A Solid Oxide Cell stack has an integrated interconnect and spacer, which is formed by bending a surplus part of the plate interconnect 180° to form a spacer part on top of the interconnect and connected to the interconnect at least by the bend.

A Solid Oxide Cell stack has an integrated interconnect and spacer, which is formed by bending a surplus part of the plate interconnect 180° to form a spacer part on top of the interconnect and connected to the interconnect at least by the bend.

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.

Materials for electrochemical cells are provided. BaZr.sub.0.4Ce.sub.0.4M.sub.0.2O.sub.3 compounds, where M represents one or more rare earth elements, are provided for use as electrolytes. PrBa.sub.0.5Sr.sub.0.5Co.sub.2−xFe.sub.xO.sub.5+δ is provided for use as a cathode. Also provided are electrochemical cells, such as protonic ceramic fuel cells, incorporating the compounds as electrolytes and cathodes.

Materials for electrochemical cells are provided. BaZr.sub.0.4Ce.sub.0.4M.sub.0.2O.sub.3 compounds, where M represents one or more rare earth elements, are provided for use as electrolytes. PrBa.sub.0.5Sr.sub.0.5Co.sub.2−xFe.sub.xO.sub.5+δ is provided for use as a cathode. Also provided are electrochemical cells, such as protonic ceramic fuel cells, incorporating the compounds as electrolytes and cathodes.

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.

Various embodiments disclose a glow plug for a solid oxide fuel cell system. The glow plug includes a housing having a first end portion and a second end portion. The glow plug includes a heating element longitudinally disposed in the housing, extending from the second end portion of the housing towards the first end portion and extending outwardly from the housing for igniting fuel. Further, the glow plug includes a pair of coiled wires electrically connected to the heating element. Further, the glow plug includes a potting compound disposed within the second end portion of the housing for securing electrical coupling of the pair of coiled wires with the heating element. Furthermore, the glow plug includes a sealing element configured to form an air-tight connection between the housing and the heating element. The sealing element is positioned on top of the potting compound.

Various embodiments disclose a glow plug for a solid oxide fuel cell system. The glow plug includes a housing having a first end portion and a second end portion. The glow plug includes a heating element longitudinally disposed in the housing, extending from the second end portion of the housing towards the first end portion and extending outwardly from the housing for igniting fuel. Further, the glow plug includes a pair of coiled wires electrically connected to the heating element. Further, the glow plug includes a potting compound disposed within the second end portion of the housing for securing electrical coupling of the pair of coiled wires with the heating element. Furthermore, the glow plug includes a sealing element configured to form an air-tight connection between the housing and the heating element. The sealing element is positioned on top of the potting compound.

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.