The present invention relates to an improved metal supported solid oxide fuel cell unit, fuel cell stacks, fuel cell stack assemblies, and methods of manufacture.

The present invention relates to an improved metal supported solid oxide fuel cell unit, fuel cell stacks, fuel cell stack assemblies, and methods of manufacture.

A solid oxide fuel cell includes a metal support cell, in which an anode layer containing nickel, an electrolyte layer and a cathode layer are stacked on a metal support portion. In the method for activating the anode layer in the solid oxide fuel cell, first, an oxygen-containing gas is introduced into the anode layer to oxidize the nickel. Next, a hydrogen-containing gas HG is introduced into the anode layer to reduce the nickel oxide formed by oxidizing the nickel, and to increase conduction paths of the nickel that electrically connect the electrolyte layer to the metal support part in the anode layer.

A solid oxide fuel cell includes a metal support cell, in which an anode layer containing nickel, an electrolyte layer and a cathode layer are stacked on a metal support portion. In the method for activating the anode layer in the solid oxide fuel cell, first, an oxygen-containing gas is introduced into the anode layer to oxidize the nickel. Next, a hydrogen-containing gas HG is introduced into the anode layer to reduce the nickel oxide formed by oxidizing the nickel, and to increase conduction paths of the nickel that electrically connect the electrolyte layer to the metal support part in the anode layer.

A solid oxide fuel cell includes a metal support cell, in which an anode layer containing nickel, an electrolyte layer and a cathode layer are stacked on a metal support portion. In the method for activating the anode layer in the solid oxide fuel cell, first, an oxygen-containing gas is introduced into the anode layer to oxidize the nickel. Next, a hydrogen-containing gas HG is introduced into the anode layer to reduce the nickel oxide formed by oxidizing the nickel, and to increase conduction paths of the nickel that electrically connect the electrolyte layer to the metal support part in the anode layer.

A solid oxide fuel cell includes a metal support cell, in which an anode layer containing nickel, an electrolyte layer and a cathode layer are stacked on a metal support portion. In the method for activating the anode layer in the solid oxide fuel cell, first, an oxygen-containing gas is introduced into the anode layer to oxidize the nickel. Next, a hydrogen-containing gas HG is introduced into the anode layer to reduce the nickel oxide formed by oxidizing the nickel, and to increase conduction paths of the nickel that electrically connect the electrolyte layer to the metal support part in the anode layer.

A cell may include a columnar support having a first main face and a second main face; and an element comprising a first electrode layer, a solid electrolyte layer, and a second electrode layer laminated in sequence on the first main face of the support. The porosity of at least one of the two end portions of the support in the longitudinal direction L may be lower than that of the central portion of the support in the longitudinal direction L.

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 with the length direction being the dominant direction of thermal expansion. A reaction zone having at least one active layer therein is spaced from the first end and includes first and second opposing electrodes, associated active first and second gas passages, and electrolyte. The active first gas passage includes sub-passages extending in the y direction and spaced apart in the x direction. An artery flow passage extends from the first end along the length and into the reaction zone and is fluidicly coupled to the sub-passages of the active first gas passage. The thickness of the artery flow passage is greater than the thickness of the sub-passages. In other embodiments, fuel cell devices include second sub-passages for the active second gas passage and a second artery flow passage coupled thereto, and extending from either the first end or the second end into the reaction zone. In yet other embodiments, one or both electrodes of a fuel cell device are segmented.

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 with the length direction being the dominant direction of thermal expansion. A reaction zone having at least one active layer therein is spaced from the first end and includes first and second opposing electrodes, associated active first and second gas passages, and electrolyte. The active first gas passage includes sub-passages extending in the y direction and spaced apart in the x direction. An artery flow passage extends from the first end along the length and into the reaction zone and is fluidicly coupled to the sub-passages of the active first gas passage. The thickness of the artery flow passage is greater than the thickness of the sub-passages. In other embodiments, fuel cell devices include second sub-passages for the active second gas passage and a second artery flow passage coupled thereto, and extending from either the first end or the second end into the reaction zone. In yet other embodiments, one or both electrodes of a fuel cell device are segmented.

A solid oxide fuel cell includes an Si support substrate having a through hole, an electrolyte film formed on the surface of an Si support substrate and containing a solid oxide having oxygen ion conductivity, a first electrode formed on a surface of the electrolyte film (surface on the side opposite to the Si support substrate), and a second electrode formed at least on a surface exposed from the through hole in a rear face of the electrolyte film. The electrolyte film includes a porous layer including the solid oxide and containing pores inside, a first dense layer formed on a surface of the porous layer (surface on the side opposite to the Si support substrate), and a second dense layer formed at the interface between a rear face of the porous layer and the Si support substrate.