Fuel cell device and system

Abstract

Fuel cell devices and systems are provided. A reaction zone positioned along a portion of the length is configured to be heated to an operating reaction temperature, and has at least one active layer therein comprising an electrolyte separating an anode from an opposing cathode, and fuel and oxidizer gas passages adjacent the respective anode and cathode. At least one cold zone positioned from the first end along another portion of the length is configured to remain below the operating reaction temperature. The anode and cathode each have electrical pathways extending to an exterior surface in the cold zone for electrical connection at the lower temperature. The electrolyte includes at least a portion thereof comprising a ceramic material sintered from a nano-sized powder. In one embodiment, the sintered nano-sized powder provides an uneven surface topography on the electrolyte.

What is claimed is: 
     
         1 . A fuel cell device comprising:
 an elongate substrate having a length that is the greatest dimension whereby the elongate substrate exhibits thermal expansion along a dominant axis that is coextensive with the length, a reaction zone along a first portion of the length configured to be heated to an operating reaction temperature, and at least one cold zone along a second portion of the length configured to remain at a low temperature below the operating reaction temperature when the reaction zone is heated;   at least one fuel passage in the elongate substrate extending from the at least one cold zone to the reaction zone, and having an associated anode in the reaction zone;   at least one oxidizer passage in the elongate substrate extending from the at least one cold zone to the reaction zone, and having an associated cathode in the reaction zone positioned in opposing relation to the anode; and   an electrolyte disposed between the opposing anode and cathode in the reaction zone, the anode and cathode each having an electrical pathway extending to an exterior surface of the at least one cold zone for electrical connection at the low temperature below the operating reaction temperature,   wherein the electrolyte includes at least a nano-portion comprising a ceramic material sintered from a nano-sized powder.   
     
     
         2 . The fuel cell device of  claim 1 , wherein the nano-portion is a surface portion of the electrolyte having an uneven topography resulting from distribution of the nano-sized powder along a surface of the electrolyte. 
     
     
         3 . The fuel cell device of  claim 1 , wherein the nano-sized powder has a fractal arrangement on the surface of the electrolyte outwardly decreasing in size. 
     
     
         4 . The fuel cell device of  claim 1 , wherein the nano-sized powder has an average particle size of 25 nm. 
     
     
         5 . The fuel cell device of  claim 1 , wherein the nano-sized powder has an average particle size of 50 nm. 
     
     
         6 . A fuel cell device, comprising:
 an active structure having an anode and cathode in opposing relation with an electrolyte therebetween;   a fuel passage adjacent the anode for supplying fuel to the active structure;   an air passage adjacent the cathode for supplying air to the active structure;   a porous ceramic layer between the anode and fuel passage and between the cathode and air passage, the porous ceramic layer having a porosity configured to permit transport of fuel and air from the respective fuel and air passage to the respective anode and cathode;   an inactive surrounding support structure monolithic with the electrolyte and the porous ceramic layers, wherein the inactive surrounding support structure lacks the anode and cathode in opposing relation and the active structure resides within the inactive surrounding support structure.   
     
     
         7 . The fuel cell device of  claim 6 , wherein the porous ceramic layer and the inactive surrounding support structure comprise the same type of ceramic material with the same or different porosity.