Abstract: According to one aspect of the present invention the fuel cell device includes an electrolyte sheet. The electrolyte sheet has a substantially non-porous body of a varied thickness, a relatively smooth surface and a more textured surface with multiple indentations therein, wherein the thickest part of the electrolyte sheet is at least 0.5 micrometers greater than the thinnest part of said electrolyte sheet. The side of the electrolyte sheet with a relatively smooth surface is subjected to the predominately tensile force and the other, more textured surface subjected to predominately compressive force. According to one embodiment, the fuel cell also includes one cathode disposed on the more textured side of said electrolyte sheet at least at least one anode disposed opposite the cathode on the relatively smooth side of aid electrolyte sheet.

Abstract: A method of replacing a fuel cell packet module in a fuel cell stack, said method comprising: (i) powering down the fuel cell stack; (ii) electrically disconnecting the fuel cell packet module from external power load, (iii) mechanically disconnecting the fuel cell packet module from the fuel cell stack; and (iv) removing the fuel cell packet module from the stack.

Abstract: An exemplary method of making a fuel cell device assemblies includes the steps of: (i) providing a ceramic batch; (ii) extruding the ceramic batch through a die and a mask to form green extrudate that, in cross-section, has at least 10 cells/in2 and wall thickness of 50 mils or less; (iii) cutting the green extrudate to an appropriate length to form a green frame blank; (iv) sintering the green frame blank at a temperature of at least 1200° C., preferably at a temperature of between 1400° C. and 1600° C. for at least one hour to form a ceramic frame with a plurality of parallel channels; (v) inserting at least one fuel cell array into its designated position within the ceramic frame; and (vi) sealing the at least one fuel cell array to the frame.

Abstract: An exemplary fuel cell device assembly includes: (i) an electrolyte sheet; (ii) a plurality of cathodes disposed on one side of the electrolyte sheet; (iii) a plurality of anodes disposed on another side of the electrolyte sheet; and (iv) a frame supporting the electrolyte sheet, the frame having a plurality of channels. Preferably the cross-sectional area of the frame has channel density of at least 20/in2 and channel wall thickness of 50 mils or less.

Abstract: According to one aspect of the invention a fuel cell device comprises: a plurality of fuel cells, each of the plurality of fuel cells having an active area, wherein at least two of the plurality of fuel cells have differently sized active area, such that ratio of the active areas of these two fuel cells is at least 1.1:1.

Abstract: A solid oxide fuel cell device comprises: (a) zirconia based electrolyte; (b) at least one ectrode situated on the electrolyte; (c) a component situated in close proximity to the electrolyte, the component comprising at least one metal or metal oxide capable, at temperatures of above 625° C., of: (i) migrating to the surface of this component, and (ii) being re-deposited on said at least one electrode; and (d) a protective coating situated on at least one surface of this component. The protective coating substantially prevents the at least one metal or metal oxide from leaving the surface of the component, which is situated under said protective coating. The protective coating is also being substantially impermeable to oxygen.