Patent ID: 8293429

Claim:
A method of making a fuel cell device comprising: forming a stacked structure having four side edges and comprising a plurality of ceramic layers, anode layers, cathode layers and internal sacrificial organic layers arranged so as to provide intervening ceramic layers separating the anode layers from the cathode layers and internal sacrificial organic layers adjacent each of the anode and cathode layers opposite the intervening ceramic layers, wherein the sacrificial organic layers are sized to provide internal gas passages, each internal gas passage extending from an input in one of the side edges to an output in one of the side edges; providing a plurality of removable structures in contact with the sacrificial organic layers, spaced between each of the inputs and outputs, and extending to one or more of the side edges of the stacked structure; laminating the stacked structure; removing the removable structures to form a plurality of bake-out ports between each of the inputs and outputs; after removing the removable structures, removing the sacrificial organic layers to form the internal gas passages by heating the stacked structure to bake out the material of the sacrificial organic layers, wherein the material exits via the plurality of bake-out ports; and thereafter, sealing the bake-out ports with a barrier material, leaving only the inputs and outputs open at the side edges to the internal gas passages.