Thermo-mechanical robust seal structure for solid oxide fuel cells

A solid oxide fuel cell device comprising:

• a frame;
• and
• a ceramic electrolyte sheet in communication with the frame, comprising:
• an active area positioned at the center of the ceramic electrolyte sheet;
• and
• an inactive area positioned around the active area, comprising:
• a street width area, concentrically positioned adjacent to the active area, and
• a seal area, concentrically positioned around the street width area;
• wherein the ceramic electrolyte sheet seal area is substantially flat, and wherein at least a portion of the ceramic electrolyte sheet has a thickness of less than about 50 μm.

A solid oxide fuel cell device comprising:

• a frame;
• a ceramic electrolyte sheet in communication with the frame, comprising:
• an active area positioned at the center of the ceramic electrolyte sheet;
• and
• an inactive area positioned around the active area, comprising:
• a street width area positioned adjacent to the active area, and
• a seal area positioned around the street width area;
• and
• at least one border material, wherein at least a portion of that one border material is in contact with at least a portion of the seal area, and wherein the border material is substantially flat.

A method of making a solid oxide fuel cell device, comprising:

• providing a frame and a device comprising a ceramic electrolyte sheet;
• applying a seal to at least a portion of the ceramic electrolyte sheet;
• and then
• attaching the device to the frame such that the seal has a uniform thickness, said method further comprising applying a seal to both at least a portion of the ceramic electrolyte sheet and at least a portion of the frame prior to attaching.