WO2024040252A9 - Empilements d'électrolyseur cox multicellulaires - Google Patents

Empilements d'électrolyseur cox multicellulaires Download PDF

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Publication number
WO2024040252A9
WO2024040252A9 PCT/US2023/072522 US2023072522W WO2024040252A9 WO 2024040252 A9 WO2024040252 A9 WO 2024040252A9 US 2023072522 W US2023072522 W US 2023072522W WO 2024040252 A9 WO2024040252 A9 WO 2024040252A9
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WO
WIPO (PCT)
Prior art keywords
anode
cathode
frame
fluidic
plate
Prior art date
Application number
PCT/US2023/072522
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English (en)
Other versions
WO2024040252A3 (fr
WO2024040252A2 (fr
Inventor
Simon Gregory Stone
Steven George Goebel
Timothy A. Bekkedahl
Emerson Gallagher
Bevan Moss
Sichao MA
Noel Farrell
Dave WHITTAKER
Original Assignee
Twelve Benefit Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US18/329,524 external-priority patent/US20240060194A1/en
Application filed by Twelve Benefit Corporation filed Critical Twelve Benefit Corporation
Publication of WO2024040252A2 publication Critical patent/WO2024040252A2/fr
Publication of WO2024040252A9 publication Critical patent/WO2024040252A9/fr
Publication of WO2024040252A3 publication Critical patent/WO2024040252A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
    • C25B9/70—Assemblies comprising two or more cells
    • C25B9/73—Assemblies comprising two or more cells of the filter-press type
    • C25B9/77—Assemblies comprising two or more cells of the filter-press type having diaphragms
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B3/00—Electrolytic production of organic compounds
    • C25B3/20—Processes
    • C25B3/25—Reduction
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B3/00—Electrolytic production of organic compounds
    • C25B3/20—Processes
    • C25B3/25—Reduction
    • C25B3/26—Reduction of carbon dioxide
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
    • C25B9/60—Constructional parts of cells
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
    • C25B9/70—Assemblies comprising two or more cells
    • C25B9/73—Assemblies comprising two or more cells of the filter-press type
    • C25B9/75—Assemblies comprising two or more cells of the filter-press type having bipolar electrodes

Definitions

  • COx electrolyzers offer a potential route for converting or reducing COx gas, e.g., CO or CO 2 , into one or more desired carbon-based byproducts, such as industrial chemicals or fuels, thereby allowing for waste CO x gas that would normally be released into the atmosphere to instead be converted into industrially useful products.
  • desired carbon-based byproducts such as industrial chemicals or fuels
  • One or more embodiments provide a COx electrolyzer apparatus capable of converting or reducing CO x gas into one or more desired byproducts.
  • One or more embodiments provide a frame capable of facilitating fluid flow in a CO x electrolyzer apparatus. Docket No. OPUSP025WO [0008]
  • One or more embodiments provide a CO x electrolyzer apparatus capable of constraining expansion of a plurality of COx electrolyzer cells in an axial direction in an operational state of the COx electrolyzer apparatus.
  • a COx electrolyzer apparatus (“apparatus”) includes a first end assembly, a second end assembly, a plurality of separator plates, and a plurality of CO x electrolyzer cells (“cells”).
  • the second end assembly is coupled to the first end assembly via a plurality of tensioning members.
  • the plurality of COx electrolyzer cells (“cells”) are interposed between the first and second end assemblies and arranged in a stack along an axial direction. Each cell among the cells includes an instance of first components and an instance of second components.
  • the first components include a membrane electrode assembly (“MEA”), a cathode frame, and a cathode flow field.
  • the MEA has a cathodic part, an anodic part, and a separator between the cathodic part and the anodic part.
  • the cathode frame is adjacent to the cathodic part.
  • the cathode flow field is at least partially disposed in a first opening in the cathode frame.
  • the second components include an anode frame adjacent to the anodic part of the MEA and an anode flow field at least partially disposed in a second opening in the anode frame.
  • the first components may further include a cathode gas diffusion layer (GDL) adjacent to the cathode frame and covering the cathode flow field.
  • GDL cathode gas diffusion layer
  • the cathode GDL and the cathode flow field may be configured to guide a flow of gaseous COx across the first opening in a first direction transverse to the axial direction and in a distributed manner with respect to at least a second direction transverse to each of the axial and first directions.
  • the second components may further include an anode porous transport layer (PTL) adjacent to the anode frame and covering the anode flow field.
  • PTL porous transport layer
  • the anode PTL and the anode flow field may be configured to guide a flow of anolyte across the second opening in a third direction transverse to the axial direction and in a distributed manner with respect to at least the second direction.
  • the cathode frame may include the first opening arranged in a central portion of the cathode frame, at least one first fluidic inlet passage fluidically connected to Docket No.
  • the anode frame may include the second opening arranged in a central portion of the anode frame, at least one third fluidic inlet passage fluidically connected to the second opening, at least one third fluidic outlet passage fluidically connected to the second opening, at least one fourth fluidic inlet passage fluidically connected to the cathodic parts of the cells, and at least one second fluidic outlet passage fluidically connected to the cathodic parts of the cells.
  • each of the separator plates may include a plurality of fastener orifices through which the frame fasteners respectively extend, at least one first hole through which an inlet anolyte flow path extends, at least one second hole through which an outlet anolyte flow path extends, at least one third hole through which an inlet gaseous COx flow path extends, and at least one fourth hole through which an outlet CO x reduction byproduct flow path extends.
  • the cathode frame may include a first surface facing the MEA and a second surface facing away from the first surface.
  • the second surface of the cathode frame may include at least one first protrusion through which the at least one first fluidic inlet passage extends, at least one second protrusion through which the at least one first fluidic outlet passage extends, at least one third protrusion through which the at least one second fluidic inlet passage extends, and at least one fourth protrusion through which the at least one second fluidic outlet passage extends.
  • the at least one first protrusion of the cathode frame may be arranged and may be configured to extend through the at least one first hole in a first separator plate among the separator plates and may abut against the anode frame of a first adjacent cell among the cells such that the at least one first fluidic inlet passage of the cathode frame is substantially aligned in the axial direction with the at least one third fluidic inlet passage of the anode frame of the first adjacent cell.
  • the at least one second protrusion of the cathode frame may be arranged and may be configured to extend through the at least one second hole in the first separator plate and may abut against the anode frame of the first adjacent cell such that the at least one first fluidic outlet passage of the cathode frame is substantially aligned in the axial direction with the at least one third fluidic outlet passage of the anode frame of the first adjacent cell.
  • the at least one third protrusion of the cathode frame may be arranged and may be configured to extend through the at Docket No.
  • OPUSP025WO least one third hole in the first separator plate and may abut against the anode frame of the first adjacent cell such that the at least one second fluidic inlet passage of the cathode frame is substantially aligned in the axial direction with the at least one fourth fluidic inlet passage of the anode frame of the first adjacent cell.
  • the at least one fourth protrusion of the cathode frame may be arranged and may be configured to extend through the at least one fourth hole in the first separator plate and may abut against the anode frame of the first adjacent cell such that the at least one second fluidic outlet passage of the cathode frame is substantially aligned in the axial direction with the at least one fourth fluidic outlet passage of the anode frame of the first adjacent cell.
  • the cathode frame may further include a plurality of first cathode fastener orifices arranged about a peripheral area of the cathode frame. The peripheral area may encircle the first opening of the cathode frame.
  • the anode frame may further include a plurality of first anode fastener orifices and a plurality of first swage nuts. The plurality of first anode fastener orifices may be arranged about a peripheral area of the anode frame.
  • the first support frame may include a first frame opening exposing a portion of the cathode GDL to the cathode flow field. The portion of the cathode GDL may abut against the cathode flow field.
  • the second support frame may be interposed between the MEA and the Docket No. OPUSP025WO anode PTL.
  • the second support frame may include a second frame opening exposing a portion of the MEA to the anode PTL. The portion of the MEA may abut against the anode PTL.
  • the first support frame, the cathode GDL, the MEA, and the second support frame may form a unitized MEA assembly.
  • the first components may further include a first cathode gasket interposed between the first support frame and the cathode frame.
  • the first cathode gasket may encircle the first opening in the cathode frame to form a first fluidic seal around the cathode flow field.
  • the second components may further include a first anode gasket set.
  • the first anode gasket set may include a first anode gasket, at least one second anode gasket, at least one third anode gasket, at least one fourth anode gasket, and at least one fifth anode gasket.
  • the first anode gasket may be interposed between the second support frame and the anode frame.
  • the first anode gasket may encircle the second opening in the anode frame to form a first fluidic seal around the anode flow field.
  • the at least one second anode gasket may be interposed between the cathode frame and the anode frame.
  • the at least one second anode gasket may encircle the at least one first fluidic inlet passage of the cathode frame and the at least one third fluidic inlet passage of the anode to form at least one fluidic seal.
  • the second anode gasket set may include a sixth anode gasket, at least one seventh anode gasket, at least one eighth anode gasket, at least one ninth anode gasket, and at least one Docket No. OPUSP025WO tenth anode gasket.
  • the sixth anode gasket may be interposed between the anode frame and a second separator plate among the separator plates.
  • the sixth anode gasket may encircle the second opening in the anode frame to form a second fluidic seal around the anode flow field.
  • the at least one seventh anode gasket may be interposed between the anode frame and the second separator plate.
  • the at least one ninth anode gasket may encircle the at least one third hole in the second separator plate and the at least one fourth fluidic inlet passage in the anode frame to form at least one fluidic seal.
  • the at least one tenth anode gasket may be interposed between the anode frame and the second separator plate.
  • the at least one ninth anode gasket may encircle the at least one fourth hole in the second separator plate and the at least one fourth fluidic outlet passage in the anode frame to form at least one fluidic seal.
  • the cells may be formed of a plurality of repeat units.
  • Each repeat unit among the repeat units may include an instance of the first components, an instance of the second components, and the separator plate that may be interposed between the cathode frame of that instance of the first components and the anode frame of that instance of the second components, that separator plate may be interposed between that instance of the first components and that instance of the second components.
  • the first end assembly may include a first end plate and a cathode interface assembly.
  • the cathode interface assembly may include an instance of the first components and a cathode interface separator plate interposed between the first end plate and a first repeat unit among the repeat units.
  • a first end cell may be formed between the cathode interface assembly and the instance of the second components of the first repeat unit.
  • the inlet anolyte flow path, the outlet anolyte flow path, the inlet gaseous CO x flow path, and the outlet CO x reduction byproduct flow path may not extend into the bus plate and the first insulation plate.
  • the first bus plate, the insulation plate, and the manifold may be sequentially stacked on the cathode interface assembly.
  • the first end assembly may further include a capping plate, an inlet runner, and an outlet runner. The inlet and outlet runners may be coupled to the manifold such that the inlet and outlet runners are stacked in the axial direction between the capping plate and the manifold.
  • the cathode and anode frames may be formed of one or more polymers.
  • the cathode and anode frames may include at least one of polyethylene terephthalate (PET), polycarbonate (PC), polyimide (PI), polyamide (PA), poly(methylmethacrylate) (PMMA), polyethylene naphthalate (PEN), polyetherketone (PEK), polyetheretherketone (PEEK), polystyrene (PS), polyetherimide (PEI), polyphenylene sulfide (PPS), polyarylate (PAR), polyether sulfone (PES), cyclic olefin copolymer (COC), polyvinyl alcohol (PVA), ethylene chlorotrifluoroethylene (ECTFE), polytetrafluoroethylene (PTFE), polybutylene terephthalate (PBT), polychlorotrifluoroethylene (PCTFE), and poly
  • the first connecting riser may extend into the proximal end of the first recess, and the distal end of the first recess may extend into the opening.
  • the frame may further include a plurality of protrusions extending in the axial direction from a surface of the first recess. The surface may be recessed from the first surface.
  • at least one of the protrusions may have a different cross-sectional area than at least another one of the protrusions.
  • the protrusions may include one or more first protrusions, one or more second protrusions, and at least one third protrusion.
  • Each of the second sides may include a first portion extending in a fourth direction transverse to the axial and second directions, a second portion extending from a first side of the first portion in a third oblique direction forming a first angle with the fourth direction, a third portion arcuately extending between and connecting the second portion to one of the first sides, a fourth portion extending from a second side of the first portion in a fourth oblique direction forming a second angle with the fourth direction, and a fifth portion arcuately extending between and connecting the fourth portion to another one of the first sides.
  • the second fluidic passage may extend through the second protrusion, and the third fluidic passage may extend through the third protrusion.
  • the second fluidic passage may be arranged adjacent to a first side of the first fluidic passage.
  • the third fluidic passage may be arranged adjacent to a second side of the first fluidic passage.
  • the second side of the first fluidic passage may oppose the first side of the first fluidic passage in a fourth direction transverse to the axial direction and the second direction.
  • the frame may further include a sixth recess in the first surface. The sixth recess may be fluidically connected to the first connecting riser and a proximal end of the Docket No. OPUSP025WO first recess.
  • the second connecting riser may be fluidically connected to a second side of the sixth recess opposing the first side of the sixth recess in the fourth direction.
  • the first recess may be one of a plurality of first recesses in the first surface that extend parallel to one another in the second direction.
  • the first recesses may include a first group of the first recesses, a second group of the first recesses, and a third group of the first recesses.
  • the first recesses of the first group may be spaced apart from one another according to a first pitch.
  • the second group of the first recesses may be arranged adjacent to a first side of the first group of the first recesses.
  • each cell among the cells may include a membrane electrode assembly (“MEA”), a cathode frame, a cathode flow field, a cathode gas diffusion layer (GDL), an anode frame, an anode flow field, and an anode porous transport layer (PTL).
  • MEA membrane electrode assembly
  • the MEA may have a cathodic part, an anodic part, and a separator between the cathodic part and the anodic part.
  • the cathode frame may be adjacent to the cathodic part.
  • the cathode flow field may be at least partially disposed in a first opening in the cathode frame.
  • the cathode GDL may be adjacent to the cathode frame and may cover the cathode flow field.
  • the anode frame may be adjacent to the anodic part of the MEA.
  • the anode flow field may be at least partially disposed in a second opening in the anode frame.
  • the anode PTL may be adjacent to the anode frame and may cover the anode flow field.
  • the second end assembly may include a first plate, a first gasket, and a second plate.
  • the first plate may include a recess in a central portion of the first plate, a second recess encircling a central region of the central portion, and a first orifice configured to receive one or more control fluids.
  • the first gasket may be at least partially disposed in the second recess.
  • the first and second orifices may be substantially aligned in the axial direction.
  • the apparatus may further include a gasket interposed between the first plate and the second end plate. The gasket may encircle the first and second orifices to form a fluidic seal.
  • the second end assembly may include a first plate, a piston, and one or more gaskets.
  • the first plate may include a first main body, a first protrusion extending from the first main body in the axial direction, a first blind opening extending into a central portion of the first protrusion in a second direction opposite the axial direction, and at least one first orifice fluidically connected to the first blind opening and configured to receive one or more control fluids.
  • the piston may include a second main body and a second protrusion extending from the second main body in the second direction, at least a portion of the second protrusion may be slidably received in at least a portion of the first blind opening in the first protrusion.
  • respective widths of the second blind openings in a direction perpendicular to the axial direction may be greater than respective widths of the third protrusions in the direction perpendicular to the axial direction.
  • respective heights of the third protrusions from the first recessed surface in the axial direction may be greater than respective depths of the second blind openings from the first protruded surface in the axial direction.
  • the first plate may be a second end plate of the apparatus configured to be coupled to the first end plate via a plurality of tensioning members extending in the axial direction.
  • the cavity in the operational state of the apparatus, may be dead- headed.
  • the first plate may further include at least one second orifice fluidically connected to the first blind opening. The at least one second orifice may be configured to bleed off excess accumulation of the one or more control fluids in the cavity in response to the accumulation of the one or more control fluids exceeding a predefined threshold.
  • the one or more control fluids and the input gaseous CO x may be substantially equivalent.
  • the apparatus may further include at least one source configured to input the gaseous CO x to the cells at a first pressure and the one or more control fluids to the second end assembly at a second pressure.
  • FIG. 1 depicts a diagram of an example MEA for use in COx reduction.
  • FIG. 2 depicts a CO2 electrolyzer configured to receive water and CO2 as a reactant at a cathode and expel CO as a byproduct.
  • FIG.3 depicts an example construction of a CO2 reduction MEA having a cathode catalyst layer, an anode catalyst layer, and an anion-conducting PEM.
  • FIG. 4 depicts an example construction of a CO reduction MEA having a cathode catalyst layer, an anode catalyst layer, and an anion-conducting PEM.
  • FIG. 5 depicts an exploded view of an example multi-cell COx electrolyzer stack. [0121] FIG.
  • FIG.11B depicts an exploded view of some cathode components of another example repeat unit of the example multi-cell COx electrolyzer stack of FIG. 6.
  • FIG. 11C depicts a cross-sectional view of the cathode components of the example repeat unit of FIG. 11B.
  • FIG.11D depicts an exploded view of anode components of the example repeat unit of the example multi-cell COx electrolyzer stack of FIG. 6.
  • FIG. 11E depicts a cross-sectional view of the anode components of the example repeat unit of FIG. 11D.
  • FIG. 12 depicts a plan view of an example manifold block of the example multi-cell COx electrolyzer of FIG. 6.
  • FIGS. 13, 14, 15, and 16 depict side views of the example manifold block of FIG. 12. Docket No. OPUSP025WO
  • FIG.17 depicts an exploded view of an example cathode interface assembly of the example multi-cell COx electrolyzer stack of FIG. 6.
  • FIG.18 depicts the example cathode interface assembly of FIG.17 in a non-exploded state.
  • FIG. 19 depicts an exploded view of an illustrative CO x electrolyzer cell of the example multi-cell COx electrolyzer stack of FIG. 6.
  • FIG.20 depicts a bottom view of a representative repeat unit of the example multi-cell COx electrolyzer stack of FIG. 6.
  • FIG. 17 depicts an exploded view of an example cathode interface assembly of the example multi-cell COx electrolyzer stack of FIG. 6.
  • FIG.18 depicts the example cathode interface assembly of FIG.17 in a non-exploded state.
  • FIG. 19 depicts an exploded view of an illustrative CO x
  • FIG. 21 depicts a cross-sectional view of the representative repeat unit of FIG. 20 taken along sectional line 21-21.
  • FIG. 22 depicts a cross-sectional view of the representative repeat unit of FIG. 20 taken along sectional line 22-22.
  • FIGS. 23 and 24 depict enlarged portions of the cross-sectional view of FIG. 22.
  • FIG.25 depicts a perspective view of the example unitized MEA assembly of the example multi-cell CO x electrolyzer stack of FIG. 6.
  • FIG. 26 depicts a top view of the example unitized MEA assembly of FIG. 25.
  • FIG. 27 depicts a cross-sectional view of the example unitized MEA assembly of FIG. 26 taken along sectional line 27-27.
  • FIG. 28 depicts a first perspective view of an example cathode frame.
  • FIG. 29 depicts a bottom view of the example cathode frame of FIG. 28.
  • FIGS. 30 and 31 depict enlarged portions of the example cathode frame of FIG. 28.
  • FIG. 32 depicts a second perspective view of the example cathode frame of FIG. 28.
  • FIG. 33 depicts a top view of the example cathode frame of FIG. 32.
  • FIG.34 depicts a cross-sectional view of the example cathode frame of FIG.33 taken along sectional line 34-34.
  • FIG. 35 depicts an enlarged portion of the example cathode frame of FIG. 33.
  • FIG.36 depicts a cross-sectional view of the example cathode frame of FIG.35 taken along sectional line 36-36.
  • FIG. 37 depicts a first perspective view of an example anode frame.
  • FIG. 38 depicts a top view of the example cathode frame of FIG. 37.
  • FIG. 39 depicts a second perspective view of the example anode frame of FIG. 37.
  • FIG. 40 depicts a bottom view of the example anode frame of FIG. 39. Docket No. OPUSP025WO [0154]
  • FIG. 41 depicts an enlarged portion of the example anode frame of FIG. 38. [0155] FIG.
  • FIG. 42 depicts an enlarged portion of the example anode frame of FIG. 40
  • FIG. 43 depicts a plan view of an example separator plate of the representative repeat unit of FIG. 11A.
  • FIG. 44 depicts an example anode interface separator of FIG. 47.
  • FIGS. 45 and 46 depict top and bottom plan views of an example cathode interface separator of the example cathode interface assembly of FIG. 18.
  • FIG. 47 depicts an exploded view of an example anode interface assembly of the example multi-cell COx electrolyzer stack of FIG. 6.
  • FIG. 48 depicts the example anode interface assembly of FIG. 47 in an assembled state. [0161] FIG.
  • FIG. 59 depicts an example of a cathode flow field that has four cathode serpentine channels arranged in a multiple serpentine channel arrangement.
  • FIG. 60 depicts a cross-sectional view of a cathode flow field with square- or rectangular- cross-section serpentine channels.
  • FIG. 61 shows a cross-sectional view of a cathode flow field with a plurality of square- or rectangular-cross-section serpentine channels with rounded interior bottom edges.
  • FIG. 62 shows a cross-sectional view of a cathode flow field with a plurality of U-shaped cross-section serpentine channels.
  • FIG. 60 depicts an example of a cathode flow field that has four cathode serpentine channels arranged in a multiple serpentine channel arrangement.
  • FIG. 60 depicts a cross-sectional view of a cathode flow field with square- or rectangular- cross-section serpentine channels.
  • FIG. 61 shows a cross-sectional view of a cath
  • FIG.74 depicts a schematic of another example of a branching parallel channel flow field.
  • FIG. 75 depicts a schematic of yet another example of a branching parallel channel flow field.
  • FIG. 76 depicts an example of a cathode flow field that features branching parallel channels.
  • FIG.77 depicts a detail view of the left and right sides of the upper half of the cathode flow field of FIG. 76, with the remainder of the flow field omitted from view.
  • FIG. 78 depicts an example of a cathode flow field with an interdigitated channel arrangement.
  • FIG. 79 depicts a side view of a gas diffusion layer. [0188] FIG.
  • FIG. 85A depicts a plan view of a portion of an illustrative anode flow field of the example multi-cell COx electrolyzer of FIG. 6.
  • FIGS. 85B and 85C depict respective cross-sectional views of the illustrative anode flow field of FIG. 85A taken along sectional lines 85B-85B and 85C-85C according to some embodiments.
  • FIG.86 depicts a plan view of an illustrative insulation plate of the example multi-cell COx electrolyzer of FIG. 6.
  • FIG. 87 depicts a cross-sectional view of the illustrative insulation plate of FIG. 86 taken along sectional line 87-87.
  • FIG. 88 depicts a plan view of an illustrative end plate of the example multi-cell COx electrolyzer of FIG. 6.
  • FIG. 89 depicts a cross-sectional view of the illustrative end plate of FIG. 88 taken along sectional line 89-89.
  • FIG. 90 depicts an enlarged portion of the cross-sectional view of FIG. 9 [0200] FIG.
  • FIG. 101 depicts a perspective view of an example piston side assembly of the example multi-cell CO x electrolyzer stack of FIG. 91 in an exploded state. Docket No. OPUSP025WO
  • FIG. 102 depicts a top plan view of the example piston side assembly of FIG. 101 in an assembled state.
  • FIG. 103 depicts a cross-sectional view of the example piston side assembly of FIG. 102 taken along sectional line 103-103.
  • FIG. 104 depicts a perspective view of an example end plate of the example piston side assembly of FIG. 101.
  • FIG. 107 depicts a perspective view of an example piston of the piston side assembly of FIG. 101.
  • FIGS. 108 and 109 depict top and bottom plan views of the example piston of FIG. 107.
  • DETAILED DESCRIPTION OF SOME EMBODIMENTS [0213] CO x electrolyzers, e.g., CO 2 electrolyzers, using membrane electrode assemblies may share some structural similarities with existing polymer electrolyte membrane (PEM) water electrolyzers, although there are several respects in which COx electrolyzers may differ significantly from such PEM water electrolyzer systems.
  • PEM polymer electrolyte membrane
  • a membrane electrode assembly may be one of multiple elements that are stacked together in what may be referred to as a “cell”; in the discussion below, the term “cell” is used to refer to this multi-element assembly.
  • FIG. 1 An example MEA 100 for use in CO x reduction is shown in FIG. 1.
  • the MEA 100 has a cathode layer 120 and an anode layer 140 separated by an ion-conducting polymer layer 160 that provides a path for ions to travel between the cathode layer 120 and the anode layer 140.
  • the cathode layer 120 includes an anion-conducting polymer and/or the anode layer 140 includes a cation-conducting polymer.
  • the cathode layer 120 and/or the anode layer 140 of the MEA 100 are porous. The pores may facilitate gas and/or fluid transport and may increase the amount of catalyst surface area that is available for reaction.
  • the ion-conducting layer 160 may, for example, include two or three sublayers: a polymer electrolyte membrane (PEM) 165, an optional cathode buffer layer 125, and/or an optional anode buffer layer 145.
  • PEM polymer electrolyte membrane
  • One or more layers in the ion-conducting layer 160 may be porous.
  • At least one layer is nonporous so that reactants and products of the cathode cannot Docket No. OPUSP025WO pass via gas and/or liquid transport to the anode and vice versa.
  • the PEM layer 165 is nonporous.
  • Example characteristics of anode buffer layers and cathode buffer layers are provided elsewhere herein.
  • the ion-conducting layer 160 includes only a single layer or two sublayers.
  • FIG. 2 shows CO2 electrolyzer 203 configured to receive water (H20) and CO2 (e.g., humidified or dry gaseous CO2) as a reactant at a cathode 205 and expel CO as a product.
  • water water
  • CO2 e.g., humidified or dry gaseous CO2
  • Electrolyzer 203 is also configured to receive water as a reactant at an anode 207 and expel gaseous oxygen (O2).
  • Electrolyzer 203 includes bipolar layers having an anion-conducting polymer 209 adjacent to cathode 205 and a cation-conducting polymer 211 (illustrated as a proton-exchange membrane) adjacent to anode 207.
  • the cathode 205 includes an anion exchange polymer (which, in this example, is the same anion- conducting polymer 209 that is in the bipolar layers), electronically conducting carbon support particles 217, and metal nanoparticles 219 supported on the support particles.
  • CO 2 and water are transported via pores (such as pore 221) and reach metal nanoparticles 219 where they react, in this case with hydroxide (OH-) ions, to produce bicarbonate (HCO3) ions and reduction reaction products (not shown).
  • CO 2 may also reach metal nanoparticles 219 by transport within anion exchange polymer 209.
  • Hydrogen ions are transported from anode 207, and through the cation-conducting polymer 211, until they reach bipolar interface 213, where they are hindered from further transport toward the cathode 205 by anion exchange polymer 209. At interface 213, the hydrogen ions may react with bicarbonate or carbonate ions to produce carbonic acid (H2CO3), which may decompose to produce CO2 and water.
  • the resulting CO2 may be provided in gas phase and may be provided with a route in the MEA back to the cathode 205 where it can be reduced.
  • the cation-conducting polymer 211 hinders transport of anions, such as bicarbonate ions, to the anode 207 where they could react with protons and release CO2, which would be unavailable to participate in a reduction reaction at the cathode 205.
  • a cathode buffer layer having an anion-conducting polymer may work in concert with the cathode 205 and its anion-conductive polymer to block transport of protons to the cathode 205.
  • While MEAs employing ion conducting polymers of appropriate conductivity types in the cathode 205 and cathode buffer layer may hinder transport of cations to the cathode 205 and, Docket No. OPUSP025WO if present, an anode buffer layer may similarly hinder transport of the anions to the anode 207, cations and anions may still come in contact in the MEA’s interior regions, such as in the membrane layer.
  • bicarbonate and/or carbonate ions combine with hydrogen ions between the cathode layer and the anode layer to form carbonic acid, which may decompose to form gaseous CO2.
  • the cathode buffer layer having inert filler and associated pores.
  • the pores create paths for the gaseous carbon dioxide to escape back to the cathode 205 where it can be reduced.
  • the cathode buffer layer is porous, but at least one layer between the cathode layer and the anode layer is nonporous. This can prevent the passage of gases and/or bulk liquid between the cathode and anode layers while preventing delamination.
  • an MEA includes a cathode layer including a reduction catalyst and a first anion-conducting polymer (e.g., Sustainion, FumaSep FAA-3, or Tokuyama anion exchange polymer), an anode layer including an oxidation catalyst and a first cation-conducting polymer (e.g., PFSA polymer), a membrane layer including a second cation-conducting polymer and arranged between the cathode layer and the anode layer to conductively connect the cathode layer and the anode layer, and a cathode buffer layer including a second anion-conducting polymer (e.g., Sustainion, FumaSep FAA
  • the cathode buffer layer can have a porosity between about 1 and 90 percent by volume but can additionally or alternatively have any suitable porosity (including, e.g., no porosity). In other examples the cathode buffer layer can have any suitable porosity (e.g., between 0.01–95%, 0.1–95%, 0.01–75%, 1–95%, 1–90%, etc.). [0224] Too much porosity can lower the ionic conductivity of the buffer layer. In some embodiments, the porosity is 20% or below, and in particular embodiments, between 0.1–20%, 1– Docket No. OPUSP025WO 10%, or 5–10%.
  • the membrane electrode assembly can include an anode buffer layer that includes a third cation-conducting polymer, and is arranged between the membrane layer and the anode layer to conductively connect the membrane layer and the anode layer.
  • the anode buffer layer preferably has a porosity between about 1 and 90 percent by volume, but can additionally or alternatively have any suitable porosity (including, e.g., no porosity).
  • the anode buffer layer can have any suitable porosity (e.g., between 0.01–95%, 0.1–95%, 0.01–75%, 1–95%, 1–90%). As with the cathode buffer layer, in some embodiments, the porosity is 20% or below, e.g. 0.1–20%, 1–10%, or 5–10%.
  • an anode buffer layer may be used in an MEA having a cathode catalyst layer with anion exchange polymer, a cathode buffer layer with anion-exchange polymer, a membrane with cation-exchange polymer, and an anode buffer layer with anion-exchange polymer.
  • the anode buffer layer may be porous to facilitate water transport to the membrane / anode buffer layer interface. Water will be split at this interface to make protons that travel through the membrane and hydroxide that travels to the anode catalyst layer.
  • at least one catalyst e.g., a carbon catalyst, a metal catalyst, etc. may be utilized to promote the splitting of the water at this interface.
  • the at least one catalyst may include a cobalt-based catalyst, an iron-nickel-based catalyst, a palladium-based catalyst, platinum-based catalyst, ruthenium (IV) dioxide (RuO 2 ), nickel-stabilized, ruthenium dioxide (Ni-RuO 2 ), iridium (IV) dioxide (IrO 2 ), graphene, graphene oxide (GO), reduced graphene oxide (rGO), graphitic carbon nitride (g-C3N4), graphene quantum dots (GQDs), graphene quantum sheets (GQSs), and/or the like.
  • ruthenium (IV) dioxide RuO 2
  • Ni-RuO 2 nickel-stabilized
  • ruthenium dioxide Ni-RuO 2
  • iridium (IV) dioxide IrO 2
  • graphene graphene oxide
  • rGO reduced graphene oxide
  • g-C3N4 graphitic carbon nitride
  • GQDs graphene quantum dots
  • An MEA containing an anion-exchange polymer membrane and an anode buffer layer containing cation-exchange polymer may be used for CO reduction.
  • water would form at the membrane / anode buffer layer interface. Pores in the anode buffer layer could facilitate water removal.
  • an acid-stable (e.g., IrOx) water oxidation catalyst is used for CO reduction.
  • the membrane electrode assembly can include a cathode buffer layer that includes a third anion-conducting polymer and is arranged between the cathode layer and the membrane layer to conductively connect the cathode layer and the membrane layer.
  • the third anion-conducting polymer can be the same or different from the first and/or second anion- conducting polymer.
  • the cathode buffer layer preferably has a porosity between about 1 and 90 percent by volume but can additionally or alternatively have any suitable porosity (including, e.g., no porosity).
  • the cathode buffer layer can have any suitable porosity (e.g., between 0.01–95%, 0.1–95%, 0.01–75%, 1–95%, 1–90%). In some embodiments, the porosity is 20% or below, and in particular embodiments, between 0.1–20%, 1– 10%, or 5–10%.
  • a cathode catalyst layer composed of Au nanoparticles 4nm in diameter supported on Vulcan XC72 or XC72R carbon and mixed with TM1 (mTPN-1) anion exchange polymer electrolyte may be used.
  • the cathode catalyst layer may be about 15 ⁇ m thick, have a gold to gold + carbon ratio by weight (Au/(Au+C)) of 20%, have a TM1 to catalyst mass ratio of 0.32, have mass loading of 1.4–1.6 mg/cm 2 (total Au+C), and have estimated porosity of 0.56.
  • an anion-exchange polymer layer composed of TM1 and PTFE particles may be provided.
  • the PTFE particles may be approximately 200 nm in diameter and the TM1 molecular weight may be approximately 30k–45k.
  • the thickness of such an example anion-exchange polymer layer may be about 15 ⁇ m, and the PTFE particles may introduce a porosity of about 8%.
  • a proton-exchange membrane layer composed of perfluorosulfonic acid polymer (e.g., Nafion 115 or Nafion 117) may also be provided, with a thickness of approximately 100 ⁇ m to approximately 200 ⁇ m.
  • the proton-exchange membrane may form a continuous layer that prevents significant movement of gas (CO 2 , CO, H 2 ) through the layer.
  • An anode catalyst layer composed of Ir or IrO x nanoparticles (100–200 nm aggregates) that is 10 ⁇ m thick may also be provided.CO x Docket No.
  • an MEA does not contain a cation-conducting polymer layer.
  • the electrolyte is not a cation-conducting polymer and the anode, if it includes an ion-conducting polymer, does not contain a cation-conducting polymer.
  • An AEM-only MEA allows conduction of anions across the MEA. In embodiments in which none of the MEA layers has significant conductivity for cations, hydrogen ions have limited mobility in the MEA.
  • an AEM-only membrane provides a neutral or an alkaline pH environment (e.g., at least about pH 7) and may facilitate CO2 and/or CO reduction by suppressing the hydrogen evolution parasitic reaction at the cathode.
  • the AEM-only MEA allows ions, notably anions such as hydroxide, bicarbonate, or carbonate ions, to move through polymer-electrolyte.
  • the pH may be lower in some embodiments; a pH of 4 or greater may be sufficient to suppress hydrogen evolution.
  • the AEM-only MEA also permits electrons to move to, and through, metal and carbon in catalyst layers.
  • the AEM- only MEA may include pores in the anode layer, pores in the cathode layer, and/or pores in the PEM, thereby permiting liquids and gas to move through such pores.
  • the AEM-only MEA comprises an anion-exchange polymer electrolyte membrane positioned between a cathode and an anode.
  • the cathode and the anode are each electrocatalyst layers.
  • one or both electrocatalyst layers also contain anion-exchange polymer-electrolyte.
  • an AEM-only MEA is formed by depositing cathode and anode electrocatalyst layers onto porous conductive supports, such as gas diffusion layers, porous transport layers, and/or the like, to form gas diffusion electrodes (GDEs). An anion-exchange membrane is then sandwiched between the gas diffusion electrodes.
  • GDEs gas diffusion electrodes
  • an AEM-only MEA is used for CO2 reduction. The use of an anion-exchange polymer electrolyte avoids a low pH environment that disfavors CO2 reduction.
  • Water transport in the MEA occurs through a variety of mechanisms, including diffusion and electro-osmotic drag.
  • electro-osmotic drag is the dominant mechanism. Water is dragged along with ions as they move through the polymer electrolyte.
  • a cation-exchange membrane such as Nafion membrane
  • the amount of water transport is well characterized and understood to rely on the pre-treatment/hydration of the membrane.
  • FIG. 3 illustrates an example construction of a CO2 reduction MEA 301 having a cathode catalyst layer 303, an anode catalyst layer 305, and an anion-conducting PEM 307.
  • cathode catalyst layer 303 may include metal catalyst particles (e.g., nanoparticles) that are unsupported or supported on a conductive substrate such as carbon particles. In some implementations, cathode catalyst layer 303 additionally includes an anion-conducting polymer. The metal catalyst particles may catalyze CO 2 reduction, particularly at or within a non-acidic environment. In certain embodiments, anode catalyst layer 305 includes metal oxide catalyst particles (e.g., nanoparticles) that are unsupported or supported on a conductive substrate such as metal oxides, carbides, etc. In some implementations, the anode catalyst layer 305 may additionally include an anion-conducting polymer.
  • metal oxide catalyst particles for anode catalyst layer 305 may include iridium oxide, nickel oxide, nickel iron oxide, iridium ruthenium oxide, platinum oxide, and the like.
  • the anion-conducting PEM 307 may include any of various anion-conducting polymers such as, for example, HNN5/HNN8 by Ionomr, FumaSep by Fumatech, TM1 by Orion, PAP-TP by W7energy, Sustainion by Dioxide Materials, and the like.
  • an AEM-only MEA may be advantageous for CO reduction.
  • the water uptake number of the AEM material can be selected to help regulate moisture at the catalyst interface, thereby improving CO availability to the catalyst.
  • AEM-only membranes can be favorable for CO reduction due to this reason.
  • Bipolar membranes can be more favorable for CO2 reduction due to better resistance to CO 2 dissolving and crossover in basic anolyte media.
  • cathode catalyst layer 403 may include metal catalyst particles (e.g., nanoparticles) that are unsupported or supported on a conductive substrate such as carbon particles.
  • cathode catalyst layer 403 may additionally include an anion- conducting polymer.
  • anode catalyst layer 405 includes metal oxide catalyst particles (e.g., nanoparticles) that are unsupported or supported on a conductive substrate such as metal oxides, carbides, etc.
  • the anode catalyst layer 405 may additionally include an anion-conducting polymer.
  • metal oxide catalyst particles for anode catalyst layer 405 may include those identified for the anode catalyst layer 305 of FIG. 3.
  • Anion-conducting PEM 407 may include any of various anion-conducting polymers such as, for example, those identified for the PEM 307 of FIG. 3.
  • CO gas may be provided to cathode catalyst layer 403.
  • the CO may be provided via a gas diffusion electrode.
  • Anions produced at the cathode catalyst layer 403 may include hydroxide ions. These may diffuse, migrate, or otherwise move to the anode catalyst layer 405. At the anode catalyst layer 405, an oxidation reaction may occur such as oxidation of water or hydroxide ion to produce diatomic oxygen and hydrogen ions or water. In some applications, the hydrogen ions may react with hydroxide ions to produce water.
  • an oxidation reaction may occur such as oxidation of water or hydroxide ion to produce diatomic oxygen and hydrogen ions or water.
  • the hydrogen ions may react with hydroxide ions to produce water.
  • FIG. 5 depicts an exploded view of an example multi-cell COx electrolyzer stack.
  • FIG. 6 depicts a perspective view of the example multi-cell COx electrolyzer of FIG. 5.
  • FIGS. 7 and 8 depict side views of the example multi-cell CO x electrolyzer of FIG. 6.
  • FIG. 9 depicts a cross- sectional view of the example multi-cell COx electrolyzer of FIG. 7 taken along sectional line 9-9.
  • FIG. 10 depicts a cross-sectional view of the example multi-cell COx electrolyzer of FIG. 8 taken along sectional line 10-10.
  • FIG.11A depicts an exploded view of an illustrative repeat unit of the example multi-cell CO x electrolyzer stack of FIG. 6.
  • FIG. 17 depicts an exploded view of a cathode interface assembly of the example multi-cell COx electrolyzer stack of FIG. 6.
  • multi-cell COx electrolyzer stack (or stack) 500 includes a plurality of COx electrolyzer cells (or cells), such as cell 501, formed by stacking a plurality of repeat units 503 (individually referenced as repeat units 503_1 to 503_n, where “n” is an integer greater than or equal to one) between cathode interface assembly 505 of port side assembly 507 and anode interface assembly 509 of bladder side assembly 511.
  • any given cell among the plurality of CO x electrolyzer cells may be formed by the conjunction of 1) cathode interface assembly 505 (which includes MEA 1105) and anode components 1101 of repeat unit 503_1; 2) cathode components 1103 (which include MEA 1105) of a first repeat unit (e.g., repeat unit 503_1) and anode components 1101 of a second repeat unit (e.g., repeat unit 503_2) adjacent to the first repeat unit; or 3) cathode components 1103 of repeat unit 503_n and anode interface assembly 509.
  • cathode interface assembly 505 which includes MEA 1105) and anode components 1101 of repeat unit 503_1
  • cathode components 1103 which include MEA 1105) of a first repeat unit (e.g., repeat unit 503_1) and anode components 1101 of a second repeat unit (e.g., repeat unit 503_2) adjacent to the first repeat unit
  • Respective end plates 519 and 525 of port side assembly 507 and bladder side assembly 511 may be coupled to one another via a plurality of tensioning members 527 (e.g., anchors, bolts, studs, tie rods, etc.) extending in the axial direction.
  • end plates 519 and 525 may include respectively pluralities of fastener orifices 519h and 525h through which tensioning members 527 may pass.
  • fastener orifices 519h and 525h may be respectively arranged about corresponding peripheral regions of end plates 519 and 525.
  • end plates 519 and 525 may be formed of any suitable material, such as aluminum, magnesium, titanium, and/or the like.
  • Tensioning members 527 may be at least partially threaded to respectively engage with, for instance, threaded fasteners 529 (e.g., nuts, rivets, etc.). In this manner, a clamping force extending in the axial direction may be applied to the plurality of cells via the conjunction of end plates 519 and 525, tensioning members 527, and threaded fasteners 529. As such, end plates 519 and 525 may generally serve to act as load-spreading members that distribute a clamping load relatively evenly over the other elements of stack 500.
  • threaded fasteners 529 e.g., nuts, rivets, etc.
  • Bus plates 513 and 521 are respectively provided with terminal portions 513t and 521t protruding outwardly from corresponding peripheral surfaces and may be respectively connected Docket No. OPUSP025WO to a power supply.
  • terminal portions 513t and 521t may have, for example, lugs, terminal blocks, and/or other electrical connection mechanisms to facilitate electrical connections between bus plates 513 and 521 and a corresponding positive or negative voltage or current source.
  • terminal portion 513t on a cathode side of stack 500 may be connected to a negative electrode of the power supply
  • terminal portion 521t on an anode side of the stack 500 may be connected to a positive electrode of the power supply.
  • bus plates 513 and 521 may provide common electrical connections for the plurality of cells of stack 500, such as cell 501, and, thereby, enable an electrical potential or current to be generated across the plurality of cells of stack 500 that may drive the reduction and oxidation reactions within the plurality of cells.
  • bus plate 513 may be sized so as not to interfere with various fluidic passages through stack 500.
  • main body 541 includes first fluidic inlet ports 1213 and 1215 in third and fourth surfaces 1205 and 1207, respectively, that are configured to interface with first fluidic inlet connectors (or inlet connectors) 543, first fluidic outlet ports (or outlet ports) 1217 and 1219 in third and fourth surfaces 1205 and 1207, respectively, that are configured to interface with first fluidic outlet connectors (or outlet connectors) 545, second fluidic inlet port (or inlet port) 1221 in fifth surface 1209 that is configured to interface with second fluidic inlet connector (or inlet connector) 547, and second fluidic outlet port (or outlet port) 1223 in sixth surface 1211 that is configured to interface with second fluidic outlet connector (or outlet connector) 549.
  • first fluidic inlet ports 1213 and 1215 respective connecting passages (e.g., connecting passage 1227), and corresponding third fluidic outlet ports (e.g., third fluidic outlet port 1225) may be configured to provide water to inlet passages 1001 and 1003 of stack 500.
  • first fluidic outlet ports 1217 and 1219, respective connecting passages (e.g., connecting passage 1235), and corresponding third fluidic inlet ports (e.g., third fluidic inlet port 1229) may be configured to allow water to be expelled from outlet passages of stack 500.
  • cathode annular insert 1134 may be at least partially supported in at least one opening in cathode frame 1131 and may encircle cathode flow field 1127.
  • first surface 1134a e.g., a top surface
  • second surface 1134b e.g., a bottom surface
  • cathode annular insert 1134 opposing first surface 1134a may abut against one or more corresponding surfaces of a unitized MEA assembly of an associated repeat unit, e.g., repeat unit 1100.
  • cathode annular insert 1134 will be described later in connection with cathode frame 1131.
  • Aspects of the various components of repeat unit 1100 will be now described in more detail not only in association with the description of cell 501, but also the text associated with FIGS.25- 43, 49-79, 83, 84A, 84B, and 85A-85C.
  • Docket No. OPUSP025WO CO x Electrolyzer Cell Referring to FIG. 19, an exploded view of cell 501 is shown. Cell 501 is formed between cathode components 1103_1 of repeat unit 503_1 and anode components 1103_2 of repeat unit 503_2.
  • Separator plates 1107_1 and 1107_2 of repeat units 503_1 and 503_2 separate cell 501 from adjacent cells of stack 500.
  • anode components 1101_1 of repeat unit 503_1 and cathode components 1103_2 of repeat unit 503_2 are shown in partially assembled states and form portions of such cells adjacent to cell 501.
  • components of cell 501 will be referenced followed by an underscore and identifier to indicate the repeat unit to which the components are a part without specifying the repeat unit itself.
  • Cell 501 may include MEA 1105_1 interposed between anode porous transport layer (PTL) 1109_2 and cathode GDL 1121_1.
  • PTL porous transport layer
  • MEA 1105_1 and cathode GDL 1121_1 may be part of a unitized MEA assembly, such as unitized MEA assembly 1119_1, which includes MEA 1105_1 and cathode GDL 1121_1 sandwiched between support frames 1123_1 and 1125_1 (see also FIGS. 25-27).
  • Support frames 1123_1 and 1125_1 may not only include respective openings 1123a_1 and 1125a_1 exposing corresponding surfaces of MEA 1105_1 and cathode GDL 1121_1 to adjacent components, but may also respectively include protruded tab portions 1123b_1 and 1125b_1 that may facilitate handling of unitized MEA assembly 1119_1 during manufacture and testing.
  • protruded tab portions 1123b_1 and 1125b_1 may be silkscreened, inscribed, embossed, or otherwise marked with identifying information, such as identifying information indicating a cell to which unitized MEA assembly 1119_1 belongs.
  • Support frame 1123_1 may also include bulged portion 1123c_1 (see also bulged portion 1123c in FIG.27) to accommodate MEA 1105_1 and cathode GDL 1121_1 in a cavity (e.g., cavity 2701 in FIG. 27) formed between support frames 1123_1 and 1125_1.
  • unitized MEA assembly 1119_1 may allow its components to be preassembled and tested before incorporation into, for example, cell 501, which may increase assembly efficiencies and reduce both cell-level and stack-level defects.
  • anode PTL 1109_2 may be interposed between MEA 1105_1 and anode flow field 1111_2, whereas cathode GDL 1121_1 may be interposed between MEA 1105_1 and cathode flow field 1127_1.
  • opening 1125a_1 in support frame 1125_1 may allow MEA 1105_1 and anode flow field 1111_2 to be fluidically connected via anode PTL 1111_2, and opening 1123a_1 in support frame 1123_1 may allow MEA 1105_1 and cathode flow Docket No. OPUSP025WO field 1127_1 to be fluidically connected via cathode GDL 1127_1.
  • anode PTL 1109_2 and anode flow field 1111_2 may, for example, be supported in one or more openings in anode frame 1115_2 and encircled by first anode gasket 1113a_2 of first anode gasket set 1113_2 at a first side of anode frame 1115_2.
  • cathode flow field 1127_1 and at least a portion of unitized MEA assembly 1119_1 (and, thereby, at least cathode GDL 1121_1) may be supported in one or more openings of cathode frame 1131_1 and encircled by first cathode gasket 1129_1 at a first side of cathode frame 1131_1.
  • anode frame 1115_2 may be stacked between unitized MEA assembly 1119_1 and separator plate 1107_2, and cathode frame 1131_1 may be stacked between separator plate 1107_1 and unitized MEA assembly 1119_1.
  • Second anode gasket set 1117_2 may be disposed between anode frame 1115_2 and separator plate 1107_2, whereas second cathode gasket 1133_1 may be disposed between cathode frame 1131_1 and separator plate 1107_1.
  • gaskets 1113a_2 and 1129_1 may be formed thin enough so that anode PTL 1109_2 and cathode GDL 1121_1 are not under-compressed when assembled as part of stack 500.
  • gaskets 1113a_2 and 1129_1 may be sized such that anode PTL 1109_2 and cathode GDL 1121_1 are compressed and sealed against corresponding surfaces of flow fields 1111_2 and 1127_1 to maintain electrical contact while preventing or discouraging fluids from pooling during operation.
  • gaskets 1117a_2 and 1133_1 may provide fluidic seals between separator plates 1107_2 and 1107_1 and corresponding surfaces of flow fields 1111_2 and 1127_1.
  • Each element within cell 501 may provide particular functionality to cell 501, and various components of stack 500 may provide shared functionality with each of the plurality of cells including cell 501.
  • end plates 519 and 525 may generally serve to act as load- spreading members that distribute a clamping load relatively evenly over the plurality of cells of stack 500 including cell 501.
  • Manifold assembly 515 may include, for example, main body 541 forming at least a portion of one or more fluidic inlet ports, which may begin at inlet connectors Docket No.
  • main body 541 of manifold assembly 515 may form at least a portion of one or more fluidic inlet ports, which may begin at inlet connector 547, and at least a portion of one or more fluidic outlet ports, which may terminate at outlet connector 549, that may be used to convey fluid to and from the cathode sides of the plurality of cells of stack 500 including cell 501.
  • bus plate 513 may be electrically connected to cathode flow field 1127_1 (and, in some instances, cathode frame 1131_1) via cathode interface separator 1701, cathode flow field 1127, cathode GDL 1121, and MEA 1105 of cathode interface assembly 505 (see FIGS. 5-10 and 17).
  • Anode and cathode flow fields 1111_2 and 1127_1 may be made of any suitable material(s) that is electrically conductive and otherwise capable of withstanding relatively long-term exposure to the fluids flowed within stack 500 during normal operating conditions.
  • flow fields 1111_2 and 1127_1 may be made from titanium or titanium alloy, stainless steel (although stainless steel may have a higher susceptibility to corrosion than other materials), porous graphite, a carbon-fiber reinforced thermoset polymer, etc.
  • anode and cathode frames 1115_2 and 1131_1 may have inlets that correspond in location to the fluidic inlet passageways that begin at inlet connectors 543 and 547, and outlets Docket No.
  • anode and cathode flow fields 1111_2 and 1127_1 may each have one or more channels that are formed in surfaces of the corresponding flow fields that are in contact with anode PTL 1109_2 and cathode GDL 1121_1, respectively, that are routed so as to allow the fluid that is conducted through the channels to come into contact with the adjacent PTL or GDL in a generally distributed manner.
  • anode flow field 1111_2 may feature one or more inlet openings (or channels) and one or more outlet openings (or channels) that may, respectively, fluidically connect with corresponding openings in anode frame 1115_2.
  • One or more anode channels e.g., serpentine channels, may be provided in a surface of anode flow field 1111_2 that is in contact with anode PTL 1109_2.
  • the anode channels may serve to distribute the fluid introduced to the anode side of cell 501 across anode PTL 1109_2 such that the anolyte is able to come into contact with anode PTL 1109_2 in a spatially distributed manner such that the anolyte may be allowed to flow through anode PTL 1109_2 in a relatively uniform manner across the entire area, or most of the entire area, of anode PTL 1109_2.
  • An illustrative anode frame 1115 and some example anode flow fields 1111 will be described in more detail in association with FIGS. 37-42 and 83-85.
  • cathode flow field 1127_1 may feature one or more inlet openings (or channels) and one or more outlet openings (or channels) that may, respectively, fluidically connect with corresponding openings in cathode frame 1131_1.
  • One or more cathode channels may be provided in a surface of cathode flow field 1127_1 that is in contact with cathode GDL 1121_1.
  • the cathode channels may serve to distribute the fluid introduced to the cathode side of cell 501 across cathode GDL 1121_1 such that the cathode fluid is able to come into contact with cathode GDL 1121_1 in a spatially distributed manner such that the cathode fluid may be allowed to flow through cathode GDL 1121_1 in a relatively uniform manner across the entire area, or most of the entire area, of cathode GDL 1121_1.
  • An illustrative cathode frame 1131 and example cathode flow fields 1127 will be described in more detail in association with FIGS. 28-36 and 49-78.
  • Anode PTL 1109_2 and cathode GDL 514 may both serve to help gases that are generated within or provided via anode flow field 1111_2 and cathode flow field 1127_1, respectively, to diffuse across the active area of MEA 1105_1.
  • a typical GDL suitable for use in a COx electrolyzer may include, for example, a fibrous substrate that provides structural support, e.g., to the catalyst layer in MEA 1105_1, and may allow gas to flow from the adjacent flow field towards Docket No. OPUSP025WO the MEA (including in directions parallel to the plane of MEA 1105_1, thereby allowing the gas to flow laterally underneath portions of the adjacent flow field that may be in contact with the GDL).
  • Such a GDL may also permit water that is present in MEA 1105_1 or that is trapped within the GDL and/or trapped between that GDL and MEA 1105_1 to escape into the channel(s) of a flow field that is adjacent to the GDL, thereby potentially allowing that water to be expelled from that flow field as a result of fluid flow through that flow field.
  • the GDL may also serve as an electrical conductor that serves to conduct electrical charge through MEA 1105_1.
  • a typical PTL suitable for use in a COx electrolyzer may include, for example, a porous, metallic matrix that provides structural support, e.g., to the catalyst layer in MEA 1105_1, and may allow water to flow from the adjacent flow field towards the MEA (including in directions parallel to the plane of MEA 1105_1, thereby allowing the water to flow laterally above portions of the adjacent flow field that may be in contact with the PTL).
  • Such a PTL may also permit gas that is present in MEA 1105_1 or that is trapped within the PTL and/or trapped between that PTL and MEA 1105_1 to escape into the channel(s) of a flow field that is adjacent to the PTL, thereby potentially allowing that water to be expelled from that flow field as a result of fluid flow through that flow field.
  • the PTL may also serve as an electrical conductor that serves to conduct electrical charge through MEA 1105_1.
  • MEA 1105_1 for a COx electrolyzer may feature a metal nanoparticle catalyst layer that is pressed into contact with cathode GDL 1121_1.
  • the metal nanoparticle catalyst layer may alternatively be formed on cathode GDL 1121_1 and pressed into contact with MEA 1105_1.
  • One example of such a catalyst layer is a layer of carbon material supporting a layer of, or incorporating, gold nanoparticles.
  • OPUSP025WO Within the context of a multi-cell architecture, such as in the case of stack 500, multiple cells (including cell 501) may be served by common fluidic inlet ports/outlet ports and/or a common electrical potential source. It is noted that the overall multi-cell stack performance may be partially defined by the uniformity of electrical efficiency and product selectivity across the plurality of cells of stack 500, and this uniformity may be driven by the uniformity of gas flow delivery to/across each of the plurality of cells. To this point, the selection of flow field geometry, in that it relates to flow field pressure drop, may have a noticeable effect on overall stack flow uniformity.
  • liquid water may be provided to the anode side of cell 501 during operation, while gaseous CO x may be provided to the cathode side of cell 501.
  • an aqueous solution may be provided in place of water, and references to water herein may be understood to also be inclusive of the use of an aqueous solution as well.
  • the liquid water may, through an electrolysis reaction on the anode side of cell 501, undergo oxidation to create oxygen (O2) gas, H+ protons, and electrons.
  • the H+ protons may be drawn through MEA 1105_1 due to the electromagnetic field that is present within cell 501 due to the electrical potential that is applied across cell 501 and may react with the bicarbonate and/or hydroxide and/or formate that is produced at the cathode side.
  • water may enter the cathode of MEA 1105_1.
  • liquid water is transported by one or more phenomena to the cathode.
  • This imbalance presents a significant challenge—for every molecule of CO x gas that is reduced on the cathode side of cell 501, between five (5) and nine (9) molecules of water may need to be removed from Docket No. OPUSP025WO the cathode side of cell 501.
  • CO x gas electrolyzers such as those that may use a copper catalyst and may be used to generate CH4, for every molecule of COx gas that is reduced on the cathode side of cell 501, between five (5) and 36 molecules of water may need to be removed from the cathode side of cell 501, presenting an even greater water management challenge.
  • CO x electrolyzers are confronted with unique challenges with liquid water management that are not encountered in fuel cells. Such issues are, of course, also not present in water electrolyzers since the reactant that is delivered to the cathode side of water electrolyzers in the first place is liquid Docket No. OPUSP025WO water that migrates from the anode, and the presence of liquid water in the cathode is, thus, not only expected, but desired and by design.
  • the increased flow velocity in fuel cells may serve to forcibly push any potential droplets of liquid water that are present in the cathode flow field channel(s) through the flow field Docket No. OPUSP025WO and to the fluidic outlet port of the cathode flow field, thereby rapidly evacuating what little liquid water is present in the flow field channels from the flow field.
  • Cathode frame (or frame) 1131 may be a generally rectangular plate-shaped body having first surface 2801 (e.g., a top surface) opposing second surface 2803 (e.g., a bottom surface) in axial direction 2901 (see FIG. 29). Although frame 1131 is described as having a generally rectangular plate-shaped configuration, embodiments are not limited thereto and any suitable geometric configuration may be utilized, such as a generally circular, generally elliptical, generally triangular, generally pentagonal, generally hexagonal, etc., configuration.
  • the side of opening 2825 extending adjacent to surface 2809 of frame 1131 may not only have central portion 2825a extending in a first direction parallel (or substantially parallel) to surface 2809, but may also have second portions 2825b extending from central portion 2825a that are angled inwards from first portion 2825a towards opening 2823 by, for instance, angle 3101.
  • Central portion 2825a may have width 3103 in the first direction, whereas second portions 2825b may have corresponding widths 3105, which may be greater than width 3103.
  • Curved (or arcuate) corners 2825c of opening 2825 may respectively extend from second portions 2825b to connect the side of opening 2825 extending adjacent to surface 2809 to corresponding sides of opening 2825 extending in a second direction transverse to the first direction, e.g., extending parallel (or substantially parallel) to surfaces 2807 and 2811 of frame 1131.
  • thickness 1134t of cathode annular insert 1134 may be equivalent (or substantially equivalent) to the depth of opening 2825, but implementations are not limited thereto.
  • cathode annular insert 1134 may fill the void in cathode frame 1131 corresponding to opening 2825. It is Docket No. OPUSP025WO also contemplated that cathode annular insert 1134 may include one or more notched portions 1134n1 and 1134n2 such that cathode annular insert 1134 does not completely fill the void corresponding to opening 2825.
  • protrusions 3003 may not only promote a draw of reactant from connecting riser 3001, but may also facilitate a distributed flow of reactant to an input portion of cathode flow field 1127 (see, e.g., FIGS. 23 and 24) at least partially supported in opening 2823.
  • Protrusions 3003, in association with buffering passage 2833 may promote a draw of byproduct from an output portion of cathode flow field 1127 (see, e.g., FIGS. 23 and 24) at least partially supported in opening 2823 to connecting riser 3109.
  • protrusions 3003 are shown as generally cylindrically shaped bosses, embodiments are not limited thereto.
  • outer peripheral surface 1118d of anode annular insert 1118 may be shaped and sized to correspond with the shape and size of an inner peripheral boundary of opening 3725.
  • thickness 1118t of anode annular insert 1118 may be equivalent (or substantially equivalent) to the depth of opening 3725, but implementations are not limited thereto.
  • anode annular insert 1118 may fill the void in frame 1115 corresponding to opening 3725. It is also contemplated that anode annular insert 1118 may not completely fill the void corresponding to opening 3725, such as can be appreciated in FIGS. 11B and 11C.
  • PTL 1109 may be formed to completely (or substantially completely) fill opening 3725 to reduce or prevent the likelihood of bypass flow 1120.
  • the presence of anode annular insert 1118 may not only prevent or reduce the likelihood of bypass flow 1120 during operation of stack 500, but may also prevent or reduce the likelihood that bypass flow 1120 or compression forces within the system (e.g., stack 500) cause the anode side of MEA 1105 to push against the outer periphery of PTL 1109 and become mechanically deteriorated via abrasion, cutting, etc.
  • first fluidic outlet passages 3719 and 3721, outlet channels 3735, collection channel 3737, connecting risers 3739 and 3741, and channels 4009, 4011, 4013, and 4015 enables, for example, water to flow from an area inside of first anode gasket 1113a of first anode gasket set 1113 (see, e.g., FIGS.11A, 23, and 24) to an area outside of first anode gasket 1113a of first anode gasket set 1113 without disturbing the integrity of or seal provided by first anode gasket 1113a of first anode gasket set 1113.
  • frame 1115 may include recesses 4017-4029 in surface 3703 that may be configured to respectively receive corresponding portions of gaskets among second anode gasket set 1117 (see, e.g., FIGS. 11A, 23, and 24) therein when, for example, frame 1115 is assembled as part of a repeat unit (e.g., repeat unit 503_1 in FIG. 5) or anode interface assembly 509 (see, e.g., FIGS. 5-10, 47, and 48).
  • a repeat unit e.g., repeat unit 503_1 in FIG. 5
  • anode interface assembly 509 see, e.g., FIGS. 5-10, 47, and 48.
  • recess 4023 may be formed to encircle a combined periphery of first fluidic outlet passages 3721, channels 4013 and 4015, and connecting riser 3741 to interface with still another one of second anode gaskets 1117b of second anode gasket set 1117 (see, e.g., FIGS. 11A, 23, and 24), whereas recess 4025 may be formed to encircle a combined periphery of first fluidic outlet passages 3719, channels 4009 and 4011, and connecting riser 3739 to interface with yet another one of second anode gaskets 1117b of second anode gasket set 1117 (see, e.g., FIGS. 11A, 23, and 24).
  • first fluidic inlet passages 3715 and 3717, channels 4001, 4003, 4005, and 4007, connecting risers 3727 and 3729, distribution channel 3731, and supply channels 3733 enables, for example, water to flow from an area outside of first anode gasket 1113a of first anode gasket set 1113 (see, e.g., FIGS. 11A, 23, and 24) to an area inside of first anode gasket 1113a of first anode gasket set 1113 without also disturbing the integrity of or seal provided by second anode gaskets 1117b of second anode gasket Docket No. OPUSP025WO set 1117 (see, e.g., FIGS. 11A, 23, and 24).
  • recesses 4027 and 4029 may be formed to at least encircle the respective peripheries of second fluidic inlet and outlet passages 3743 and 3745 and interface with third anode gaskets 1117c of second anode gasket set 1117 (see, e.g., FIGS. 11A, 23, and 24). It is noted that the size, shape, and location of recesses 4019-4029 may correspond with the size, shape, and location of protrusions 3305 and 3307 (see FIGS. 32-36) of cathode frame 1131 to enable second and third anode gaskets 1117b and 1117c (see, e.g., FIGS.
  • swage nuts 1135 may be pressed into, for example, the counterbored portions of first, second, and third fastener orifices 3761, 3763, and 3765 such that, when frame 1115 is assembled as part of a repeat unit (e.g., repeat unit 503_1 in FIG.5) or as part of anode interface assembly 509 (see, e.g., FIGS.5-10, 47, and 48), first, second, and third fastener orifices 3761, 3763, and 3765 may be configured to respectively engage with corresponding fasteners 1137 (see, e.g., FIGS.
  • frame 1115 and/or anode annular insert 1118 may be formed of any suitable thermoplastic and/or thermosetting material, such as, for instance, PET, PC, PI, PA, PMMA, PEN, PEK, PEEK, PEI, PPS, PAR, PES, COC, PVA, PS, ECTFE, PTFE, Docket No. OPUSP025WO PBT, PCTFE, PETG, and/or the like.
  • frame 1115 and/or anode annular insert 1118 may be formed of one or more metals or metal alloys, such as, for example, aluminum, aluminum alloy, copper, copper alloy, tin, tin alloy, titanium, titanium alloy, tungsten, tungsten alloy, zinc, zinc alloy, steel, stainless steel, etc. It is noted, however, that when formed of a metal or metal alloy, frame 1115 and/or anode annular insert 1118 may, in some embodiments, include a coating or other feature to, for instance, electrically insulate frame 1115 or anode annular insert 1118 from a corresponding anode PTL (e.g., anode PTL 1109 in FIG.
  • anode PTL e.g., anode PTL 1109 in FIG.
  • anode flow field e.g., anode flow field 1111 in FIG. 11A
  • a base material of frame 1131 and/or anode annular insert 1118 may be coated with, for instance, one or more other materials, e.g., one or more corrosion-resistant materials. That being said, in some cases, anode annular insert 1118 may be formed of one or more materials with equivalent, substantially equivalent, or at least similar chemical inertness as PTL 1109. To this end, anode annular insert 1118 may have a porous or non-porous configuration.
  • FIG. 43 depicts a plan view of an example separator plate of the representative repeat unit of FIG. 11A.
  • Separator plate 1107 may be a generally rectangular plate-shaped body having first surface 4301 (e.g., a top surface) opposing a second surface in axial direction 4303.
  • separator plate 1107 may have a symmetrical configuration about one or more reference planes perpendicular to axial direction 4303.
  • separator plate 1107 may be symmetrical about either or both of reference planes 4315 and 4317 (apart from the presence of terminal 4307t), but embodiments are not limited thereto.
  • separator plate 1107 includes first openings 4319 and 4321 adjacent to peripheral surface 4305, second openings 4323 and 4325 adjacent to peripheral surface 4309, third opening 4327 adjacent to peripheral surface 4305, and fourth opening 4329 adjacent to peripheral surface 4309. Openings 4319 and 4321 may be sized, shaped, and located in correspondence with the size, shape, and location of protrusions 3305 (see, e.g., FIGS.
  • openings 4319 and 4321 may be sized, shaped, and located in correspondence with the size, shape, and location of protrusions 3305 adjacent to peripheral surface 2809 of cathode frame 1131 (see, e.g., FIGS. 32 and 33) such that, when separator plate 1107 is incorporated as part of a repeat unit (e.g., repeat unit 1100 in FIG. 11A).
  • protrusions 3305 adjacent to peripheral surface 2809 of cathode frame 1131 may be received in openings 4323 and 4325.
  • openings 4327 and 4329 may be sized, shaped, and located in correspondence with the size, shape, and location of protrusions 3307 adjacent to peripheral surfaces 2805 and 2809 of cathode frame 1131 (see, e.g., FIGS. 24, 32, and 33) such that, when separator plate 1107 is incorporated as part of a repeat unit (e.g., repeat unit 1100 in FIG. 11A), protrusions 3307 adjacent to peripheral surfaces 2805 and 2809 of cathode frame 1131 may be respectively received in openings 4327 and 4329 (see also FIG. 24).
  • a repeat unit e.g., repeat unit 1100 in FIG. 11A
  • first surface 4301 of separator plate 1107 may abut against surface 3701 of anode frame 1115 (see, e.g., FIGS. 23, 24, 37, and 38) and the second surface of separator plate 1107 may abut against surface 2801 of Docket No. OPUSP025WO cathode frame 1131 (see, e.g., FIGS. 23, 24, 32, and 33) when the repeat unit (e.g., repeat unit 1100 in FIG.
  • a pitch between adjacent second fastener orifices 4333 and a pitch between adjacent third fastener orifices 4335 may be smaller than the pitch(es) between adjacent first fastener orifices 4331.
  • first, second, and third fastener orifices 4331, 4333, and 4335 may extend completely through separator plate 1107 such that, when separator plate 1107 is assembled as part of a repeat unit (e.g., repeat unit 1100 in FIG.
  • fasteners 1137 extending from cathode frame 1131 may extend through separator plate 1107 and may be threadedly engaged with corresponding swage nuts 1135 pressed and/or clinched into first, second, and third fastener orifices 3761, 3763, and 3765 of anode frame 1115 (see also FIGS.11A and 21).
  • first, second, and third fastener orifices 4331, 4333, and 4335 may be sized to form respective clearance or interference fits with corresponding fasteners 1137 (see FIG. 11A) or corresponding portions (e.g., shoulder portions) of fasteners 1137 (see, e.g., FIG.
  • first, second, and third fastener orifices 4331, 4333, and 4335 may be sized to form respective clearance fits with corresponding fasteners 1137 (see FIG. 11A) or corresponding portions (e.g., shoulder portions) of fasteners 1137 (see, e.g., FIG.
  • first, second, and third fastener orifices 4331, 4333, and 4335 may be sized to form respective interference fits with corresponding fasteners 1137 (see FIG.11A) or corresponding portions (e.g., shoulder portions) of fasteners 1137 (see, e.g., FIG. 21).
  • respective sizes (e.g., diameters) of first, second, and third fastener orifices 4331, 4333, and 4335 may be about 0.01% to about 10% larger (in the case of a clearance fit) or about 0.01% to about 5% smaller (in the case of an interference fit) than corresponding widths (e.g., diameters) of respective portions (e.g., shoulder portions) of fasteners 1137 (see, e.g., FIGS. 11A, 17, and 21).
  • OPUSP025WO third fastener orifices 4331, 4333, and 4335 may be sized to form respective clearance fits with corresponding fasteners 1137 (see, e.g., FIGS. 11A, 17, and 21) or corresponding portions (e.g., shoulder portions) of fasteners 1137 (see, e.g., FIG. 21) when separator plate 1107 is assembled as part of a repeat unit (e.g., repeat unit 1100 in FIG. 11A) and stack 500 (see, e.g., FIG.
  • fasteners 1137 may expand to form corresponding interference fits with the one or more of first, second, and third fastener orifices 4331, 4333, and 4335.
  • These clearance and/or interference fits may be utilized to constrain in-plane expansion (e.g., expansion in, for instance, a plane parallel to an x-y plane (see FIG. 11A)) of anode and cathode frames 1115 and 1131 during operation of stack 500 (see, e.g., FIG. 5) without unduly stressing anode and cathode frames 1115 and 1131.
  • separator plate 1107 when separator plate 1107 is assembled as part of a repeat unit (e.g., repeat unit 1100 in FIG.11A) with cathode frame 1131 coupled to anode frame 1115 via fasteners 1137 and swage nuts 1135 (see also FIGS. 11A and 21-24), some of the various gaskets of second anode gasket set 1117 may not only be interposed between surface 4301 of separator plate 1107 and some of the various recesses in surface 3703 of anode frame 1115 (see, e.g., FIGS.39 and 40), but may also encircle the various protrusions extending from surface 2801 of cathode frame 1131 (see, e.g., FIGS.
  • second gaskets 1117b of second anode gasket set 1117 may not only be interposed between surface 4301 of separator plate 1107 and corresponding recesses 4019-4025 in surface 3703 of anode frame 1115 (see also FIGS. 39 and 40), but may also encircle protrusions 3305 extending from surface 2801 of cathode frame 1131 (see also FIGS. 32 and 33) to fluidically seal corresponding first fluidic inlet and outlet passageways between cathode frame 1131 and anode frame 1115 (see, e.g., second anode gasket 1117b fluidically sealing first fluidic inlet passageway 2301 that is outlined in FIG.
  • third gaskets 1117c of second anode gasket set 1117 may not only be interposed between surface 4301 of separator plate 1107 and corresponding recesses 4027-4029 in surface 3703 of anode frame 1115 (see also FIGS. 39 and 40), but may also encircle protrusions 3307 extending from surface 2801 of cathode frame 1131 (see also FIGS.
  • separator plate 1107 may be formed of any suitable thermoplastic and/or thermosetting material, such as, for instance, PET, PC, PI, PA, PMMA, PEN, PEK, PEEK, PEI, PPS, PAR, PES, COC, PVA, PS, ECTFE, PTFE, PBT, PCTFE, PETG, and/or the like.
  • separator plate 1107 may be formed of one or more metals or metal alloys, such as, for example, aluminum, aluminum alloy, copper, copper alloy, tin, tin alloy, titanium, titanium alloy, tungsten, tungsten alloy, zinc, zinc alloy, steel, stainless steel, etc.
  • separator plate 1107 may be formed of titanium, which may increase the strength and rigidity of a repeat unit, such as repeat unit 1100 in FIG. 11A, as well as enable electrical conductivity between adjacent cells of stack 500 (see, e.g., FIGS.5 and 7).
  • a material(s) and/or configuration of separator plate 1107 may be stronger and/or more rigid than a material(s) and/or configuration of anode and cathode frames 1115 and 1131 (see also FIG.11A).
  • an electrical conductivity of separator plate 1107 may be greater than corresponding electrical conductivities of anode and cathode frames 1115 and 1131 (see also FIG. 11A).
  • FIG.17 depicts an exploded view of an example cathode interface assembly of the example multi-cell CO x electrolyzer stack of FIG. 6.
  • FIG. 18 depicts the example cathode interface assembly of FIG. 17 in a non-exploded state.
  • cathode frame 1131 may be coupled to cathode interface separator 1701, which will now be described in more detail in association with FIGS. 45 and 46.
  • cathode interface separator 1701 may be a generally rectangular plate-shaped body having first surface 4501 (e.g., a top surface) opposing second surface 4503 (e.g., a bottom surface) in axial direction 4601.
  • cathode interface separator 1701 may have a symmetrical configuration about one or more reference planes perpendicular to axial direction 4601. For instance, a configuration of cathode interface separator 1701 may be symmetrical about either or both of reference planes 4603 and 4605, but embodiments are not limited thereto. [0340] According to various embodiments, cathode interface separator 1701 may include first fluidic inlet passages 4515 and 4517 adjacent to peripheral edge 4505, and first fluidic outlet passages 4519 and 4521 adjacent to peripheral edge 4509. With additional reference to FIGS.
  • first fluidic inlet passages 4515 and 4517 may form portions of inlet passages 1001 and 1003 of stack 500 in association with inlet connectors 543 of manifold assembly 515 that provide, for example, input water to anode frames 1115 of stack 500, and, thereby, to the corresponding anode flow fields 1111 of the plurality of cells, such as cell 501.
  • First fluidic outlet passages 4519 and 4521 may form portions of outlet passages (that are similar to inlet passages 1001 and 1003, but associated with outlet connectors 545 of manifold assembly 515 versus inlet connectors 543) of stack 500 that output water from anode frames 1115, and, thereby, from corresponding anode flow fields 1111 of the plurality of cells, such as cell 501 (see also FIGS. 5-11A).
  • first fluidic inlet and outlet passages 4515-4521 may be defined by respective pluralities of orifices separated from one another via corresponding septal walls.
  • Outlet passage 903 may enable one or more byproducts of the COx reduction process to be expelled from the various cathode frames 1131 of stack 500, and, thereby, from the corresponding cathode flow fields 1127 supported in association therewith (see, e.g., FIGS. 5-11A and 19).
  • cathode interface separator 1701 may also include recesses 4527-4537 in surface 4501 that may be configured to respectively receive corresponding portions of gaskets 553 and 555 when, for example, cathode interface assembly 505 is assembled as part of stack 500, e.g., when cathode interface assembly 505 is stacked in relation to manifold assembly 515 with bus plate 513 interposed therebetween (see, e.g., FIGS.5-10, 17, and 18).
  • first and second protrusions 3305 and 3307 of cathode frame 1131 are not limited thereto.
  • the depth at which first and second recessed 4607-4617 extend into surface 4503 may be greater than or smaller than height 3401 (see FIG. 34) provided sufficient fluidic seals may be formed between cathode interface separator 1701 and cathode frame 1131 when a cell is formed between cathode interface assembly 505 and repeat unit 503_1 (see also FIGS. 5-10 and 17).
  • first and second recesses 4607-4617 may at least permit a portion of first and second protrusions 3305 and 3307 of cathode frame 1131 to be received therein when a cell is formed between cathode interface assembly 505 and repeat unit 503_1 (see also FIGS.5-10).
  • first and second recesses 4607-4613 may be sized and shaped to interface with corresponding protrusions among first and second protrusions 3305 and 3307 of cathode frame 1131 (see FIGS. 32-33).
  • third and fourth cathode gaskets 1703 and 1705 may prevent cross-flow between first and second fluidic inlet and outlet passages 4515-4525. It is also noted that, when a cell is formed between cathode interface assembly 505 and repeat unit 503_1 Docket No. OPUSP025WO (see, e.g., FIGS. 5-10), second cathode gasket 1133 may be interposed between a central portion of surface 4503 and recess 3303 in cathode frame 1131 (see FIGS.17, 32, and 33) to form a fluidic seal around cathode flow field 1127 at least partially supported in an opening of cathode frame 1131.
  • Cathode interface separator 1701 may also include first threaded fastener orifices 4539 arranged about a peripheral area of cathode interface separator 1701 at one or more intervals.
  • first, second, and third threaded fastener orifices 4539-4543 may be formed similar to first, second, and third fastener orifices 3761-3765 of anode frame 1115 (see, e.g., FIGS. 11A and 37-42), and, thereby, include swage nuts 1135 versus being threaded. Regardless, when cathode interface separator 1701 is assembled as part of cathode interface assembly 505 (see also FIGS.
  • first, second, and third threaded fastener orifices 4539, 4541, and 4543 may be configured to respectively engage with corresponding fasteners 1137 respectively received in and extending from corresponding first, second, and third fastener orifices 2837, 2839, and 2841 of cathode frame 1131 (see FIGS. 28, 29, 32, 33, and 35). Further, as can be appreciated from at least FIG. 17, cathode frame 1131 of cathode interface assembly 505 may be coupled to cathode interface separator 1701 with second, third, and fourth cathode gaskets 1133, 1703, and 1705 interposed therebetween.
  • cathode interface separator 1701 may be formed of any suitable thermoplastic and/or thermosetting material, such as, for instance, PET, PC, PI, PA, PMMA, PEN, PEK, PEEK, PEI, PPS, PAR, PES, COC, PVA, PS, ECTFE, PTFE, PBT, PCTFE, Docket No. OPUSP025WO PETG, and/or the like.
  • suitable thermoplastic and/or thermosetting material such as, for instance, PET, PC, PI, PA, PMMA, PEN, PEK, PEEK, PEI, PPS, PAR, PES, COC, PVA, PS, ECTFE, PTFE, PBT, PCTFE, Docket No. OPUSP025WO PETG, and/or the like.
  • cathode interface separator 1701 may be formed of one or more metals or metal alloys, such as, for example, aluminum, aluminum alloy, copper, copper alloy, tin, tin alloy, titanium, titanium alloy, tungsten, tungsten alloy, zinc, zinc alloy, steel, stainless steel, etc.
  • metals or metal alloys such as, for example, aluminum, aluminum alloy, copper, copper alloy, tin, tin alloy, titanium, titanium alloy, tungsten, tungsten alloy, zinc, zinc alloy, steel, stainless steel, etc.
  • cathode interface separator 1701 may be formed of titanium, which may increase the strength and rigidity of cathode interface assembly 505 (see, e.g., FIGS.5-10, 17, and 18).
  • a material(s) and/or configuration of cathode interface separator 1701 may be stronger and/or more rigid than a material(s) and/or configuration of anode and cathode frames 1115 and 1131 (see also FIG. 11A).
  • an electrical conductivity of cathode interface separator 1701 may, in some embodiments, be greater than corresponding electrical conductivities of anode and cathode frames 1115 and 1131 (see also FIG. 11A).
  • a base material of cathode interface separator 1701 may be coated with, for instance, one or more other materials, e.g., one or more corrosion-resistant materials.
  • first anode gasket 1113a of first anode gasket set 1113 may interface with a recess in surface 4701a of anode frame 4701 similar to recess 3747 in surface 3701 of anode frame 1115, abut against a corresponding surface of support frame 1125 of unitized MEA assembly 1119 (see also FIGS.25- 27), and encircle opening 1125a in support frame 1125 (see also FIGS.25-27).
  • first and second anode gaskets 1117a and 1117b of second anode gasket set 1117 may simply interface with recesses in surface 4701b of anode frame 4701 similar to recesses 4017-4025 in surface 3703 of anode frame 1115 (see also FIGS.39, 40, and 42) and may abut against first surface 4703a of anode interface separator 4703.
  • Bladder As previously discussed, bladder side assembly 511 (see, e.g., FIG.
  • FIG. 87 depicts a cross-sectional view of the illustrative insulation plate of FIG. 86 taken along sectional line 87-87.
  • FIG. 88 depicts a plan view of an illustrative end plate of the example multi-cell COx electrolyzer of FIG. 6.
  • FIG. 89 depicts a cross-sectional view of the illustrative end plate of FIG. 88 taken along sectional line 89-89.
  • FIG. 90 depicts an enlarged portion of the cross-sectional view of FIG. 9. Docket No. OPUSP025WO [0351] Referring to FIGS.
  • insulation plate 523 may be a generally rectangular plate- shaped body having first surface 8601 (e.g., a top surface) opposing second surface 8603 (e.g., a bottom surface) in axial direction 8605.
  • first surface 8601 e.g., a top surface
  • second surface 8603 e.g., a bottom surface
  • insulation plate 523 is described as having a generally rectangular plate-shaped configuration, embodiments are not limited thereto and any suitable geometric configuration may be utilized, such as a generally circular, generally elliptical, generally triangular, generally pentagonal, generally hexagonal, etc., configuration.
  • insulation plate 523 will be described in association with a generally rectangular configuration.
  • Second recess 8629 may be configured to interface with gasket 559 (see, e.g., FIGS. 5 and 90) in a manner that, when bus plate 521 and insulation plate 523 are assembled as part of stack 500, lower surface 521b (see FIG.90) of bus plate 521 may at least abut against gasket 559, and, depending on an extent of compression of the various components of stack 500, may either abut against surface 8623 of insulation plate 523 (such as shown in FIG. 90) or may be spaced apart from surface 8623 in an axial direction, which may extend parallel (or substantially parallel) to the z-axis direction shown in FIGS.5 and 90 and may be the same as axial direction 8605.
  • a distance in axial direction 8605 between lower surface 521b of bus plate 521 and surface 8623 of insulation plate 523 may be controlled to Docket No. OPUSP025WO constrain axial expansion of the plurality of cells, such as cell 501, of stack 500 (see, e.g., FIGS. 5-10) during the COx reduction process(es) to maintain corresponding fluidic seals and electrical conductivity between associated components of stack 500, but in a manner that prevents or reduces the likelihood that the plurality of cells (and the associated components of the cells) are overly compressed.
  • one or more control fluids may be introduced between bus plate 521 and insulation plate 523 to regulate a distance between lower surface 521b of bus plate 521 and surface 8623 of insulation plate 523.
  • the one or more control fluids may be provided via orifice 8631 in surface 8623 that extends through insulation plate 523 to surface 8603.
  • a size, shape, and location of orifice 8631 may correspond with a size, shape, and location of blind orifice 8801 in surface 525a of end plate 525 (see FIGS.88-90).
  • Blind orifice 8801 of end plate 525 may be fluidically connected to fluidic inlet connector 563 via fluidic passageway 8803 as seen in FIGS. 88-90.
  • the one or more control fluids may be caused to flow between bus plate 521 and insulation plate 523 via the conjunction of fluidic inlet connector 563, fluidic passageway 8803, blind orifice 8801, and orifice 8631, as well as source 9001 (see FIG.90) of the one or more control fluids.
  • source 9001 of the one or more control fluids may be the same as the source of input providing, for instance, gaseous CO x , to second fluidic inlet connector 547 (see FIG. 5).
  • source 9001 may be configured to supply the gaseous CO x to second fluidic inlet connector 547 (see, e.g., FIGS.5-9) at a first pressure and to supply the Docket No. OPUSP025WO one or more control fluids (e.g., gaseous CO x ) to fluidic inlet connector 563 (see, e.g., FIGS. 5-9 and 90) at a second pressure.
  • the first and second pressures may be equivalent or substantially equivalent.
  • projections 8301 may be rectangular prisms having length 8307 in a first direction (e.g., the x-axis direction) transverse to the axial direction, width 8309 in a second direction (e.g., the y-axis direction) transverse to the axial direction and the first direction, and height 8311 in the axial direction, but embodiments are not limited thereto.
  • one or more of projections 8301 may be alternatively formed as cylindrical prisms, triangular prisms, pentagonal prisms, and/or the like. Projections 8301 may be spaced apart from one another by pitch 8313 in the first direction and pitch 8315 in the second direction.
  • Multiple serpentine channels may also allow for relatively even distribution of the fluid that flows within them across the cathode GDL 1121 but with decreased total flow path length for each such serpentine channel as compared with multiple serpentine channel or single serpentine channel implementations having the same or similar channel depth and width and total open channel area in contact with the cathode GDL 1121 but with fewer numbers of such channels.
  • OPUSP025WO about 2.3 mm 2 and about 3.1 mm 2 , between about 3.1 mm 2 and about 3.8 mm 2 , between about 3.8 mm 2 and about 4.5 mm 2 , between about 4.5 mm 2 and about 5.3 mm 2 , or between about 5.3 mm 2 and about 6 mm 2 .
  • cathode flow fields with serpentine channels may also have structural characteristics relating to the thickness of the walls that are interposed between adjacent longer segments of one or more of the serpentine channels.
  • the wall thickness in between adjacent longer segments of one or more of the serpentine channels (and thus the distance between surfaces of that channel or those channels that are closest to one another) may be selected to be between about between about 0.00005 and about 0.0013333, between about 0.00005 and about 0.00069, between about 0.00069 and about 0.0013333, between about 0.00005 and about 0.00037, between about 0.00037 and about 0.00069, between about 0.00069 and about 0.001, between about 0.001 and about 0.0013333, between about 0.00005 and about 0.00021, between about 0.00021 and about 0.00037, between about 0.00037 and about 0.00053, between about 0.00053 and about 0.00069, between about 0.00069 and about 0.00085, between about 0.00085 and about 0.001, between about 0.001 and about 0.0012, or between
  • OPUSP025WO about 0.88 psi and about 1 psi, between about 1 psi and about 1.1 psi, between about 1.1 psi and about 1.3 psi, between about 1.3 psi and about 1.4 psi, between about 1.4 psi and about 1.5 psi, between about 1.5 psi and about 1.6 psi, between about 1.6 psi and about 1.8 psi, between about 1.8 psi and about 1.9 psi, between about 1.9 psi and about 2 psi, between about 2 psi and about 2.1 psi, between about 2.1 psi and about 2.3 psi, between about 2.3 psi and about 2.4 psi, between about 2.4 psi and about 2.5 psi, between about 2.5 psi and about 2.6 psi, between about 2.6 psi and about 2.8 psi, between about
  • FIG. 61 shows a cross-sectional view of a similar structure with a cathode flow field 6116 that is pressed against a cathode GDL 6114.
  • the peninsular walls 6364 may taper towards their tips such that the tip width 6370 is less than the root width 6368, thereby causing the flow resistance under the peninsular walls 6364 to decrease from what it was near the root of a peninsular wall 6364 as the flow nears the tip of the peninsular wall 6364.
  • fluid that flows down a longer segment A, through a shorter segment B, and into another longer segment A that neighbors the original longer segment A, e.g., along the heavy dashed line 6574 shown in association with the leftmost two longer segments A in FIG. 65 will experience a pressure drop that is generally proportional to the sum of the lengths of the two longer segments A and the shorter segment B that joins them.
  • the gas flow through the cathode serpentine channel 6556 is not limited to staying within the cathode serpentine channel 6556.
  • the side of the cathode flow field 6516 in which the cathode serpentine channel 6556 is provided may be compressed against a porous or fibrous GDL (not shown) that provides an alternate flow path that allows gas to also or alternatively flow under partition walls 6566 that lie in between each pair of Docket No. OPUSP025WO adjacent longer segments A, e.g., through the GDL that is sandwiched between the cathode flow field 6516 and an adjacent structure, e.g., an MEA.
  • the gas flow may also flow between the two longer segments A at the left of FIG. 65 via a flow path along dotted line 6576.
  • the per-unit-length flow resistance of the GDL may be much higher than the per- unit-length flow resistance of the cathode serpentine channel 6556.
  • the overall flow resistance of the flow path 6574 will increase with increasing length of the longer segments A of the cathode serpentine channel 6556.
  • shorter lengths of the longer segments A will result in less gas flow along the flow paths 6576 than longer lengths of the longer segments A.
  • the cathode flow field 6616 is divided into two zones 6670 that are separated by a boundary 6672.
  • Each zone 6670 has a set of four cathode serpentine channels 6656 that switchback in a nested or interleaved manner between the boundary 6672 and the edge of the relevant zone 6670 that is farthest from the boundary 6672.
  • the cathode flow field of FIGS.66 and 67 may, for example, have an active area (generally corresponding to the area within the bounds of the depicted component in FIG.66) on the order of 750–800 cm 2 , e.g., 760–790 cm 2 or 770–780 cm 2 , while the cathode serpentine channels 6656 themselves may, for example, each have a length of approximately 5000 to 6000 mm, e.g., 5200 to 5800 mm, 5400 to 5600 mm, 5400 to 5800 mm, or 5200 to 5600 mm.
  • the cathode serpentine channels may each be generally rectangular or square in cross-section, e.g., having a transverse width (generally perpendicular to the direction of gas flow within the cathode serpentine channels) and/or depth that ranges from 0.5 mm to 2 mm, e.g., 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, etc.
  • cathode serpentine channels 6656 are each separated from adjacent cathode serpentine channels by peninsular walls 6666 that are, for example, 0.5 mm to 2 mm in transverse width, e.g., 0.5 mm to 2 mm, e.g., 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, etc.
  • FIGS. 68 and 69 are generally similar to that of FIGS. 66 and 67, with corresponding elements labeled with figure callouts sharing the last two digits in common with their counterparts in the implementation of FIGS. 66 and 67.
  • the discussion above regarding such elements in the context of FIGS. 66 and 67 is equally applicable to those same elements in FIGS. 68 and 69 unless otherwise indicated below.
  • the implementation of FIGS. 68 and 69 for example, features a larger number of cathode serpentine channels 6856 in each zone 6870, e.g., seven cathode serpentine channels 6856 in each Docket No.
  • parallel channel arrangements will typically also include a larger number of potential alternate flow paths, e.g., tens or hundreds of flow paths, as compared with serpentine channel arrangements, which tend to include fewer numbers of flow paths, e.g., 2, 3, 4, or other relatively low numbers of flow paths.
  • serpentine channel arrangements which tend to include fewer numbers of flow paths, e.g., 2, 3, 4, or other relatively low numbers of flow paths.
  • Such parallel channels may also have depths that are between about 0.3 mm and about 3 mm, between about 0.3 mm and about 1.6 mm, between about 1.6 mm and about 3 mm, between about 0.3 mm and about 0.98 mm, between about 0.98 mm and about 1.6 mm, between about 1.6 mm and about 2.3 mm, between about 2.3 mm and about 3 mm, between about 0.3 mm and about 0.64 mm, between about 0.64 mm and about 0.98 mm, between about 0.98 mm and about 1.3 mm, between about 1.3 mm and about 1.6 mm, between about 1.6 mm and about 2 mm, between about 2 mm and about 2.3 mm, between about 2.3 mm and about 2.7 mm, or between about 2.7 mm and about 3 mm.
  • Such parallel channels may also have per-channel cross-sectional areas of between about 0.15 mm 2 and about 6 mm 2 , between about 0.15 mm 2 and about 3.1 mm 2 , between about 3.1 mm 2 and about 6 mm 2 , between about 0.15 mm 2 and about 1.6 mm 2 , between about 1.6 mm 2 and about Docket No.
  • the wall thickness between adjacent channels may be, for example, between about 0.15 mm and 5 mm, between about 0.15 mm and about 2.6 mm, between about 2.6 mm and about 5 mm, between about 0.15 mm and about 1.4 mm, between about 1.4 mm and about 2.6 mm, between about 2.6 mm and about 3.8 mm, between about 3.8 mm and about 5 mm, between about 0.15 mm and about 0.76 mm, between about 0.76 mm and about 1.4 mm, between about 1.4 mm Docket No.
  • the inlet passages 7181 and outlet passages 7183 may generally extend along directions parallel to the Docket No. OPUSP025WO second direction 7188 but may also include segments that extend in the first direction 7186 in order to connect with the fluidic inlet ports 7128 or the fluidic outlet ports 7130 (as appropriate), and the fluidic inlet ports 7128 and the fluidic outlet ports 7130 may each be located at locations near, and centered on (as a group), the symmetry axis 7172. While not depicted here, the fluidic inlet ports 7128 and the fluidic outlet ports 7130 may each connect with a corresponding common inlet or common outlet, as appropriate and as shown in other example flow fields herein.
  • each gas flow may subdivide into the separate parallel channels 7158 that are in the respective cluster 7178a/b/c/d of parallel channels 7158 that fluidically connect with the inlet branch passage 7180 that those parallel channels 7158 connect with.
  • the number of parallel channels 7158 that are in each cluster 7178a/b/c/d may generally decrease as a function of increasing flow path length from the corresponding fluidic inlet port 7128 to the corresponding inlet branch passage 7180 (although, in some instances, the number of parallel channels 7158 that are in some adjacent clusters may remain the same).
  • a cluster 7178 of the clusters 7178a/b/c/d where gas travels along a longer inlet passage 7181 path length before reaching that cluster may have fewer parallel channels 7158 in it than a cluster 7178 of the clusters 7178a/b/c/d where gas travels along a shorter inlet passage 7181 path length before reaching it.
  • Such a configuration allows for more even distribution of the gas that is flowed through the cathode flow field 7116.
  • the overall flow resistance experienced by gas flowing through such parallel channels 7158 may be higher than with gas that flows through Docket No. OPUSP025WO the parallel channels 7158 that are, for example, in the clusters 7178a/b/c (which flows along shorter flow path lengths and thus encounters lower flow resistance).
  • FIG. 72 depicts an example of a branching parallel channel flow field
  • FIG. 73 depicts the same branching channel flow field as in FIG. 72 but in enlarged form and with the middles of the parallel channels omitted by way of a break section.
  • a cathode flow field 7216 with a parallel channel arrangement is shown.
  • the cathode flow field 7216 includes 7 clusters 7278a/b/c/d/e/f/g of parallel channels 7258 on either side of a symmetry axis (not shown, but bisecting the cathode flow field 7216 horizontally with respect to the page orientation).
  • the parallel channels 7258 are separated by partition walls 7266; further partition walls 7266 may define other channels of the cathode flow field 7216.
  • the parallel channels 7258 of each cluster 7278a/b/c/d/e/f/g are each connected at one end to corresponding inlet branch passages 7280a/b/c/d/e/f/g and at the other end to corresponding outlet branch passages 7282a/b/c/d/e/f/g, which generally extend along directions that are perpendicular to the parallel channels 7258 (only the inlet branch passages 7280 in the upper left quadrant and the outlet branch passages 7282 in the upper right quadrant of the depicted cathode flow field 7216 are called out, but it will be understood that additional inlet branch passages 7280 and outlet branch passages 7282 of similar design are visible in FIGS.
  • Each inlet branch passage 7280 may be connected via a corresponding inlet passage 7281 to one of the fluidic inlet ports 7228.
  • each outlet branch passage 7282 may be connected via a corresponding outlet passage 7283 to one of the fluidic outlet ports 7230..
  • the cathode flow field of FIGS.72 and 73 may, for example, have an active area (generally corresponding to the area within the bounds of the depicted component in FIG.72) on the order of 750–800 cm 2 , e.g., 760–790 cm 2 or 770–780 cm 2 , while the parallel channels 7258 themselves may, for example, each have a length of approximately 250 to 300 mm, e.g., 260 to 290 mm, 260 to 280 mm, 270 to 280 mm, 270 to 290 mm, or 270 to 280 mm.
  • the parallel channels may each be generally rectangular or square in cross-section, e.g., having a transverse width (generally perpendicular to the direction of gas flow within the parallel channels) and/or depth that ranges from 0.5 mm to 2 mm, e.g., 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.1 mm, 1.2 mm, etc.
  • a cathode flow field 7416 is shown in which there are multiple clusters of parallel channels 7458 (similar, for example, to the clusters 7178 depicted in FIG. 71).
  • the parallel channels 7458 in each cluster of parallel channels 7458 may be connected at one end to an inlet branch passage 7480 and at the other end to an outlet branch passage 7482.
  • Each inlet branch passage 7480 may be connected with a corresponding fluidic inlet port 7428 via a corresponding inlet passage 7481
  • each outlet branch passage 7482 may be connected with a corresponding fluidic outlet port 7430 via a corresponding outlet passage 7483.
  • inlet branch passage 7480, outlet branch passage 7482, inlet passage 7481, and outlet passage 7483 are indicated with callouts, but it will be understood that other pairs of inlet/outlet branch passages 7480/7482 and inlet/outlet passages 7481/7483 are present as well in association with each cluster of parallel channels 7458.
  • the arrangement of parallel channels 7458 and inlet/outlet branch passages 7480/7482 shown in FIG. 74 is very similar to that shown in FIG. 71. However, there is one significant difference—the inlet branch passages 7480 and the outlet branch passages 7482 for each cluster of parallel channels 7458 in FIG.
  • the inlet branch passage 7480 is connected to an inlet passage 7481 that leads to one of the fluidic inlet ports 7428
  • the outlet branch passage 7482 is connected to an outlet passage 7483 that leads to one of the fluidic outlet ports 7430.
  • the inlet passage 7481 leading to the fluidic inlet port 7428 connects to the inlet branch passage 7480 at a location along the inlet branch passage 7480 that is closest to that fluidic inlet port 7428, while the outlet passage 7483 leading to the fluidic outlet port 7430 connects to the outlet branch passage 7482 at a location along the outlet branch passage 7482 that is furthest from that fluidic outlet port 7430.
  • the reverse arrangement may be used as well (essentially flipping the depicted arrangement left-to-right).
  • the inlet passage 7481 that leads from the fluidic inlet port 7428 connects with the inlet branch passage 7480 at a location that is proximate to one of the two outermost parallel channels 7458 in the cluster of parallel channels Docket No. OPUSP025WO 7458 that the inlet branch passage 7480 provides gas to, while the outlet passage 7483 that leads to the fluidic outlet port 7430 connects with the outlet branch passage 7482 at a location that is proximate to the other of the two outermost parallel channels 7458 in the cluster of parallel channels 7458 that the outlet branch passage 7482 receives gas from.
  • FIG. 75 depicts a schematic of yet another example of a branching parallel channel flow field.
  • a cathode flow field 7516 is shown in which there are multiple clusters of parallel channels 7558 (similar, for example, to the clusters depicted in FIG. 71).
  • the parallel channels 7558 in each cluster of parallel channels 7558 may be connected at one end with inlet branch passages 7580 (7580' and 7580'') and at the other end with outlet branch passages 7582 (7582' and 7582'').
  • the inlet passage 7581 that connects the fluidic inlet port 7528 to the inlet branch passage 7580 connects with the inlet branch passage 7580 at a location approximately midway along its length, with some of the parallel channels 7558 in the associated cluster of parallel channels 7558 connecting with a first sub-portion 7580' of the inlet branch passage 7580 on one side of that connection point, and the other parallel channels 7558 in the associated cluster of parallel channels 7558 connecting with a second sub-portion 7580'' of the inlet branch passage 7580 on the other side of that connection point.
  • FIG. 75 depicts an example of a cathode flow field that features branching parallel channels.
  • FIG. 77 depicts a detail view of the left and right sides of the upper half of the cathode flow field of FIG. 76, with the remainder of the flow field omitted from view.
  • OPUSP025WO 7682a' and 7682a'' (connected to outlet passage 7683 by corresponding outlet branch passage extensions 7685, e.g., 7685a' and 7685a''), each of which is associated with a different one of the sub-groups of parallel channels 7658 in the sub-groups 7678a' and 7678a'', respectively.
  • This arrangement is generally similar to that shown in FIG.75 and exhibits similar uniformity behavior.
  • Dimensional values of the various depicted features that are within the ranges indicated for the cathode flow field 7216 may, for example, provide gas flow with high uniformity and sufficient water ejection capability for use in CO x electrolyzers.
  • FIG. 78 depicts an example interdigitated channel cathode flow field.
  • a cathode flow field 7816 is depicted that has a fluidic inlet port 7828 and a fluidic outlet port 7830.
  • the fluidic inlet port 7828 and the fluidic outlet port 7830 may each be fluidically connected with a corresponding plenum passage 7872 or 7872', respectively.
  • the plenum passages 7872 and 7872' may generally extend along directions that are parallel to one another and may have a plurality of channels 7858 or 7858' extending away from the corresponding plenum passage 7872 or 7872' and towards the other of plenum passage 7872' or 7872, respectively (for more easy reference, the plenum passage 7872 and the channels 7858 are shaded differently than the plenum passage 7872' and the channels 7858').
  • Each pair of adjacent channels 7858 may have a channel 7858' interposed therebetween, and each pair of adjacent channels 7858' may have a channel 7858 interposed therebetween (thus providing two sets of interdigitated channels).
  • Cathode flow fields with interdigitated channel arrangements may, similarly to parallel channel arrangements, offer more direct fluid flow paths than serpentine channel arrangements may provide for coverage areas that are similar to coverage area 7852, and the average distances that accumulated liquid water must be moved through in order to evacuate it from a channel in such arrangements are significantly shorter in an interdigitated channel than in a serpentine channel for a similarly sized COx electrolyzer.
  • parallel channel arrangements will typically also include a larger number of potential alternate flow paths, e.g., tens or hundreds of flow paths, as compared with serpentine channel arrangements, which tend to include fewer numbers of flow paths, e.g., 2, 3, 4, or other relatively low numbers of flow paths.
  • serpentine channel arrangements which tend to include fewer numbers of flow paths, e.g., 2, 3, 4, or other relatively low numbers of flow paths.
  • interdigitated cathode flow fields may, in essence, force COx gas to come into contact with portions of the cathode GDL and the MEA that are underneath the walls 7848, thereby ensuring that CO x gas reaches such regions—in parallel and serpentine channel arrangements, CO x gas may still come into contact with such portions of the MEA and the cathode GDL, but it is not necessarily forced to do so.
  • Interdigitated cathode flow fields CO x electrolyzers may have channels with various dimensional characteristics that may make them particularly well-suited to use in the CO x electrolyzer context, e.g., with respect to facilitating water removal from the cathode flow field.
  • the ratio of the channel width to wall width of the walls in between each pair of adjacent channels or channel portions may be between about 0.08 and about 10, between about 0.08 and about 5, between about 5 and about 10, between about 0.08 and about 2.6, between about 2.6 and about 5, between about 5 and about 7.5, between about 7.5 and about 10, between about 0.08 and about 1.3, between about 1.3 and about 2.6, between about 2.6 and about 3.8, between about 3.8 and about 5, between about 5 and about 6.3, between about 6.3 and about 7.5, between about 7.5 and about 8.8, or between about 8.8 and about 10.
  • the increased residence time of the gas in the decreased flow speed region that results from such lower flow speed may provide additional time for water that is present in the cathode GDL to evaporate and/or diffuse into the gas flowing through the channel(s) in the decreased flow speed region, thereby humidifying the gas before it flows downstream into the increased flow speed region.
  • Such implementations may assist with reducing the likelihood that portions of the cathode GDL may dry out, thereby potentially compromising the performance of the GDL.
  • OPUSP025WO about 0.75 psi and about 1 psi, between about 1 psi and about 1.3 psi, between about 1.3 psi and about 1.5 psi, between about 1.5 psi and about 1.8 psi, between about 1.8 psi and about 2 psi, between about 2 psi and about 2.3 psi, between about 2.3 psi and about 2.5 psi, between about 2.5 psi and about 2.8 psi, between about 2.8 psi and about 3 psi, between about 3 psi and about 3.3 psi, between about 3.3 psi and about 3.5 psi, between about 3.5 psi and about 3.8 psi, between about 3.8 psi and about 4 psi, between about 0.001 psi and about 0.13 psi, between about 0.13 psi and about 0.25 psi, between about 0.25
  • the pressure drop may exceed the above ranges under certain circumstances, e.g., if the exit stream from the fluidic outlet port(s) goes to an inlet port of another electrolyzer cell, if water accumulates within a channel and obstructs flow through the channel, if the cathode GDL bulges up into the flow field channels when compressed, etc. Pressure drops lower than 0.5 psi may also work but may also increase the risk of the COx gas flows through the cathode flow field simply re-routing in instances where liquid water blocks a particular cathode channel (assuming multiple cathode channels are present) rather than acting to eject the liquid water from the blocked channel.
  • Pressure drops higher than one or more of the ranges listed above may also work, but may not provide any additional performance benefit, i.e., may simply result in excess energy consumption by the COx electrolyzer while providing gas distribution uniformity and water ejection capability that may be provided by lower pressure drops as well.
  • Such pressure drops are, it is to be understood, to be evaluated in the context of typical operating conditions of a COx electrolyzer, e.g., with a COx gas pressure in the range of 50 psig to 400 psig or 75 psig to 400 psig range and a gas flow velocity of 0.019 m/s to 30 m/s within at least some portions of the channels.
  • cathode flow fields such as those discussed above, or ones similar thereto, may be used in a COx electrolyzer cell in which CO x -containing gas is flowed into the fluidic inlet ports of the cathode flow fields at a flow rate of between 2 sccm and 21 sccm per square centimeter of active cathode flow field area, inlet pressures of between 50 psig and 400 psig, and temperatures of between 30 °C and 80 °C.
  • the thicker GDLs used in the tests included GDLs having uncompressed thicknesses in the 350 to 550 ⁇ m range, 950 to 1250 ⁇ m range, and 1350 to 1750 ⁇ m range (such GDLs were composed of multiple discrete GDLs that were arranged in a stacked configuration in order to obtain the desired thicknesses, as commercially available GDLs in such thicknesses were not available—presumably due to their detrimental performance in the context of fuel cells).
  • thicker GDLs e.g., 600 ⁇ m or thicker (uncompressed and inclusive of MPL and backing layer) yielded more repeatable and higher performance than thinner, e.g., 315 ⁇ m (inclusive of MPL and backing layer) GDLs.
  • one or more hot press operations may be utilized to reflow (or at least soften), if present, the polyacrylonitrile, PTFE, and/or other hydrophobic (or hydrophilic) component(s) of the MPL and/or the fibrous substrate to enable more rapid pre-compression and adherence of the GDLs to one another. It is also contemplated that, if multiple compression cycles are performed, the stack of multiple discrete GDLs may be rotated between cycles to reduce the effects of non-parallelism between pressing platens and non-uniformity of heat application.
  • a stack of GDLs is prepared, such as stack 8101.
  • multiple discrete GDLs may be cut (e.g., die cut, laser cut, etc.) from a commercially available GDL source (such as a roll, sheet, etc.), and layered on one another in an orientation that would otherwise exist when the GDLs are assembled as part of a cell.
  • two different layers have different hydrophobic additive contents, e.g., a GDL with an MPL and three different backing layers, each with a different hydrophobic additive content, e.g., MPL/layer A/layer B/layer C, with layer A having about 5%, layer B having about 10%, and layer C having about 20% (by weight) PTFE in them.
  • MPL/layer A/layer B/layer C a different hydrophobic additive content
  • layer A having about 5%
  • layer B having about 10%
  • layer C having about 20% (by weight) PTFE
  • MPLs for GDLs for CO x electrolyzer usage may have between about 15% and 55%, e.g., about 25%, by weight PTFE content.
  • a structure of a PTL may be generally smooth and relatively flat so as to prevent (or otherwise reduce the likelihood of) puncturing of the MEA material under non-operating and operating conditions of a stack, such as stack 500 in FIG. 5. It is also noted that the environment adjacent to the anode side of an MEA may exhibit a pH of about 0 to about 7 and oxygen evolution potential of about 1.4 V to about 2.0 V.
  • port side assembly 9107 may include bus plate 9601, insulation plate 9603, manifold block 9605, manifold runners 9607, and capping plate 9609 sequentially stacked from a first side of cathode interface assembly 9105 in a first direction, e.g., an axial direction, which may extend parallel to the z-axis direction shown in at least FIGS. 91-104 and 107.
  • a first direction e.g., an axial direction
  • the axial direction should be understood as referring to the z-axis direction.
  • the first side of cathode interface assembly 9105 may face away from the plurality of repeat units 9103.
  • port side assembly 9107 may at least be configured to provide one or more reactants to the cells to feed the COx reduction process and output one or more byproducts from the cells in association therewith.
  • Bus plate 9601 may be equivalent (or substantially equivalent) to bus plate 513 of stack 500 (see, e.g., FIGS. 5-10), except bus plate 9601 may include a plurality of fastener orifices 9601h, which may be countersunk with respect to surface 9601a of bus plate 9601.
  • Insulation plate 9603 may be equivalent (or substantially equivalent) to insulation plate 517 of stack 500 (see, e.g., FIGS. 5-10), but differences will be described below in association with FIGS. 99 and 100.
  • manifold assembly 9611 may be configured to provide one or more reactants to the plurality of cells of stack 9100 (see FIG.91) to feed the COx reduction process(es), as well as configured to expel one or more byproducts of the CO x reduction process(es) from the plurality of cells of stack 9100 (see FIG.91).
  • First and second surfaces 9701 and 9703 may be bounded by various peripheral surfaces (or surfaces) 9707, 9709, 9711, and 9713 that may be connected to one another via one or more other peripheral surfaces, such as peripheral surface (or surface) 9715.
  • peripheral surfaces or surface
  • inlet and outlet manifold runners 9607 may include inlet port 9123 as a start of one or more fluidic inlet passages 9401 (see FIG. 94) to supply, for instance, water to the anode sides of the plurality of cells of stack 9100 (see FIG. 91), and outlet port 9125 as an end of one or more fluidic outlet Docket No. OPUSP025WO passages configured to expel, for instance, water from the anode sides of the plurality of cells of stack 9100 (see FIG.91).
  • the one or more fluidic outlet passages may be similar to the one or more fluidic inlet passages 9401 (see FIG. 94), but may interface with outlet port 9125 versus inlet port 9123.
  • second fluidic inlet and outlet ports 9721 and 9723 may include corresponding threaded regions to engage with respective threaded regions of the inlet and outlet connectors similar to fluidic inlet and outlet connectors 547 and 549 (see, e.g., FIG. 5).
  • the fluidic inlet and outlet connectors may be respectively welded, e.g., sweat welded, to second inlet and outlet ports 9721 and 9723 or otherwise coupled to second inlet and outlet ports 9721 and 9723.
  • second inlet port 9721 may form a starting portion of fluidic inlet passage 9501 (see FIG.
  • First surface 9701 may further include recesses 9733 and 9735 respectively encircling first fluidic inlet and outlet ports 9717 and 9719.
  • Recesses 9733 and 9735 may be configured to receive and interface with corresponding ones of manifold runner gaskets 9613.
  • manifold runner gaskets 9613 may form corresponding fluidic seals between main body 9607 and manifold runners 9607, as well as form corresponding fluidic seals around first fluidic inlet and outlet ports 9717 and 9719.
  • respective fluidic seals may be formed between main body 9605 and insulation plate 9603 around first fluidic inlet and outlet ports 9717 and 9719 via gaskets 9619.
  • respective fluidic seals may be formed between main body 9605 and insulation plate 9603 around second fluidic outlet and inlet ports 9727 and 9725 via gaskets 9621.
  • Main body 9605 may further include first and second fastener orifices 9745 and 9747 arranged about a periphery of main body 9605 at one or more intervals.
  • First and second fastener orifices 9745 and 9747 may be physically connected to one another to allow tensioning members 9113 (see, e.g., FIGS. 91-95) to pass therethrough.
  • main body 9605 may also function as a load-spreading member similar to end plate 519 in stack 500 (see, e.g., FIGS. 5-10).
  • main body 9605 and end plate 10107 of stack 9100 may be coupled to one another via tensioning members 9113, first and second washers 9115 and 9117, and threaded fasteners 9119 and 9121 (see, e.g., FIGS. 91-95).
  • first fastener orifices 9745 may form generally circular openings in surface 9701
  • second fastener orifices 9747 may form generally oval (or generally elliptical) openings in surface 9703, but any other suitable geometric configuration may be utilized in association with first and second fastener orifices 9745 and 9747.
  • the oval shape of the openings of second fastener orifices 9747 may allow some lateral displacement of tensioning members 9113 to prevent undue stress being applied to the various components of stack 9100 as stack 9100 expands and contracts.
  • Main body 9605 may also include port 9749 fluidically connected to connecting passage 9731.
  • piston side assembly 9111 may include bus plate 10101, insulation plate 10103, piston 10105, and end plate 10107 sequentially stacked from a first side of anode interface assembly 9109 in a direction opposite the axial direction, e.g., in a direction opposite the z-axis direction. It is noted that the first side of anode interface assembly 9109 may face away from the plurality of repeat units 9103.
  • Bus plate 10101 may also include terminal portion 10101t similar to how bus plate 521 includes terminal portion 521t (see, e.g., FIGS. 5-10).
  • Insulation plate 10103 may be equivalent (or substantially equivalent) to insulation plate 523 of stack 500 (see, e.g., FIGS.5-10, 86, and 87), except insulation plate 10103 may exclude fastener orifices 523h, exclude fastener orifices 8633, exclude second recess 8629, include recess 10109 in surface 10103a instead of first recess 8621, and include recess 10110 (see FIG.103) in surface 10103b.
  • end plate 10107 may be a generally rectangular plate-shaped body having first surface 10401 (e.g., a top surface) opposing second surface 10403 (e.g., a bottom surface) in axial direction 10601, which extend parallel (or substantially parallel) to the z-axis direction.
  • first surface 10401 e.g., a top surface
  • second surface 10403 e.g., a bottom surface
  • end plate 10107 is described as having a generally rectangular plate-shaped configuration, embodiments are not limited thereto and any suitable geometric configuration may be utilized, such as a generally circular, generally elliptical, generally triangular, generally pentagonal, generally hexagonal, etc., configuration.
  • end plate 10107 will be described in association with a generally rectangular configuration.
  • First and second surfaces 10401 and 10403 may be bounded by one or more peripheral surfaces, such as peripheral surfaces (or surfaces) 10405, 10407, 10409, and 10411, that may be connected to one another via one or more other peripheral surfaces, such as peripheral surface (or surface) 10413.
  • end plate 10107 may have a symmetrical configuration about one or more reference planes perpendicular to axial direction 10601. For instance, a configuration of end plate 10107 may be symmetrical about either or both of reference planes 10603 and 10605, but embodiments are not limited thereto. Docket No.
  • end plate 10107 may include a generally rectangular protrusion 10415 extending from a first central region of first surface 10401 in axial direction 10601.
  • protrusion 10415 is described as having a generally rectangular configuration, embodiments are not limited thereto and any suitable geometric configuration may be utilized, such as a generally circular, generally elliptical, generally triangular, generally pentagonal, generally hexagonal, etc., configuration.
  • protrusion 10415 will be described in association with a generally rectangular configuration.
  • Protrusion 10415 may include central opening 10417 exposing surface 10419 of end plate 10107.
  • Surface 10419 may correspond with first surface 10401, e.g., surface 10419 may form a second central region of first surface 10401 that is encircled by the first central region of first surface 10401.
  • a plurality of protrusions 10421 may extend from surface 10419 in axial direction 10601.
  • end plate 10107 may include nine (9) protrusions 10421 extending from surface 10419 spaced apart from one another at one or more intervals.
  • protrusions 10421 may be evenly (or substantially evenly) distributed in the area exposed by opening 10417. It is contemplated, however, that end plate 10101 may include any suitable number of protrusions, such as less than nine (9) or more than nine (9).
  • protrusions 10421 may be formed as cylindrical, annular protrusions respectively including corresponding central openings 10423, but other or additional geometric configurations may be utilized. Respective upper surfaces 10425 of protrusions 10421 may be recessed from upper surface 10427 of protrusion 10415. As will become more apparent below, protrusions 10421 may be sized, shaped, located, and/or otherwise configured to enable a corresponding plurality of biasing members (e.g., disk springs, such as Belleville springs, etc.) 10117 to be supported in opening 10417 when end plate 10107 is assembled as part of stack 9100.
  • biasing members e.g., disk springs, such as Belleville springs, etc.
  • End plate 10107 may also include fastener orifices 10429 through which tensioning members 9113 may pass.
  • Tensioning members 9113 may be equivalent (or substantially equivalent) with tensioning members 527 (see, e.g., FIGS.5-10), except tensioning members 9113 may be longer than tensioning members 527 to at least account for the presence of a greater number of repeat units 9103 than repeat units 503 in stack 500 (see, e.g., FIGS. 5-10).
  • fastener orifices 10429 may be arranged about a peripheral region of end plate 10107 at one or more intervals.
  • FIG. 107 depicts a perspective view of an example piston of the piston side assembly of FIG.101.
  • FIGS.108 and 109 depict top and bottom plan views of the example piston of FIG.107. [0553] Referring to FIGS.
  • piston 10105 may be a generally rectangular plate-shaped body having first surface 10701 (e.g., a top surface) opposing second surface 10703 (e.g., a bottom surface) in axial direction 10801.
  • first surface 10701 e.g., a top surface
  • second surface 10703 e.g., a bottom surface
  • piston 10105 is described as having a generally rectangular configuration, embodiments are not limited thereto and any suitable geometric configuration may be utilized, such as a generally circular, generally elliptical, generally triangular, generally pentagonal, generally hexagonal, etc., configuration.
  • piston 10105 will be described in association with a generally rectangular configuration.
  • First and second surfaces 10701 and 10703 may be bounded by one or more peripheral surfaces, such as peripheral surfaces (or surfaces) 10705, 10707, 10709, and 10711, that may be connected to one another via one or more other peripheral surfaces, such as peripheral surface (or surface) 10713.
  • piston 10105 may have a symmetrical configuration about one or more reference planes perpendicular to axial direction 10801, which may extend parallel (or substantially parallel) to the z-axis direction (see, e.g., FIG. 107).
  • a configuration of piston 10105 may be symmetrical about either or both of reference planes 10803 and 10805, but embodiments are not limited thereto.
  • piston 10105 may include a generally rectangular protrusion 10715 extending from a first central region of second surface 10703 in a direction opposite the axial direction 10801 (see FIG. 108).
  • protrusion 10715 is described as having a generally rectangular configuration, embodiments are not limited thereto and any suitable geometric configuration may be utilized, such as a generally circular, generally elliptical, generally triangular, generally pentagonal, generally hexagonal, etc., configuration.
  • protrusion 10715 will be described in association with a generally rectangular configuration.
  • Protrusion 10715 may terminate at surface 10717, which may be bounded by a plurality of peripheral surfaces, such as peripheral surface 10719.
  • a plurality of blind openings 10721 may be formed in surface 10717 and extend in axial direction 10801 towards surface 10701.
  • the number, location, and configuration of blind openings Docket No. OPUSP025WO 10721 may correspond to the number, location, and configuration of protrusions 10421 of end plate 10107 (see also FIGS. 104 and 105) such that, when piston 10105 and end plate 10107 are incorporated as part of stack 9100, respective blind openings 10721 may be concentrically aligned (or substantially concentrically aligned) with corresponding protrusions 10421 (see, e.g., FIG. 103).
  • Respective depths of blind openings 10721 from surface 10717 in axial direction 10801 may, in some implementations, be smaller than corresponding heights of protrusions 10421 from surface 10419 in axial direction 10601 (see FIGS. 104-106), which may correspond with axial direction 10801.
  • the respective depths of blind openings 10721 may correspond to a maximum (or substantially maximum) amount of axial expansion that stack 9100 may be permitted to experience when stack 9100 is pressured.
  • respective widths of blind openings 10721 in a direction perpendicular to axial direction 10801 may be greater than corresponding widths of protrusions 10421 in a direction perpendicular to axial direction 10601 (see FIGS.
  • biasing members 10117 may provide a first amount of axial compression to the plurality of cells of stack 9100 when stack 9100 is not pressurized, e.g., when stack 9100 is in a cooled, non-operational state.
  • Piston 10105 may also include a plurality of recesses 10723 formed in the peripheral surfaces (e.g., peripheral surface 10719) of protrusion 10715. Corresponding depths of recesses 10723 may extend inwards from a respective peripheral surface of protrusion 10715 towards blind openings 10721.
  • the plurality of recesses 10723 may include first and second recesses 10723a and 10723b, but embodiments are not limited thereto.
  • protrusion 10715 may include one recess in some cases, or include three or more recesses in other cases.
  • the plurality of recesses 10723 may be configured to interface with a corresponding plurality of piston gaskets 10119, which may include, for instance, first and second piston gaskets 10119a and 10119b.
  • piston gaskets 10119 which may include, for instance, first and second piston gaskets 10119a and 10119b.
  • piston gaskets 10119 may form corresponding fluidic seals between recesses 10723 of piston 10105 and inner sidewalls (such as inner sidewall 10417sw) of opening 10417 of end plate 10107.
  • a fluidically sealed cavity (or cavity) 10301 may be formed between piston 10105 and end plate 10107.
  • one or more control fluids e.g., gaseous COx
  • one or more control fluids may be introduced to cavity 10301 to regulate a distance between surface 10717 of protrusion 10715 of piston 10105 and surface 10419 of end plate 10107.
  • the one or more control fluids may be flowed into cavity 10301 via fluidic inlet ports 10303 and 10305 formed in peripheral surfaces 10409 and 10405 of end plate 10107.
  • Fluidic inlet port 10303 may be fluidically connected to blind orifice 10501 formed in surface 10419 of end plate 10107 via connecting passage 10307
  • fluidic inlet port 10305 may be fluidically connected to blind orifice 10503 formed in surface 10419 of end plate 10107 via connecting passage 10309.
  • the one or more control fluids may be caused to flow into cavity 10301 via the conjunction of fluidic inlet ports 10303 and 10305, connecting passages 10307 and 10309, and blind orifices 10501 and 10503, as well as source 10311 of the one or more control fluids.
  • source 10311 of the one or more control fluids may be the same as the source of input providing, for instance, gaseous COx, to the cathode sides of the cells of stack 9100. Regardless of the source, the distance between surface 10717 of protrusion 10715 of piston 10105 and surface 10419 of end plate 10107 may be controlled based on an accumulated pressure of the one or more control fluids in cavity 10301.
  • regulating the distance between surface 10717 of protrusion 10715 of piston 10105 and surface 10419 of end plate 10107 may be utilized to constrain axial expansion of the plurality of cells, such as cell 9101, during operation. This may help maintain corresponding fluidic seals and electrical conductivity between associated components of stack 9100, and, thereby, provide a second amount of axial compression to the plurality of cells of stack 9100 when stack 9100 is pressurized, e.g., in an operational state of stack 9100.
  • the distance between surface 10717 of piston 10105 and surface 10419 of end plate 10107 may increase to point at which fluidic seals formed in association with Docket No. OPUSP025WO piston gaskets 10119 may become compromised. If and when the fluidic seals formed in association with piston gaskets 10119 become compromised, at least some of the one or more control fluids may escape (or bleed) from cavity 10301 that may cause the accumulated pressure to decrease, and, as such, the distance between surface 10717 of piston 10105 and surface 10419 of end plate 10107 to also decrease. Such a configuration may be utilized to prevent over compression of the various components of stack 9100.
  • fluidic inlet ports 10303 and 10305 may be utilized to introduce one or more control fluids to cavity 10301, but a corresponding fluidic outlet port may not be provided (apart from piston gaskets 10119 becoming compromised and allowing at least some of the one or more control fluids to escape from cavity 10301).
  • piston 10105, end plate 10107, and piston gaskets 10119 may form a “dead-headed” piston in which the one or more control fluids are caused to remain in cavity 10301 until a flow of the one or more control fluids is terminated and the one or more control fluids in cavity 10301 are allowed to backflow out of one or both of fluidic inlet ports 10303 and 10305.
  • fluidic inlet ports 10303 and 10305 may be additionally (or alternatively) configured as a fluidic outlet port, which may interface with, for instance, a pressure relief valve configured to release, bleed-off, or otherwise exhaust accumulated pressure in cavity 10301 in response to the accumulated pressure reaching a threshold pressure and/or based on a control signal received from a controller.
  • a pressure relief valve configured to release, bleed-off, or otherwise exhaust accumulated pressure in cavity 10301 in response to the accumulated pressure reaching a threshold pressure and/or based on a control signal received from a controller.
  • Such a configuration may enable finer regulation of the accumulated pressure in cavity 10301 that may, in turn, allow for finer control over the constriction of the axial expansion of the plurality of cells of stack 9100 when stack 9100 is pressurized.
  • source 10311 may be configured to supply the gaseous COx to second fluidic inlet port 9721 (see, e.g., FIG. 95) at a first pressure and to supply the one or more control fluids (e.g., gaseous CO x ) to fluidic inlet ports 10303 and 10305 at a second pressure.
  • the first and second pressures may be equivalent or substantially equivalent.
  • source 10311 may be configured to control (e.g., adjust) one or more of the first and second pressures based on conditions of stack 9100, e.g., based on an extent of expansion of one or more cells of stack 9100 in the axial direction, based on an accumulated pressure in cavity 10301, based on the temperature of one or more components of stack 9100, and/or the like. As such, the first and second pressures may reach equilibrium, such as, in response to steady state conditions. It is also noted that source 10311 may be configured to Docket No. OPUSP025WO supply the gaseous CO x to second fluidic inlet port 9721 (see, e.g., FIG.
  • control fluids e.g., gaseous COx
  • first and second times may occur simultaneously or substantially simultaneously.
  • source 10311 may be configured to delay the supply of the one or more control fluids to fluidic inlet ports 10303 and 10305 with respect to the provisioning of the gaseous COx to second fluidic inlet port 9721 (see, e.g., FIG.95).
  • source 10311 may be configured to delay the supply of the one or more control fluids to fluidic inlet ports 10303 and 10305 until one or more conditions are satisfied, e.g., an extent of expansion of one or more cells of stack 9100 in the axial direction reaches one or more defined thresholds, a temperature of one or more components of stack 9100 reaches one or more defined thresholds, flow of the gaseous CO x to second fluidic inlet port 9721 (see, e.g., FIG. 95) reaches steady state, and/or the like.
  • Additional and/or Alternative Embodiments [0562] Unless otherwise specified, the illustrated embodiments are to be understood as providing example features of varying detail of some embodiments.
  • each ⁇ item> of the one or more ⁇ items> is inclusive of both a single-item group and multiple-item groups, i.e., the phrase “for . . . each” is used in the sense that it is used in programming languages to refer to each item of whatever population of items is referenced.
  • OPUSP025WO “comprising,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It is also noted that, as used herein, the terms “substantially,” “about,” and other similar terms, are used as terms of approximation and not as terms of degree, and, as such, are utilized to account for inherent deviations in measured, calculated, and/or provided values that would be recognized by one of ordinary skill in the art.
  • substantially means within 5% of a referenced value.
  • substantially perpendicular means within ⁇ 5% of parallel.
  • the various dimensional parameter ranges provided herein may be combined with any other dimensional parameter ranges provided herein. For example, if a channel is described as potentially having a length in ranges A, B, or C, a width in ranges D, E, or F, and a depth in ranges G, H, or I, this is to be understood to explicitly contemplate channels having a length, width, and depth representing any combination of such ranges.
  • such a channel may have a length, width, and height of AEI, AEJ, AEK, AEL, AFI, AFJ, AFK, AFL, AGI, AGJ, AGK, AGL, AHI, AHJ, AHK, AHL, BEI, BEJ, BEK, BEL, BFI, BFJ, BFK, BFL, BGI, BGJ, BGK, BGL, BHI, BHJ, BHK, BHL, CEI, CEJ, CEK, CEL, CFI, CFJ, CFK, CFL, CGI, CGJ, CGK, CGL, CHI, CHJ, CHK, CHL, DEI, DEJ, DEK, DEL, DFI, DFJ, DFK, DFL, DGI, DGJ, DGK, DGL, DHI, DHJ, DHK, or DHL, with the first letter of each letter triplet representing the length range of the channel, the second
  • two consecutively described processes may be performed substantially at the same time or performed in an order opposite to the described order.
  • an element such as a frame
  • it may be directly on, directly connected to, or directly coupled to the other element or at least one intervening element may be present.
  • an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element, there are no intervening elements present.
  • connection may refer to physical, electrical, and/or fluid connection.
  • the phrase “fluidically connected” is used with respect to volumes, plenums, holes, orifices, etc., that may be connected to one another, either directly or via one or more intervening components or volumes, to form a fluidic connection, similar to how the phrase “electrically connected” is used with respect to components that are connected to form an electric connection.
  • fluidically interposed may be used to refer to a component, volume, plenum, hole, orifice, passage, etc., that is fluidically connected with at least two other components, volumes, plenums, holes, orifices, passages, etc., such that fluid flowing from one of those other components, volumes, plenums, holes, orifices, passages, etc., to the other or another of those components, volumes, plenums, holes, orifices, passages, etc., would first flow through the “fluidically interposed” component before reaching that other or another of those components, volumes, plenums, holes, orifices, passages, etc..
  • fluid flowing from the reservoir to the outlet would first flow through the pump before reaching the outlet.
  • fluidically adjacent refers to placement of a fluidic element relative to another fluidic element such that no potential structures fluidically are interposed between the two elements that might potentially interrupt fluid flow between the two fluidic elements.
  • the first valve would be fluidically adjacent to the second valve, the second valve fluidically adjacent to both the first and third valves, and the third valve fluidically adjacent to the second valve.
  • first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another element. Thus, a first element discussed below could be termed a second element without departing from the teachings of the disclosure. To this end, use of such identifiers, e.g., “a first element,” should not be read as suggesting, implicitly or inherently, that there is necessarily another instance, e.g., “a second element.” Further, the use, if any, of ordinal indicators, such as (a), (b), (c), . . ., or (1), (2), (3), . .
  • step (i), (ii), and (iii) are three steps labeled (i), (ii), and (iii), it is to be understood that these steps may be performed in any order (or even concurrently, if not otherwise contraindicated), unless indicated otherwise.
  • step (ii) involves the handling of an element that is created in step (i)
  • step (ii) may be viewed as happening at some point after step (i).
  • step (i) involves the handling of an element that is created in step (ii)
  • the reverse is to be understood.
  • Spatially relative terms such as “beneath,” “below,” “under,” “lower,” “above,” “upper,” “over,” “higher,” “side” (e.g., as in “sidewall”), and the like, may be used herein for descriptive purposes, and, thereby, to describe one element’s spatial relationship to at least one other element as illustrated in the drawings.
  • Spatially relative terms are intended to encompass different orientations of an apparatus in use, operation, and/or manufacture in addition to the orientation depicted in the drawings. For example, if the apparatus in the drawings is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” or “over” the other elements or features.
  • a controller may be described as being operatively connected with (or to) a source of, for instance, control fluid, which is inclusive of the controller being connected with a sub-controller of the source that is electrically connected with a relay that is configured to controllably connect or disconnect the source with a power source that is capable of providing an amount of power that is able to power the source so as to generate a desired flow of control fluid.
  • the controller itself likely will not supply such power directly to the source due to the current(s) involved, but it is to be understood that the controller is nonetheless operatively connected with the source.
  • the singular forms, “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It is also to be understood that the phrases “for each ⁇ item> of the one or more ⁇ items>,” “each ⁇ item> of the one or more ⁇ items>,” and/or the like, if used herein, are inclusive of both a single-item group and multiple-item groups, i.e., the phrase “for ...
  • each is used in the sense that it is used in programming languages to refer to each item of whatever population of items is referenced. For example, if the population of items referenced is a single item, then “each” would refer to only that single item (despite dictionary definitions of “each” frequently defining the term to refer to “every one of two or more things”) and would not imply that there must be at least two of those items.
  • the term “set” or “subset” should not be viewed, in itself, as necessarily encompassing a plurality of items—it is to be understood that a set or a subset can encompass only one member or multiple members (unless the context indicates otherwise).
  • each block, unit, and/or module may be implemented by dedicated hardware, or as a combination of dedicated hardware to perform some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) to perform other functions.
  • each block, unit, and/or module of some embodiments may be physically separated into two or more interacting and discrete blocks, units, and/or modules without departing from the inventive concepts.
  • the blocks, units, and/or modules of some embodiments may Docket No. OPUSP025WO be physically combined into more complex blocks, units, and/or modules without departing from the teachings of the disclosure.
  • the first components include: a membrane electrode assembly (“MEA”) having a cathodic part, an anodic part, and a separator between the cathodic part and the anodic part; a cathode frame adjacent to the cathodic part; and a cathode flow field at least partially disposed in a first opening in the cathode frame.
  • MEA membrane electrode assembly
  • the second components include: an anode frame adjacent to the anodic part of the MEA; and an anode flow Docket No. OPUSP025WO field at least partially disposed in a second opening in the anode frame.
  • the second components further include an anode porous transport layer (PTL) adjacent to the anode frame and covering the anode flow field.
  • PTL porous transport layer
  • the anode PTL and the anode flow field are configured to guide a flow of anolyte across the second opening in a third direction transverse to the axial direction and in a distributed manner with respect to at least the second direction.
  • Implementation 3 The apparatus of either implementation 1 or implementation 2, in which the cathode frame includes: the first opening arranged in a central portion of the cathode frame; at least one first fluidic inlet passage fluidically connected to the anodic parts of the cells; at least one first fluidic outlet passage fluidically connected to the anodic parts of the cells; at least one second fluidic inlet passage fluidically connected to the first opening; and at least one second fluidic outlet passage fluidically connected to the first opening.
  • Implementation 4 The apparatus of any one of implementations 1-3, in which the anode frame includes: the second opening arranged in a central portion of the anode frame; at least one third fluidic inlet passage fluidically connected to the second opening; at least one third fluidic outlet passage fluidically connected to the second opening; at least one fourth fluidic inlet passage fluidically connected to the cathodic parts of the cells; and at least one second fluidic outlet passage fluidically connected to the cathodic parts of the cells.
  • Implementation 5 The apparatus of any one of implementations 1-4, in which each of the separator plates includes: a plurality of fastener orifices through which the frame fasteners respectively extend; at least one first hole through which an inlet anolyte flow path extends; at least one second hole through which an outlet anolyte flow path extends; at least one third hole Docket No. OPUSP025WO through which an inlet gaseous COx flow path extends; and at least one fourth hole through which an outlet COx reduction byproduct flow path extends.
  • Implementation 6 The apparatus of any one of implementations 3-5, in which the cathode frame includes a first surface facing the MEA and a second surface facing away from the first surface.
  • the second surface of the cathode frame includes: at least one first protrusion through which the at least one first fluidic inlet passage extends; at least one second protrusion through which the at least one first fluidic outlet passage extends; at least one third protrusion through which the at least one second fluidic inlet passage extends; and at least one fourth protrusion through which the at least one second fluidic outlet passage extends.
  • Implementation 7 The apparatus of implementation 6, in which the at least one first protrusion of the cathode frame is arranged and configured to extend through the at least one first hole in a first separator plate among the separator plates and abut against the anode frame of a first adjacent cell among the cells such that the at least one first fluidic inlet passage of the cathode frame is substantially aligned in the axial direction with the at least one third fluidic inlet passage of the anode frame of the first adjacent cell.
  • the at least one second protrusion of the cathode frame is arranged and configured to extend through the at least one second hole in the first separator plate and abut against the anode frame of the first adjacent cell such that the at least one first fluidic outlet passage of the cathode frame is substantially aligned in the axial direction with the at least one third fluidic outlet passage of the anode frame of the first adjacent cell.
  • the at least one third protrusion of the cathode frame is arranged and configured to extend through the at least one third hole in the first separator plate and abut against the anode frame of the first adjacent cell such that the at least one second fluidic inlet passage of the cathode frame is substantially aligned in the axial direction with the at least one fourth fluidic inlet passage of the anode frame of the first adjacent cell.
  • the at least one fourth protrusion of the cathode frame is arranged and configured to extend through the at least one fourth hole in the first separator plate and abut against the anode frame of the first adjacent cell such that the at least one second fluidic outlet passage of the cathode frame is substantially aligned in the axial direction with the at least one fourth fluidic outlet passage of the anode frame of the first adjacent cell.
  • Implementation 8 The apparatus of implementation 7, in which at least one of the first to fourth protrusions is sized to form a clearance fit with a corresponding one of the first to fourth holes. Docket No.
  • Implementation 9 The apparatus of any one of implementations 1-8, in which the cathode frame further includes a plurality of first cathode fastener orifices arranged about a peripheral area of the cathode frame. The peripheral area encircles the first opening of the cathode frame.
  • the anode frame further includes a plurality of first anode fastener orifices and a plurality of first swage nuts.
  • the first anode fastener orifices are arranged about a peripheral area of the anode frame.
  • the peripheral area encircles the second opening of the anode frame.
  • the first cathode fastener orifices are substantially aligned with the first anode fastener orifices in the axial direction.
  • Each first swage nut among the first swage nuts is disposed in one or the other of a corresponding one of the first anode fastener orifices and a corresponding one of the first cathode fastener orifices.
  • the first swage nuts are configured to interface with corresponding frame fasteners among the frame fasteners.
  • Implementation 11 The apparatus of any one of implementations 1-10, in which the frame fasteners are shoulder screws.
  • Implementation 12 The apparatus of any one of implementations 2-11, in which the first components further include a first support frame and a second support frame. The first support frame is interposed between the cathode GDL and the cathode frame.
  • the first support frame includes a first frame opening exposing a portion of the cathode GDL to the cathode flow field. The portion of the cathode GDL abuts against the cathode flow field.
  • the second support frame is interposed between the MEA and the anode PTL.
  • the second support frame includes a second frame opening exposing a portion of the MEA to the anode PTL. The portion of the MEA abuts against the anode PTL.
  • the first support frame, the cathode GDL, the MEA, and the second support frame form a unitized MEA assembly.
  • Implementation 13 The apparatus of implementation 12, in which the first components further include a first cathode gasket interposed between the first support frame and the cathode frame.
  • the first cathode gasket encircles the first opening in the cathode frame to form a first fluidic seal around the cathode flow field.
  • the second components further include a first anode Docket No. OPUSP025WO gasket set.
  • the first anode gasket set includes: a first anode gasket interposed between the second support frame and the anode frame, the first anode gasket encircling the second opening in the anode frame to form a first fluidic seal around the anode flow field; at least one second anode gasket interposed between the cathode frame and the anode frame, the at least one second anode gasket encircling the at least one first fluidic inlet passage of the cathode frame and the at least one third fluidic inlet passage of the anode to form at least one fluidic seal; at least one third anode gasket interposed between the cathode frame and the anode frame, the at least one third anode gasket encircling the at least one first fluidic outlet passage in the cathode frame and the at least one third fluidic outlet passages in the anode frame to form at least one fluidic seal; at least one fourth anode gasket interposed between the cathode frame and the anode frame
  • Implementation 14 The apparatus of implementations 5 and 12, in which the first components further include a second cathode gasket interposed between a first separator plate among the separator plates and the cathode frame.
  • the second cathode gasket encircles the first opening in the cathode frame to form a second fluidic seal around the cathode flow field.
  • the second components further include a second anode gasket set.
  • the second anode gasket set includes: a sixth anode gasket interposed between the anode frame and a second separator plate among the separator plates, the sixth anode gasket encircling the second opening in the anode frame to form a second fluidic seal around the anode flow field; at least one seventh anode gasket interposed between the anode frame and the second separator plate, the at least one seventh anode gasket encircling the at least one first hole in the second separator plate and the at least one third fluidic inlet passage in the anode frame to form at least one fluidic seal; at least one eighth anode gasket interposed between the anode frame and the second separator plate, the at least one eighth anode gasket encircling the at least one second hole in the second separator plate and the at least one third fluidic outlet passage in the anode frame to form at least one fluidic seal; at least one ninth anode gasket interposed between the anode frame and the second separator plate, the at least one
  • OPUSP025WO at least one fourth fluidic inlet passage in the anode frame to form at least one fluidic seal; and at least one tenth anode gasket interposed between the anode frame and the second separator plate, the at least one ninth anode gasket encircling the at least one fourth hole in the second separator plate and the at least one fourth fluidic outlet passage in the anode frame to form at least one fluidic seal.
  • Implementation 15 The apparatus of any one of implementations 1-14, in which the cells are formed of a plurality of repeat units.
  • Each repeat unit among the repeat units includes: an instance of the first components; an instance of the second components; and the separator plate that is interposed between the cathode frame of that instance of the first components and the anode frame of that instance of the second components. That separator plate is interposed between that instance of the first components and that instance of the second components.
  • Implementation 16 The apparatus of implementation 15, in which the first end assembly includes a first end plate and a cathode interface assembly.
  • the cathode interface assembly includes an instance of the first components, and a cathode interface separator plate interposed between the first end plate and a first repeat unit among the repeat units.
  • a first end cell is formed between the cathode interface assembly and the instance of the second components of the first repeat unit.
  • the first end cell is interposed between the first end plate and the plurality of cells.
  • Implementation 17 The apparatus of implementations 5 and 16, in which the first end assembly further includes a first insulation plate, a manifold, and a first bus plate between the first end plate and the cathode interface assembly.
  • the manifold includes at least one first inlet fluidically connected to the anodic parts of the cells via the inlet anolyte flow path, at least one first outlet fluidically connected to the anodic parts of the cells via the outlet anolyte flow path, at least one second inlet fluidically connected to the cathodic parts of the cells via the inlet gaseous COx flow path, and at least one second outlet fluidically connected to the cathodic parts of the cells via the outlet COx reduction byproduct flow path.
  • the first bus plate is configured to receive a first electric potential.
  • the first insulation plate is configured to electrically insulate the first end plate from the first bus plate.
  • Implementation 18 The apparatus of implementation 17, in which the first bus plate, the manifold, and the first insulation plate are sequentially stacked on the cathode interface assembly.
  • Implementation 19 The apparatus of either implementation 17 or implementation 18, in which the inlet anolyte flow path, the outlet anolyte flow path, the inlet gaseous COx flow path, Docket No. OPUSP025WO and the outlet COx reduction byproduct flow path do not extend into the bus plate and the first insulation plate.
  • Implementation 20 The apparatus of implementation 17, in which the first bus plate, the insulation plate, and the manifold are sequentially stacked on the cathode interface assembly.
  • Implementation 21 The apparatus of implementation 19, in which the first end assembly further includes a capping plate, an inlet runner, and an outlet runner.
  • the inlet and outlet runners are coupled to the manifold such that the inlet and outlet runners are stacked in the axial direction between the capping plate and the manifold.
  • Implementation 22 The apparatus of implementation 21, in which the inlet anolyte flow path, the outlet anolyte flow path, the inlet gaseous COx flow path, and the outlet COx reduction byproduct flow path extend through the first insulation plate.
  • Implementation 23 The apparatus of any one of implementations 17-20, in which the first bus plate is coupled to the manifold via a plurality of first fasteners different from the tensioning members and the frame fasteners. The first insulation plate is coupled to the first end plate via a plurality of second fasteners different from the tensioning members, the frame fasteners, and the first fasteners.
  • Implementation 24 The apparatus of any one of implementations 17, 21, and 22, in which the first bus plate is coupled to the first insulation plate via a plurality of first fasteners different from the tensioning members and the frame fasteners. The first insulation plate is coupled to the manifold via the first fasteners.
  • Implementation 25 The apparatus of any one of implementations 15-24, in which the second end assembly includes a second end plate and an anode interface assembly.
  • the anode interface assembly includes an instance of the second components, and an anode interface separator plate interposed between a second repeat unit among the repeat units and the second end plate.
  • a second end cell is formed between the instance of the first components of the second repeat unit and the anode interface assembly.
  • the second end cell is interposed between the plurality of cells and the second end plate.
  • Implementation 26 The apparatus of implementation 25, in which the second end assembly further includes a second bus plate and a second insulation plate sequentially stacked in the axial direction between the anode interface assembly and the second end plate.
  • the second bus plate is Docket No.
  • OPUSP025WO configured to receive a second electric potential.
  • the second insulation plate is configured to electrically insulate the second end plate from the second bus plate.
  • Implementation 27 The apparatus of implementation 26, in which the second insulation plate is coupled to the second end plate via a plurality of third fasteners different from the tensioning members and the frame fasteners.
  • Implementation 28 The apparatus of any one of implementations 25-27, in which the second end assembly further includes a bladder gasket.
  • the second insulation plate includes: a first recess formed in a central portion of the second insulation plate; a second recess encircling a central region of the central portion, the second recess supporting the bladder gasket therein; and an orifice configured to receive one or more control fluids.
  • the bus plate is slidably disposed in the first recess and configured to abut against the bladder gasket and/or a surface of the first recess facing the bus plate in the axial direction.
  • a distance in the axial direction between the bus plate and the surface of the first recess facing the bus plate in the axial direction is configured to increase in response to accumulation of the one or more control fluids in an area between the bus plate and the insulation plate that is fluidically sealed via at least the bladder gasket.
  • Implementation 29 The apparatus of implementation 26, in which the second end plate includes a first main body, a second end plate protrusion extending from the first main body in the axial direction, and a second end plate opening extending into a central portion of the second end plate protrusion in a direction opposite the axial direction and terminating at a recessed surface facing the cells.
  • the second end assembly further includes a piston interposed between the second insulation plate and the second end plate.
  • the piston includes a second main body, and a piston protrusion extending from the second main body in the direction opposite the axial direction and terminating at a protruded surface facing the recessed surface. At least a portion of the piston protrusion is slidably disposed in at least a portion of the second end plate opening.
  • Implementation 30 The apparatus of implementation 29, in which the second end assembly further includes a plurality of biasing members.
  • the piston protrusion includes a plurality of piston protrusion openings extending into the protruded surface in the axial direction.
  • the second end plate further includes a plurality of support protrusions extending in the axial direction from the recessed surface and arranged in correspondence with the piston protrusion openings.
  • the biasing members are respectively supported in the second end plate opening via corresponding support protrusions among the support protrusions such that, in a first compressed state of the second end Docket No.
  • Implementation 31 The apparatus of either implementation 29 or implementation 30, in which the second end plate further includes one or more orifices fluidically connected to the second end plate opening. The one or more orifices are configured to receive one or more control fluids.
  • the piston protrusion includes a plurality of piston gaskets encircling the piston protrusion and offset from one another in the axial direction.
  • the piston gaskets interface with one or more inner sidewalls of the second end plate opening such that the second end plate opening, the piston protrusion, and the piston gaskets form a cavity within the second end assembly.
  • a distance in the axial direction between the protruded surface and recessed surface is configured to increase in response to accumulation of the one or more control fluids in the cavity.
  • Implementation 32 The apparatus of any one of implementations 28, 30, and 31, in which the cells are configured to reduce input gaseous COx into one or more byproducts, and the one or more control fluids and the input gaseous COx are equivalent.
  • Implementation 33 The apparatus of implementation 31, further including a source of gaseous COx.
  • Implementation 36 The apparatus of any one of implementations 1-35, in which the cathode and anode frames are formed of one or more polymers.
  • Implementation 37 The apparatus of any one of implementations 1-36, in which the cathode and anode frames include at least one of polyethylene terephthalate (PET), polycarbonate (PC), polyimide (PI), polyamide (PA), poly(methylmethacrylate) (PMMA), polyethylene Docket No.
  • PET polyethylene terephthalate
  • PC polycarbonate
  • PI polyimide
  • PA polyamide
  • PMMA poly(methylmethacrylate)
  • OPUSP025WO naphthalate PEN
  • polyetherketone PEK
  • polyetheretherketone PEEK
  • polystyrene PS
  • polyetherimide PEI
  • polyphenylene sulfide PPS
  • polyarylate PAR
  • polyether sulfone PES
  • cyclic olefin copolymer COC
  • polyvinyl alcohol PVA
  • ECTFE ethylene chlorotrifluoroethylene
  • PTFE polytetrafluoroethylene
  • PBT polybutylene terephthalate
  • PCTFE polychlorotrifluoroethylene
  • PETG polyethylene terephthalate glycol
  • Implementation 38 The apparatus of any one of implementations 1-37, in which the separator plates are formed of one or more metals.
  • Implementation 39 The apparatus of any one of implementations 1-38, in which the separator plates include at least one of aluminum, aluminum alloy, copper, copper alloy, tin, tin alloy, titanium, titanium alloy, tungsten, tungsten alloy, zinc, zinc alloy, steel, and stainless steel.
  • Implementation 40 The apparatus of any one of implementations 1-39, in which, when viewed in the axial direction, the tensioning members encircle the cells such that the cells are spaced apart from the tensioning members.
  • a COx electrolyzer frame (“frame”) includes a main body portion, an opening, a first fluidic passage, a first recess, a second recess, and a first connecting riser.
  • the main body portion has a first surface opposing a second surface in an axial direction.
  • the opening extends through a central region of the main body portion in the axial direction.
  • the first fluidic passage extends through the main body portion in the axial direction.
  • the first recess is in the first surface.
  • the first recess is fluidically connected to the opening and extends in a second direction transverse to the axial direction.
  • the second recess is in the second surface.
  • the second recess is fluidically connected to the first fluidic passage and extends in a third direction transverse to the axial direction.
  • the first connecting riser extends in the axial direction and is fluidically interposed between the first recess and the second recess such that the opening is fluidically connected to the first fluidic passage.
  • Implementation 42 The frame of implementation 41, further including a third recess in the first surface.
  • the third recess encircles the opening and the first recess.
  • Implementation 43 The frame of implementation 42, in which, when viewed in the axial direction, the second recess crosses underneath the third recess.
  • Implementation 44 The frame of either implementation 42 or implementation 43, further including a fourth recess in the first surface.
  • Implementation 45 The frame of implementation 44, in which, when viewed in the axial direction, the second recess crosses underneath the fourth recess.
  • Implementation 46 The frame of any one of implementations 41-45, further including a fifth recess in the second surface and encircling the opening. When viewed in the axial direction, the first recess crosses above the fifth recess.
  • Implementation 48 The frame of implementation 47, in which the first connecting riser extends into the proximal end of the first recess, and the distal end of the first recess extends into the opening.
  • Implementation 49 The frame of any one of implementations 41-43 and 46-48, further including a plurality of protrusions extending in the axial direction from a surface of the first recess. The surface is recessed from the first surface.
  • Implementation 50 The frame of implementation 49, in which at least one of the protrusions has a different cross-sectional area than at least another one of the protrusions.
  • the one or more second protrusions are disposed closer to the proximal end of the first recess than each of the one or more first protrusions and the at least one third protrusion.
  • a majority of the one or more first protrusions are disposed closer to the opening than each of the one or more second protrusions and the at least one third protrusion.
  • the at least one third protrusion is disposed between the one or more second protrusions and the majority of the one or more first protrusions.
  • Implementation 52 The frame of implementation 42, in which the third recess includes first sides and second sides. The first sides extend generally in the second direction. The second sides extend between the first sides.
  • the second fluidic passage extends through the main body portion in the axial direction.
  • the third fluidic passage extends through the main body portion in the axial direction. Within the frame, the second and third fluidic passages are fluidically isolated from the first fluidic passage and the opening.
  • Implementation 54 The frame of any one of implementations 41-43 and 46-53, further including a first protrusion extending from the second surface in the axial direction. The first fluidic passage, the second recess, and the first connecting riser are formed in the first protrusion.
  • Implementation 55 The frame of either implementation 53 or implementations 53 and 54, further including a second protrusion and a third protrusion. The second protrusion extends from the second surface in the axial direction.
  • Implementation 60 The frame of implementation 59, in which the first recesses include a first group of the first recesses, a second group of the first recesses, and a third group of the first recesses.
  • the first recesses of the first group are spaced apart from one another according to a first pitch.
  • the second group of the first recesses is arranged adjacent to a first side of the first group of the first recesses.
  • the first recesses of the second group are spaced apart from one another according to a second pitch different from the first pitch.
  • the third group of the first recesses is arranged adjacent to a second side of the first group of the first recesses.
  • Implementation 78 The apparatus of either implementation 76 or implementation 77, in which the second end assembly includes a first plate, a first gasket, and a second plate.
  • the first plate includes a recess in a central portion of the first plate, a second recess encircling a central region of the central portion, and a first orifice configured to receive one or more control fluids.
  • the first gasket is at least partially disposed in the second recess.
  • OPUSP025WO configured to electrically insulate the first bus plate from at least one other component of the first and/or second end assemblies.
  • Implementation 80 The apparatus of either implementation 78 or implementation 79, in which the second end assembly further includes a second end plate. The first plate is interposed between the second plate and the second end plate.
  • Implementation 81 The apparatus of implementation 80, in which the first insulation plate is coupled to the second end plate via a plurality of first fasteners.
  • Implementation 82 The apparatus of either implementation 80 or implementation 81, in which the first orifice is formed in the recessed surface and extends through the first plate in the axial direction.
  • Implementation 93 The apparatus of any one of implementations 86-92, in which the second end assembly further includes an insulation plate and a first bus plate sequentially stacked in the axial direction from the piston such that the first bus plate and the insulation plate are interposed between the cells and the piston, the first bus plate is configured to receive a first electric potential, and the insulation plate is configured to electrically insulate the first bus plate from at least one other component of the second end assembly and/or the first end plate.
  • Implementation 94 The apparatus of implementation 93, in which the first bus plate and the insulation plate are coupled to the piston via a plurality of fasteners.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Electrolytic Production Of Non-Metals, Compounds, Apparatuses Therefor (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)

Abstract

Diverses architectures multicellulaires d'électrolyseur COx sont fournies, comprenant diverses structures de cadre, de champ d'écoulement, de couche de diffusion de gaz et d'unité de répétition qui peuvent être particulièrement utiles dans le contexte de cellules d'électrolyseur COx multicellulaires.
PCT/US2023/072522 2022-08-19 2023-08-18 Empilements d'électrolyseur cox multicellulaires WO2024040252A2 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202263373035P 2022-08-19 2022-08-19
US63/373,035 2022-08-19
US18/329,524 2023-06-05
US18/329,524 US20240060194A1 (en) 2022-08-19 2023-06-05 MULTI-CELL COx ELECTROLYZER STACKS

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WO2024040252A2 WO2024040252A2 (fr) 2024-02-22
WO2024040252A9 true WO2024040252A9 (fr) 2024-07-04
WO2024040252A3 WO2024040252A3 (fr) 2024-08-02

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Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5232880B2 (fr) * 1974-09-06 1977-08-24
KR102563338B1 (ko) * 2016-01-15 2023-08-04 악신 워터 테크놀로지스 아이엔씨. 오염 물질의 제거율이 증가된 폐수 처리 용 전기 화학 전지
CA3238869A1 (fr) 2016-05-03 2017-11-09 Twelve Benefit Corporation Reacteur a architecture avancee destine a la reaction electrochimique de co2, de co, et d'autres composes chimiques
BR112020014938A2 (pt) 2018-01-22 2021-02-23 Opus-12 Incorporated sistema e método para o controle de reator de dióxido de carbono
KR20240026879A (ko) * 2021-02-03 2024-02-29 트웰브 베네핏 코포레이션 COx 전해조 셀 유동장 및 가스확산층

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