Patent ID: 7790332

Claim:
A method avoiding assembly of separately manufactured parts, and capable of manufacturing a fuel cell device having at least one electrochemical cell, each cell being less than 0.2 mm thick, comprising an electrolyte matrix material body and, fully embedded within said electrolyte matrix material, at least two separate electrodes forming said electrochemical cell, electrodes characterized as formed simultaneously with formation of the fuel cell; electrode material consisting of a mixture of a conductive material for conducting electrons; a catalyst, and a high vapor pressure material for creation of pores within electrodes; the electrodes being rod shaped and sufficiently porous to allow gas flow through them; one electrode being an electrically negative anode and the other electrode being an electrically positive cathode, and said electrolyte capable of carrying charged particles between said anode and cathode; said anode and cathode capable of being electrically connected to form an electrical circuit; said method of manufacturing consisting of steps: a) distributing in two separate predetermined patterns, mixtures of powder particles of said electrode material within a solid electrolyte matrix material, to create a composite, said distributed electrode material being completely surrounded by said electrolyte matrix material, b) heating said composite to a pore forming temperature to evaporate said high vapor pressure material to cause it to form interconnecting pores within said electrodes, the pores causing said electrodes to expand, said interconnecting pores allowing passage through and delivery of reactant gases to electrolyte-electrode interfaces.