Patent ID: 8278013

Claim:
A method of making a fuel cell device comprising: providing a first elongate green ceramic layer; applying an anode layer on a first side of the first elongate green ceramic layer and applying a cathode layer on an opposing second side of the first elongate green ceramic layer, the anode layer and cathode layer being in general alignment within a first portion of the first elongate green ceramic layer to provide an active fuel cell portion; applying a sacrificial organic layer over each of the anode layer and the cathode layer; positioning at least one removable structure on each of the first and second sides of a second portion of the first elongate green ceramic layer with a first end of each removable structure overlapping the respective sacrificial organic layer and a second end extending at least to an edge of the first elongate green ceramic layer; applying a second elongate green ceramic layer over the sacrificial organic layer and removable structure on each of the first and second sides in general alignment with the first elongate green ceramic layer to provide a ceramic support structure surrounding the active fuel cell portion; laminating all the layers and removable structures together to form a laminated structure; removing the removable structures from the laminated structure to form non-active passages along the second portion between the respective edge and the anode and cathode layers and within the ceramic support structure; and heating the laminated structure to a temperature sufficient to burn-out the sacrificial organic layers to form active passages in the active fuel cell portion along the anode and cathode layers and surrounded by the ceramic support structure.