Patent ID: 7150933

Claim:
A method for making a fuel cell layer comprising the steps of: a. forming a porous substrate comprising a top and bottom, a first side and a second side; b. coating at least a portion of said top with a first coating; c. coating at least a portion of said bottom with a second coating; d. forming a plurality of distinct channels using the porous substrate, wherein each distinct channel comprises a first channel wall and a second channel wall; e. forming a plurality of anodes by depositing a plurality of first catalyst layers on said first channel walls; f. forming a plurality of cathodes by depositing a plurality of second catalyst layers in said second channel walls; g. disposing electrolyte in at least a portion of each distinct channel; h. disposing a first sealant barrier on at least a portion of said first side; i. disposing a second sealant barrier on at least a portion of said second side; j. forming a plurality of third sealant barriers between each of said distinct channels creating a plurality of independent fuel cells adjacent each other in the porous substrate; k. attaching a positive electrical connection to the first side of said porous substrate; l. attaching a negative electrical connection to said second side of said porous substrate; m. attaching a fuel cell positive electrical connection to each independent fuel cell; n. attaching a fuel cell negative electrical connection to each independent fuel cell forming a fuel cell layer; and o. disposing a sealant barrier around at least a portion of said fuel cell layer.