is heated to sinter all the layers and burn out the sacrificial layers. A pair of gas passages is thus formed with a thick sintered ceramic therebetween as a passive supporting portion and an anode, thin electrolyte and cathode therebetween as an active portion of the device.

Abstract: The present invention relates to a method of making fuel cell devices. A stack structure is formed having plural ceramic layers, anode layers, cathode layers, and sacrificial layers, where the sacrificial layers are sized to provide internal gas passages. Removable structures are placed in contact with the sacrificial layers and extend to an edge. After laminating the stacked structure, the removable structures are pulled out to form bake-out paths that facilitate removal of the sacrificial material during a heating step, which paths are later sealed.