Patent ID: 9577281
Date: 2017-02-21
CPC Classifications: H01M,Y02E,Y02P

Claim:
1. A method of making a monolithic fuel cell device comprising: preparing a first active cell structure comprising a first anode layer, a first cathode layer, and a first electrolyte layer therebetween; preparing a second active cell structure comprising a second anode layer, a second cathode layer, and a second electrolyte layer therebetween, each of the first and second anode layers and first and second cathode layers having a plurality of embedded spaced-apart removable physical structures therein; preparing a first interconnect sublayer comprising a first layer of non-conductive material with a first pattern of holes formed therein and a first conductor layer formed on one surface of the first layer of non-conductive material; preparing a second interconnect sublayer comprising a second layer of non-conductive material with a second pattern of holes formed therein and a second conductor layer formed on one surface of the second layer of non-conductive material; preparing an interconnect layer by placing the first and second interconnect sublayers together with the first and second conductor layers in contact and with the first and second pattern of holes offset such that holes of the first pattern of holes do not overlap with holes of the second pattern of holes; stacking the interconnect layer between the first anode layer and the second cathode layer; laminating the first active cell structure, the interconnect layer, and the second active cell structure together to form a laminated multi-layer stack wherein the first anode layer fills the first pattern of holes and the second cathode layer fills the second pattern of holes; pulling the removable physical structures out of the laminated multi-layer stack to reveal gas passages embedded and spaced apart in each of the first and second anode layers and first and second cathode layers; and sintering the laminated multi-layer stack to form first and second active cells connected in series by the interconnect layer.