Fuel cell and method of manufacturing same using chemical/mechanical planarization

A method of making a fuel cell stack, further comprising the steps of:

• placing a first pattern on a base surface to create a predetermined topography on the base surface;
• depositing at least one of an anode layer, a cathode layer and an electrolyte layer over the first pattern;
• placing a second pattern on the at least one of an anode layer, a cathode layer and an electrolyte layer;
• depositing at least one of an anode layer, a cathode layer and an electrolyte layer over the second pattern;
• and
• removing areas of higher topography from areas of lower topography using chemical mechanical planarization to form a predetermined fuel cell stack structure.

A fuel cell, comprising:

• at least one free standing membrane structure having an end region not in contact with any adjacent structure, the end region of the free standing membrane structure comprising one leg of a substantially V shaped member, and the membrane structure comprising:
• an electrolyte layer;
• an anode aver disposed on one side of the electrolyte layer;
• and
• a cathode layer disposed on the one side or an opposed side of the electrolyte layer;
• and
• a base surface upon which an other leg of the substantially V shaped member is disposed.

A fuel cell, comprising:

• at least one free standing membrane structure having an end region not in contact with any adjacent structure, the membrane structure comprising:
• an electrolyte layer;
• an anode layer disposed on one side of the electrolyte layer;
• and
• a cathode layer disposed on the one side or an opposed side of the electrolyte layer;
• wherein the fuel cell is a dual chamber fuel cell, wherein reactants are adapted to flow into a first gas flow passage exposed to the anode layer, and wherein oxidants are adapted to flow into a second gas flow passage exposed to the cathode layer.

A fuel cell, comprising:

• at least one free standing membrane structure having an end region not in contact with any adjacent structure, the membrane structure comprising:
• an electrolyte layer;
• an anode layer disposed on one side of the electrolyte layer;
• and
• a cathode layer disposed on the one side or an opposed side of the electrolyte layer;
• wherein each of the anode layer, electrolyte layer, and cathode layer has a width, and wherein the width of each of the anode and the cathode ranges between about 1.5 μm and about 100 μm.

A method of forming a single chamber solid oxide fuel cell, comprising the steps of:

• depositing an electrode layer on a substrate;
• patterning the electrode layer to create a predetermined topography on the substrate;
• depositing an electrolyte layer over the patterned electrode layer;
• depositing a counter electrode layer over the electrolyte layer;
• and
• removing areas of higher topography from areas of lower topography using chemical mechanical planarization to form a predetermined solid oxide fuel cell structure.