Method for making thin fuel cell electrolyte

1. A method for making at least one freestanding electrolyte for use with a thin film fuel cell comprising the steps of:

forming a first structure on a substrate;

forming at least one chamber in said first structure, said at least one chamber defining a core and at least one projection extending from said core;

filling said at least one chamber with electrolyte material; and

removing said first structure to expose a freestanding electrolyte having a core and at least one projection extending therefrom, said at least one projection separated from said substrate.

2. A method for making at least one freestanding electrolyte as defined by claim 1 wherein the step of forming said at least one chamber comprises a first step of forming a core portion of said chamber and a second step of forming at least one projection portion of said chamber.

3. A method for making at least one freestanding electrolyte as defined by claim 1 wherein the step of forming said first structure comprises forming at least a first layer and a second layer on said substrate, each of said first and said second layers having different etch selectivity's.

4. A method for making at least one freestanding electrolyte as defined by claim 3 wherein said first layer is made of a first material and said second layer is made of a second material.

5. A method for making at least one freestanding electrolyte as defined by claim 3 wherein the step of forming said chamber comprises at least a first step of removing at least a part of said at least a first layer and at least a part of said at least a second layer, and a second step of removing a second portion of said structure, said second portion including one or more parts of said second layer but substantially no portion of said first layer.

6. A method for making at least one freestanding electrolyte as defined by claim 1 wherein the step of forming said structure comprises depositing a plurality of layers on said substrate, and wherein the step of forming said chamber comprises one or more steps of etching said plurality of layers to form a pattern.

7. A method for making at least one freestanding electrolyte as defined by claim 6 wherein at least a first of said plurality of layers has a first etch selectivity and at least a second of said plurality of layers has a second etch selectivity, and wherein the step of etching said pattern into said plurality of layers comprises a first step of etching a core portion of said at least one chamber from said first and said second layers, and a second step of etching a plurality of projection portions of said chamber through etching a portion of said second layer but not said first layer.

8. A method for making at least one freestanding electrolyte as defined by claim 1 wherein said substrate is made of said electrolyte material.

9. A method for making a fuel cell comprising the method of making at least one freestanding electrolyte as defined by claim 1 , and further comprising the steps of:

forming a cathode in contact with a first portion of said freestanding electrolyte; and,

forming an anode in contact with a second portion of said freestanding electrolyte, said anode separated from said cathode.

10. A method for making a fuel cell as defined by claim 9 wherein the method further comprises the step of providing at least one enclosure for containing the fuel cell.

11. A method for making at least one freestanding electrolyte as defined by claim 1 wherein said chamber defines a plurality of projections extending from said core, and wherein said at least one freestanding electrolyte has a plurality of projections extending therefrom.

12. A method for making at least one freestanding electrolyte as defined by claim 1 wherein said at least one chamber comprises a plurality of chambers, and wherein said at least one freestanding electrolyte comprises a plurality of freestanding electrolytes.

13. A method for making a plurality of freestanding electrolytes as defined by claim 12 wherein each of said plurality of chambers are substantially identical and have a first side with a first plurality of projections extending therefrom and an opposite second side with a second plurality of projections extending therefrom.

14. A method for making at least one freestanding electrolyte as defined by claim 1 wherein said substrate has opposing first and second sides, said at least a first structure formed on said first side, and the method further comprises the steps of:

forming a second structure on said second side of said substrate;

forming at least one chamber in said second structure, said at least one chamber defining a core and at least one projection extending from said core;

filling said at least one chamber on said substrate second side with electrolyte; and

removing said second structure to leave at least one freestanding electrolyte having a core and at least one projection extending therefrom on said substrate second side, said at least one projection separated from said substrate second side.

15. A method for making at least one freestanding electrolyte as defined by claim 1 wherein the method further comprises the steps of:

depositing an electrolyte substrate layer on top of said chamber filled with said electrolyte material and said structure;

forming a second structure on top of said electrolyte layer;

defining a second chamber in said second structure, said second chamber defining a core chamber and at least one projection chamber;

filling said second chamber with said electrolyte material; and

removing said second structure to expose a free standing electrolyte on said electrolyte substrate layer, said free standing electrolyte having a core and at least one projection extending therefrom, said at least one projection separated from said electrolyte substrate layer.

16. A method for making at least one freestanding electrolyte material as defined by claim 15 wherein said first chamber and said second chamber are substantially identical.

17. A method for making a freestanding electrolyte structure comprising the steps of:

forming an electrolyte structure on a substrate; and

etching said electrolyte structure to define a core and at least one projection extending from said core and separated from said substrate.

18. A method for making a freestanding electrolyte structure as defined by claim 17 wherein the step of forming said electrolyte structure comprises forming a plurality of layers on said substrate, at least two of said layers having different etch selectivity's.