Patent ID: 7455925

Claim:
A fuel cell layer comprising at least one fuel cell in communication with a first reactant plenum and a second reactant plenum, wherein one of the reactant plenums contains oxidant and the other reactant plenum contains fuel, wherein said at least one fuel cell comprises: a gas barrier region formed by disposing gas barrier material on a substrate; b. a second region having a first port extending along an edge of the second region by disposing on the gas baffler: i. a first gas diffusion electrode having a first perimeter ii. a first seal at least partially disposed around the first perimeter; wherein said first port communicates with the first gas diffusion electrode and the first reactant plenum; c. an electrolyte region formed by disposing electrolyte material on the second region; d. a fourth region having a second port extending along an edge of the fourth region by disposing on the electrolyte region: i. a second gas diffusion electrode having a second perimeter; ii. a second seal at least partially disposed around the second perimeter, wherein said second port communicates with the second gas diffusion electrode and the second reactant plenum; and iii. wherein the second and fourth regions are in communication with the electrolyte region, and the gas baffler region separates the first reactant plenum from the second reactant plenum, further wherein prior to disposition on the substrate, the substrate is gouged to form a channel, and then each region is disposed into the channel.