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 composite membrane includes an ion-conductive polymer layer; and a plurality of gas blocking inorganic particles non-continuously aligned on the ion-conductive polymer layer, wherein the composite membrane has a radius of curvature of about 10 millimeters or less.

A composite membrane includes an ion-conductive polymer layer; and a plurality of gas blocking inorganic particles non-continuously aligned on the ion-conductive polymer layer, wherein the composite membrane has a radius of curvature of about 10 millimeters or less.

An ion conductive intercalation membrane is useful to separate anode and cathode compartments in an electrochemical cell and provide ion transport between the anode and cathode compartments. The intercalation membrane does not receive and release electrons during operation of the electrochemical cell. An electric potential and current source is connected to an anode and a cathode disposed in respective anode and cathode compartments to cause oxidation and reduction reactions to occur at the anode and cathode, to cause electrons to flow through an external circuit coupled to the anode and cathode, and to cause ions to transport through the intercalation membrane to maintain charge neutrality within the electrochemical cell. The electrochemical cell operates at a current density greater than 25 mA/cm.sup.2 across the intercalation membrane.

An ion conductive intercalation membrane is useful to separate anode and cathode compartments in an electrochemical cell and provide ion transport between the anode and cathode compartments. The intercalation membrane does not receive and release electrons during operation of the electrochemical cell. An electric potential and current source is connected to an anode and a cathode disposed in respective anode and cathode compartments to cause oxidation and reduction reactions to occur at the anode and cathode, to cause electrons to flow through an external circuit coupled to the anode and cathode, and to cause ions to transport through the intercalation membrane to maintain charge neutrality within the electrochemical cell. The electrochemical cell operates at a current density greater than 25 mA/cm.sup.2 across the intercalation membrane.

A fuel cell system is provided. The fuel cells system may be a segmented-in-series, solid-oxide fuel cell system. The system may comprise a fuel cell tube. The fuel cell tube may comprise a substrate having a first and second ends and a pair of generally planar opposing major surfaces extending between the ends. The fuel cell may further comprise a plurality of fuel disposed on one of the major surfaces proximate the first end of the substrate. The fuel cell tube may further comprise a sheet conductor. The sheet conductor may be electrically coupled to the plurality of fuel cells and may provide an electrical path from a location on one of the major surfaces to a location on the other the major surfaces proximate a first end of the substrate.

A fuel cell system is provided. The fuel cells system may be a segmented-in-series, solid-oxide fuel cell system. The system may comprise a fuel cell tube. The fuel cell tube may comprise a substrate having a first and second ends and a pair of generally planar opposing major surfaces extending between the ends. The fuel cell may further comprise a plurality of fuel disposed on one of the major surfaces proximate the first end of the substrate. The fuel cell tube may further comprise a sheet conductor. The sheet conductor may be electrically coupled to the plurality of fuel cells and may provide an electrical path from a location on one of the major surfaces to a location on the other the major surfaces proximate a first end of the substrate.

The present disclosure provides a method for manufacturing a fuel cell separator that ensures easy manufacture of the fuel cell separator having sufficiently excellent conductive property. The method for manufacturing the fuel cell separator according to the present disclosure is a method for manufacturing a fuel cell separator where a conductive oxide film is formed on a surface of a metal substrate using a mist CVD method, and the method includes: preparing a raw material solution containing a precursor of the conductive oxide film and hydrochloric acid; atomizing the raw material solution to generate a mist; and supplying the mist to the surface of the metal substrate to form the conductive oxide film on the surface of the metal substrate through a reaction by heat.

An alloy member includes a base member that includes a recess in a surface of the base member and is constituted by an alloy material containing chromium, an anchor portion that is disposed in the recess and contains an oxide containing manganese, and a covering layer that is connected to the anchor portion and contains a low-equilibrium oxygen pressure element whose equilibrium oxygen pressure is lower than that of chromium.