A metal-supported anode for a solid oxide fuel cell is provided that includes a metal substrate having at least one hole formed therein, and an anode material formed on a first surface of the metal substrate. The anode material is also formed within each of the at least one hole. The at least one hole extends from the first surface of the metal substrate to a second surface of the metal substrate opposite the first surface, and the at least one hole has a different size at the first surface of the metal substrate than at the second surface of the metal substrate.

A fuel cell 1 includes a silicon substrate 2, a porous support material layer 5, a plurality of holes 60 or columns 40, and a stacked body. The stacked body includes an upper electrode layer 10, a solid electrolyte layer 100 and a lower electrode layer 20. The upper electrode layer 10 is also formed on a surface parallel to a main surface of the silicon substrate 2 in a manner of being continuous to the upper electrode layer 10 formed in the plurality of holes 60 or columns 40, or the lower electrode layer 20 is also formed on a surface parallel to the main surface of the silicon substrate 2 in a manner of being continuous to the lower electrode layer 20 formed in the plurality of holes 60 or columns 40. The stacked body is supported by the porous support material layer 5 in at least upper end portions and lower end portions of the plurality of holes 60 or columns 40.

A design of and the process for forming a rigidly bonded metal supported electro-chemical device stack is provided. The electro-chemical device stack can be a solid oxide fuel cell or solid oxide electrolysis stack. The stack comprises multiple planar cells connected in serial by planar metal interconnects. The cells have metal support layers on both anode and cathode sides. The interconnect has gas channels embedded. Thin ceramic electro-chemical active electrodes and electrolyte are sandwiched between the metal support layers. The cells and interconnects are rigidly bonded to form a rigid body stack. The process comprises the steps of a). forming metal supported electro-chemical device cells with metal supports on both anode and cathode sides, b). sealing the peripherals of porous cell layers with an electrically insulating sealing material such as glass. c). bonding the cells and interconnects through commonly used metal-to-metal bonding methods, such as brazing or laser welding.

A design of and the process for forming a rigidly bonded metal supported electro-chemical device stack is provided. The electro-chemical device stack can be a solid oxide fuel cell or solid oxide electrolysis stack. The stack comprises multiple planar cells connected in serial by planar metal interconnects. The cells have metal support layers on both anode and cathode sides. The interconnect has gas channels embedded. Thin ceramic electro-chemical active electrodes and electrolyte are sandwiched between the metal support layers. The cells and interconnects are rigidly bonded to form a rigid body stack. The process comprises the steps of a). forming metal supported electro-chemical device cells with metal supports on both anode and cathode sides, b). sealing the peripherals of porous cell layers with an electrically insulating sealing material such as glass. c). bonding the cells and interconnects through commonly used metal-to-metal bonding methods, such as brazing or laser welding.

A composite member includes a base member and a covering layer. The base member includes a first surface not exposed to an oxidizing atmosphere and contains chromium. The covering layer covers the first surface and includes a first outer surface that is not exposed to the oxidizing atmosphere. At least one of the base member and the covering layer includes an exposed surface that is exposed to the oxidizing atmosphere. The surface roughness of the exposed surface is different from the surface roughness of the first surface or the first outer surface.

A composite member includes a base member and a covering layer. The base member includes a first surface not exposed to an oxidizing atmosphere and contains chromium. The covering layer covers the first surface and includes a first outer surface that is not exposed to the oxidizing atmosphere. At least one of the base member and the covering layer includes an exposed surface that is exposed to the oxidizing atmosphere. The surface roughness of the exposed surface is different from the surface roughness of the first surface or the first outer surface.

A method of forming an interlayer of a solid oxide cell unit on the surface of a substrate may include: providing a base interlayer solution comprising a solution of a soluble salt precursor of a metal oxide (crystalline) ceramic and crystalline nanoparticles, depositing the base interlayer solution onto the surface of the substrate, drying the base interlayer solution to define a nanocomposite sub-layer of the soluble salt precursor and nanoparticles, heating the sub-layer to decompose it and form a film of metal oxide comprising nanoparticles on the surface, and firing the substrate with the film on the metal surface, to form a nanocomposite crystalline layer.

A method of forming an interlayer of a solid oxide cell unit on the surface of a substrate may include: providing a base interlayer solution comprising a solution of a soluble salt precursor of a metal oxide (crystalline) ceramic and crystalline nanoparticles, depositing the base interlayer solution onto the surface of the substrate, drying the base interlayer solution to define a nanocomposite sub-layer of the soluble salt precursor and nanoparticles, heating the sub-layer to decompose it and form a film of metal oxide comprising nanoparticles on the surface, and firing the substrate with the film on the metal surface, to form a nanocomposite crystalline layer.

Disclosed is a method of manufacturing a solid oxide fuel cell including a multi-layered electrolyte layer using a calendering process. The method for manufacturing a solid oxide fuel cell is a continuous process, thus providing high productivity and maximizing facility investment and processing costs. In addition, the solid oxide fuel cell manufactured by the method includes an anode that is free of interfacial defects and has a uniform packing structure, thereby advantageously greatly improving the production yield and power density. In addition, the solid oxide fuel cell has excellent interfacial bonding strength between respective layers included therein, and includes a multi-layered electrolyte layer in which the secondary phase at the interface is suppressed and which has increased density, thereby advantageously providing excellent output characteristics and long-term stability even at an intermediate operating temperature.

A planar SOFC cell unit is formed from a plurality of planar elements (1100, 1200, 1300) stacked one above another. The cell unit encloses a cell chamber (1400) that includes a solid oxide fuel cell (2000) configured for electro-chemical generation, compliantly supported within the cell chamber. The plurality planar elements each comprise a thermally conductive material having a co-efficient of thermal conductivity that is a least 100 W/mK such as aluminum or copper. The planar elements are thermally conductively coupled to each other to provide a continuous thermally conductive pathway that extends from perimeter edges of the cell chamber to perimeter edges of the plurality of planar elements. An SOFC stack comprises a plurality of the planar SOFC cell units stacked one above another.