A cell of the present invention is obtained by locating a first electrode layer on a porous supporting body, a solid electrolyte layer that is formed of a ceramic on the first electrode layer, and a second electrode layer on the solid electrolyte layer, wherein an amount of Na in the supporting body is 3010.sup.6 mass % or less.

Herein disclosed is a method of making an electrochemical reactor comprising a) depositing a composition on a substrate to form a slice; b) drying the slice using a non-contact dryer; c) sintering the slice using electromagnetic radiation (EMR), wherein the electrochemical reactor comprises an anode, a cathode, and an electrolyte between the anode and the cathode. In an embodiment, the electrochemical reactor comprises at least one unit, wherein the unit comprises the anode, the cathode, the electrolyte and an interconnect and wherein the unit has a thickness of no greater than 1 mm. In an embodiment, the anode is no greater than 50 microns in thickness, the cathode is no greater than 50 microns in thickness, and the electrolyte is no greater than 10 microns in thickness.

Herein disclosed is a method of making an electrochemical reactor comprising a) depositing a composition on a substrate to form a slice; b) drying the slice using a non-contact dryer; c) sintering the slice using electromagnetic radiation (EMR), wherein the electrochemical reactor comprises an anode, a cathode, and an electrolyte between the anode and the cathode. In an embodiment, the electrochemical reactor comprises at least one unit, wherein the unit comprises the anode, the cathode, the electrolyte and an interconnect and wherein the unit has a thickness of no greater than 1 mm. In an embodiment, the anode is no greater than 50 microns in thickness, the cathode is no greater than 50 microns in thickness, and the electrolyte is no greater than 10 microns in thickness.

Various embodiments may provide a method of forming an energy conversion device. The method may include forming an electrolyte layer on the first surface of the semiconductor substrate. The method may also include forming a cavity on the second surface of the semiconductor substrate using a deep reactive ion etch. The method may further include enlarging said cavity by carrying out one or more wet etches so that the enlarged cavity is at least partially defined by a vertical arrangement comprising a first lateral cavity surface of the semiconductor substrate extending substantially along a first direction, and a second lateral cavity surface of the semiconductor substrate adjoining the first lateral cavity surface. The method may include forming a first electrode on a first surface of the electrolyte layer, and forming a second electrode on a second surface of the electrolyte layer.

Various embodiments may provide a method of forming an energy conversion device. The method may include forming an electrolyte layer on the first surface of the semiconductor substrate. The method may also include forming a cavity on the second surface of the semiconductor substrate using a deep reactive ion etch. The method may further include enlarging said cavity by carrying out one or more wet etches so that the enlarged cavity is at least partially defined by a vertical arrangement comprising a first lateral cavity surface of the semiconductor substrate extending substantially along a first direction, and a second lateral cavity surface of the semiconductor substrate adjoining the first lateral cavity surface. The method may include forming a first electrode on a first surface of the electrolyte layer, and forming a second electrode on a second surface of the electrolyte layer.

The fuel cell single cell of the present invention includes: a fuel cell unit in which an anode electrode, an electrolyte layer and a cathode electrode are sequentially laminated; a separator; and a current collection assisting layer disposed between the cathode electrode of the fuel cell unit and the separator. The separator has protruded portions that are in contact with the current collection assisting layer to form gas channels between the separator and the current collection assisting layer. Further, at least a part of an end of the cathode electrode in a planar direction of the cathode electrode extends outward beyond an end of the current collection assisting layer in a planar direction of the current collection assisting layer.

The fuel cell single cell of the present invention includes: a fuel cell unit in which an anode electrode, an electrolyte layer and a cathode electrode are sequentially laminated; a separator; and a current collection assisting layer disposed between the cathode electrode of the fuel cell unit and the separator. The separator has protruded portions that are in contact with the current collection assisting layer to form gas channels between the separator and the current collection assisting layer. Further, at least a part of an end of the cathode electrode in a planar direction of the cathode electrode extends outward beyond an end of the current collection assisting layer in a planar direction of the current collection assisting layer.

In various embodiments, techniques for fabricating solid oxide fuel cells utilize setter plates composed of or having outer surfaces composed of materials unreactive with species found in the layers of the cell.

In various embodiments, techniques for fabricating solid oxide fuel cells utilize setter plates composed of or having outer surfaces composed of materials unreactive with species found in the layers of the cell.

The invention provides solid oxide fuel cell devices and systems, each including an elongate substrate having an active end region for heating to an operating reaction temperature, and a non-active end region that remains at a low temperature below the operating reaction temperature when the active end region is heated. An electrolyte is disposed between anodes and cathodes in the active end region, and the anodes and cathodes each have an electrical pathway extending to an exterior surface in the non-active end region for electrical connection at low temperature. The system further includes the devices positioned with their active end regions in a hot zone chamber and their non-active end regions extending outside the chamber. A heat source is coupled to the chamber to heat the active end regions to the operating reaction temperature, and fuel and air supplies are coupled to the substrates in the non-active end regions.