MECHANICAL REINFORCEMENT SYSTEM FOR AN ELECTROLYZER CELL AND METHOD OF USING THE SAME

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This nonprovisional application claims the benefit and priority, under 35 U.S.C. § 119(e) and any other applicable laws or statutes, to U.S. Provisional Patent Application Ser. No. 63/720,590 filed on Nov. 14, 2024, the entire disclosure of which is hereby expressly incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a mechanical reinforcement system for an electrolyzer cell and methods of using the mechanical reinforcement system to provide increased mechanical stability to the electrolyzer cell.

SUMMARY

Embodiments of the present disclosure are included to meet these and other needs.

In one aspect described herein, a reinforced electrolyzer assembly comprises an electrolyzer cell, a frame, and a mechanical reinforcement system. The electrolyzer cell includes a gas diffusion layer, a porous transport layer spaced apart from the gas diffusion layer along a first axis, and a membrane located between the gas diffusion layer and the porous transport layer. The membrane is formed to include an active area and a non-active area located on each side of the active area of the membrane along a second axis that is perpendicular to the first axis. The frame includes an upper frame arranged above the non-active area of the membrane relative to the first axis and a lower frame arranged below the non-active area of the membrane relative to the first axis. The mechanical reinforcement system is configured to increase a mechanical stability of the membrane of the electrolyzer cell outside of the active area of the membrane so that shorting is minimized. The mechanical reinforcement system includes at least one of an upper reinforcement layer arranged between the upper frame and the non-active area of the membrane relative to the first axis and a lower reinforcement layer arranged between the non-active area of the membrane and the lower frame relative to the first axis.

In some embodiments, the gas diffusion layer may include a first wall and a second wall opposite the first wall relative to the first axis. In some embodiments, the gas diffusion layer may define a first step that extends inwardly from the first wall toward the second wall and a second step that extends inwardly from the first wall toward the second wall in spaced apart relation to the first step relative to the second axis.

In some embodiments, the upper reinforcement layer may extend into the first step and the second step of the gas diffusion layer. In some embodiments, the porous transport layer may include a first wall and a second wall opposite the first wall relative to the first axis. In some embodiments, the porous transport layer may define a first step that extends inwardly from the first wall toward the second wall and a second step that extends inwardly from the first wall toward the second wall in spaced apart relation to the first step relative to the second axis.

In some embodiments, the lower reinforcement layer may extend into the first step and the second step of the porous transport layer. In some embodiments, the upper reinforcement layer may include a first upper reinforcement portion located in the first step of the gas diffusion layer and a second upper reinforcement portion spaced apart from the first upper reinforcement portion relative to the second axis and located in the second step of the gas diffusion layer. In some embodiments, the lower reinforcement layer may include a first lower reinforcement portion located in the first step of the porous transport layer and a second lower reinforcement portion spaced apart from the first lower reinforcement portion relative to the second axis and located in the second step of the porous transport layer.

In some embodiments, the first upper reinforcement portion and the second upper reinforcement portion may both have a first length defined along the second axis. In some embodiments, the first lower reinforcement portion and the second lower reinforcement portion may both have a second length defined along the second axis. In some embodiments, the first length may be different than the second length.

In some embodiments, the first upper reinforcement portion, the second upper reinforcement portion, the first lower reinforcement portion, and the second lower reinforcement portion may each have a first thickness defined along the first axis. In some embodiments, the first step and the second step of the gas diffusion layer and the first step and the second step of the porous transport layer may each have the first thickness.

In some embodiments, the first step and the second step of the gas diffusion layer and the first step and the second step of the porous transport layer may each have a length. In some embodiments, the length may be about 2 mm to about 6 mm.

In some embodiments, the upper frame may include a first upper plate and a second upper plate spaced apart from the first upper plate relative to the second axis to locate the gas diffusion layer between the first upper plate and the second upper plate. In some embodiments, the lower frame may include a first lower plate and a second lower plate spaced apart from the first lower plate relative to the second axis to locate the porous transport layer between the first lower plate and the second lower plate.

In some embodiments, a first gap may be formed between the first upper plate and the gas diffusion layer relative to the second axis, a second gap may be formed between the gas diffusion layer and the second upper plate relative to the second axis, a third gap may be formed between the first lower plate and the porous transport layer relative to the second axis, and a fourth gap may be formed between the porous transport layer and the second lower plate relative to the second axis. In some embodiments, the first gap, the second gap, the third gap, and the fourth gap may each be about 0.1 mm to about 0.3 mm.

In some embodiments, the upper reinforcement layer may include a first upper reinforcement portion located between the first upper plate and the non-active area of the membrane and a second upper reinforcement portion located between the second upper plate and the non-active area of the membrane. In some embodiments, the lower reinforcement layer may include a first lower reinforcement portion located between the non-active area of the membrane and the first lower plate and a second lower reinforcement portion located between the non-active area of the membrane and the second lower plate.

In some embodiments, the gas diffusion layer may have a first thickness above the active area of the membrane. In some embodiments, the first upper reinforcement portion and the second upper reinforcement portion may have a second thickness. In some embodiments, the first upper plate and the second upper plate may have a third thickness. In some embodiments, the first thickness may be greater than the third thickness, and the third thickness may be greater than the second thickness.

In another aspect described herein, a method of forming a reinforced electrolyzer assembly comprises aligning a gas diffusion layer and an upper frame with one another to form a first component; aligning a porous transport layer, a lower frame, and a lower reinforcement layer with one another; adhering the lower reinforcement layer to the porous transport layer and the lower frame to form a second component, wherein the lower reinforcement layer is adhered to a first wall of the lower frame and a first wall of the porous transport layer; aligning the first component and the second component with a membrane to locate the membrane between the first component and the lower reinforcement layer of the second component, and coupling the first component and the second component to the membrane so that the lower reinforcement layer extends along a non-active area of the membrane to form the reinforced electrolyzer assembly.

In some embodiments, the step of aligning the gas diffusion layer and the upper frame to form the first component may include aligning the gas diffusion layer, the upper frame, and an upper reinforcement layer and adhering the upper reinforcement layer to a first wall of the gas diffusion layer and a first wall of the upper frame, and wherein the method may comprise compressing a portion of the gas diffusion layer such that the gas diffusion layer is formed to define a first step and a second step spaced apart from the first step. In some embodiments, the first step and the second step may extend inwardly from the first wall of the gas diffusion layer toward a second wall of the gas diffusion layer opposite the first wall. In some embodiments, the method may comprise compressing a portion of the porous transport layer such that the porous transport layer is formed to define a first step and a second step spaced apart from the first step. In some embodiments, the first step and the second step may extend inwardly from the first wall of the porous transport layer toward a second wall of the porous transport layer.

In some embodiments, the lower reinforcement layer may comprise an adhesive material and polyethylene naphthalate.

In another aspect described herein, a method of forming a reinforced electrolyzer assembly comprises aligning a gas diffusion layer, an upper frame, and an upper reinforcement layer with one another; adhering the upper reinforcement layer to the gas diffusion layer and the upper frame to form a first component, wherein the upper reinforcement layer is adhered to a first wall of the upper frame and a first wall of the gas diffusion layer; aligning a porous transport layer and a lower frame with one another to form a second component; aligning the first component and the second component with a membrane to locate the membrane between the upper reinforcement layer of the first component and the second component; and coupling the first component and the second component to the membrane so that the upper reinforcement layer extends along a non-active area of the membrane to form the reinforced electrolyzer assembly.

In some embodiments, the step of aligning the porous transport layer and the lower frame with one another to form the second component may include aligning the porous transport layer, the lower frame, and a lower reinforcement layer and adhering the lower reinforcement layer to a first wall of the porous transport layer and a first wall of the lower frame. In some embodiments, the method may further comprise compressing a portion of the porous transport layer such that the porous transport layer is formed to define a first step and a second step spaced apart from the first step, the first step and the second step extending inwardly from the first wall of the porous transport layer toward a second wall of the porous transport layer opposite the first wall.

In some embodiments, the method may further comprise compressing a portion of the gas diffusion layer such that the gas diffusion layer is formed to define a first step and a second step spaced apart from the first step, the first step and the second step extending inwardly from the first wall of the gas diffusion layer toward a second wall of the gas diffusion layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of an electrolyzer cell stack according to the present disclosure;

FIG. 1B is a schematic view of an electrolysis system configured to utilize the electrolyzer cell stack of FIG. 1A;

FIG. 1C is a schematic view of an additional portion of the electrolysis system of FIG. 1B;

FIG. 2A is a diagrammatic view of a reinforced electrolyzer assembly including an electrolyzer cell, a frame arranged around the electrolyzer cell, and a mechanical reinforcement system arranged between the electrolyzer cell and the frame, the mechanical reinforcement system including an upper reinforcement layer and a lower reinforcement layer;

FIG. 2B is a diagrammatic view of the reinforced electrolyzer assembly of FIG. 2A;

FIG. 3 is a top view of a gas diffusion layer of the electrolyzer cell of FIG. 2A;

FIG. 4 is an enlarged side view of the gas diffusion layer of FIG. 3 showing that the gas diffusion layer is formed to define a step to receive a portion of the upper reinforcement layer of the mechanical reinforcement system therein;

FIG. 5 is a partial exploded view of the reinforced electrolyzer assembly of FIG. 2A showing that the gas diffusion layer, an upper frame of the frame, and the upper reinforcement layer are assembled together to form a first component, a porous transport layer of the electrolyzer cell, a lower frame of the frame, and the lower reinforcement layer are assembled together to form a second component, and the membrane is located between the first component and the second component;

FIG. 6 is an enlarged perspective view of the reinforced electrolyzer assembly of FIG. 5 showing that the upper reinforcement layer is adhered to the upper frame and the gas diffusion layer at the step thereof and the lower reinforcement layer is adhered to the lower frame and the porous transport layer at a step thereof;

FIG. 7 is an exploded view of the reinforced electrolyzer assembly of FIG. 2A before the first component and the second component are formed;

FIG. 8 is a diagrammatic view of another embodiment of a reinforced electrolyzer assembly;

FIG. 9 is a diagrammatic view of another embodiment of a reinforced electrolyzer assembly;

FIG. 10 is an exploded view of another embodiment of a reinforced electrolyzer assembly;

FIG. 11 is a diagrammatic view of the reinforced electrolyzer assembly of FIG. 10;

FIG. 12 is an exploded view of another embodiment of a reinforced electrolyzer assembly;

FIG. 13 is a cross-sectional view of the reinforced electrolyzer assembly of FIG. 12;

FIG. 14 is a top view of a portion of the reinforced electrolyzer assembly of FIG. 12;

FIG. 15A is an enlarged view of a portion of the reinforced electrolyzer assembly of FIG. 14;

FIG. 15B is an enlarged view of a portion of the reinforced electrolyzer assembly of FIG. 14; and

FIG. 16 is a diagrammatic view of the reinforced electrolyzer assembly of FIG. 12.

DETAILED DESCRIPTION

Electrolyzer systems are known for their efficient use of water and electricity to produce hydrogen and oxygen. Typical electrolyzer cells include a catalyst-coated membrane (CCM) that enables electrochemical reactions.

Membranes of electrolyzer cells are prone to failure near outer edges of the membranes. The outer edges of the membranes are non-active areas of the membranes. The non-active areas of the membranes may experience compromised mechanical strength. Thus, it may be advantageous to increase the mechanical stability of the membranes near the outer edges of the membranes.

Therefore, the present disclosure is directed to a mechanical reinforcement system for an electrolyzer cell and methods of using the mechanical reinforcement system to increase the mechanical stability of the electrolyzer cell.

As shown in FIGS. 1B and 1C, electrolysis systems 110 are typically configured to utilize water and electricity to produce hydrogen and oxygen. An electrolysis system 110 typically includes one or more electrolyzer cells 180 that utilize electricity to chemically produce substantially pure hydrogen 113 and oxygen 115 from deionized water 130. Often the electrical source for the electrolysis systems 110 is produced from power or energy generation systems, including renewable energy systems such as wind, solar, hydroelectric, and geothermal sources for the production of green hydrogen. In turn, the pure hydrogen produced by the electrolysis systems 110 is often utilized as a fuel or energy source for those same power generation systems, such as fuel cell systems. Alternatively, the pure hydrogen produced by the electrolysis systems 110 may be stored for later use.

The typical electrolyzer cell 180, or electrolytic cell, is comprised of multiple assemblies compressed and bound into a single assembly, and multiple electrolyzer cells 180 may be stacked relative to each other, along with bipolar plates (BPP) 184, 185 therebetween, to form an electrolyzer cell stack (for example, electrolyzer cell stacks 111, 112 in FIG. 1B). Each electrolyzer cell stack 111, 112 may house a plurality of electrolyzer cells 180 connected together in series and/or in parallel. The number of electrolyzer cell stacks 111, 112 in the electrolysis systems 110 can vary depending on the amount of power required to meet the power need of any load (e.g., fuel cell stack). The number of electrolyzer cells 180 in an electrolyzer cell stack 111, 112 can vary depending on the amount of power required to operate the electrolysis systems 110 including the electrolyzer cell stack 111, 112.

An electrolyzer cell 180 includes a multi-component membrane electrode assembly (MEA) 181 that has an electrolyte 181E, an anode 181A, and a cathode 181C, as shown in FIG. 1A. Typically, the anode 181A, the cathode 181C, and the electrolyte 181E of the membrane electrode assembly (MEA) 181 are configured in a multi-layer arrangement that enables the electrochemical reaction to produce hydrogen and/or oxygen via contact of the water with one or more gas diffusion layers 182, 183. The gas diffusion layers (GDL) 182, 183, which may also be referred to as porous transport layers (PTL), are typically located on one or both sides of the MEA 181. Bipolar plates (BPP) 184, 185 often reside on either side of the GDLs and separate the individual electrolyzer cells 180 of the electrolyzer cell stack 111, 112 from one another. One bipolar plate 185 and the adjacent gas diffusion layers 182, 183 and MEA 181 can form a repeating unit 188.

As shown in FIGS. 1B and 1C, an exemplary electrolysis system 110 can include two electrolyzer cell stacks 111, 112 and a fluidic circuit 110FC including the various fluidic pathways shown in FIGS. 1B and 1C that is configured to circulate, inject, and purge fluid and other components to and from the electrolysis systems 110. A person skilled in the art would understand that one or a variety of a number of components within the fluidic circuit 110FC, as well as more or less than two electrolyzer cell stacks 111, 112, may be utilized in the electrolysis systems 110. For example, the electrolysis systems 110 may include one electrolyzer cell stack 111, and in other examples, the electrolysis systems 110 may include three or more electrolyzer cell stacks.

The electrolysis systems 110 may include one or more types of electrolyzer cell stacks 111, 112 therein. In the illustrated embodiment, a polymer electrolyte membrane (PEM) electrolyzer cell 180 may be utilized in the stacks 111, 112. A PEM electrolyzer cell 180 typically operates at about 4° C. to about 150° C., including any specific or range of temperatures comprised therein. A PEM electrolyzer cell 180 also typically functions at about 100 bar or less, but can go up to about 1000 bar (including any specific or range of pressures comprised therein), which reduces the total energy demand of the system. A standard electrochemical reaction that occurs in a PEM electrolyzer cell 180 to produce hydrogen is as follows.

Additionally, a solid oxide electrolyzer cell 180 may be utilized in the electrolysis systems 110. A solid oxide electrolyzer cell 180 will function at about 500° C. to about 1000° C., including any specific or range of temperatures comprised therein. A standard electrochemical reaction that occurs in a solid oxide electrolyzer cell 180 to produce hydrogen is as follows.

Moreover, an AEM electrolyzer cell 180 may be utilized, which uses an alkaline media. An exemplary AEM electrolyzer cell 180 is an alkaline electrolyzer cell 180. Alkaline electrolyzer cells 180 comprise aqueous solutions, such as potassium hydroxide (KOH) and/or sodium hydroxide (NaOH), as the electrolyte. Alkaline electrolyzer cells 180 typically perform at operating temperatures ranging from about 0° C. to about 150° C., including any specific or range of temperatures comprised therein. Alkaline electrolyzer cells 180 generally operate at pressures ranging from about 1 bar to about 100 bar, including any specific or range of pressures comprised therein. A typical hydrogen-generating electrochemical reaction that occurs in an alkaline electrolyzer cell 180 is as follows.

As shown in FIG. 1B, the electrolyzer cell stacks 111, 112 include one or more electrolyzer cells 180 that utilize electricity to chemically produce substantially pure hydrogen and oxygen from water. In turn, the pure hydrogen produced by the electrolyzer may be utilized as a fuel or energy source. As shown in FIG. 1B, the electrolyzer cell stack 111, 112 outputs the produced hydrogen along a fluidic connecting line 113 to a hydrogen separator 116 and also outputs the produced oxygen along a fluidic connecting line 115 to an oxygen separator 114.

The hydrogen separator 116 may be configured to output pure hydrogen gas and also send additional output fluid to a hydrogen drain tank 120, which then outputs fluid to a deionized water drain 121. The oxygen separator 114 may output fluid to an oxygen drain tank 124, which in turn outputs fluid to a deionized water drain 125. A person skilled in the art would understand that certain inputs and outputs of fluid may be pure water or other fluids such as coolant or byproducts of the chemical reactions of the electrolyzer cell stacks 111, 112. For example, oxygen and hydrogen may flow away from the cell stacks 111, 112 to the respective separators 114, 116. The system 110 may further include a rectifier 132 configured to convert electricity 133 flowing to the cell stacks 111, 112 from alternating current (AC) to direct current (DC).

The deionized water drains 121, 125 each output to a deionized water tank 140, which is part of a polishing loop 136 of the fluidic circuit 110FC, as shown in FIG. 1C. Water with ion content can damage electrolyzer cell stacks 111, 112 when the ionized water interacts with internal components of the electrolyzer cell stacks 111, 112. The polishing loop 136, shown in greater detail in FIG. 1C, is configured to deionize the water such that it may be utilized in the cell stacks 111, 112 and not damage the cell stacks 111, 112.

In the illustrated embodiment, the deionized water tank 140 outputs fluid, in particular water, to a deionized water polishing pump 144. The deionized water polishing pump 144 in turn outputs the water to a water polishing heat exchanger 146 for polishing and treatment. The water then flows to a deionized water resin tank 148.

Coolant is directed through the electrolysis systems 110, in particular through a deionized water heat exchanger 172 that is fluidically connected to the oxygen separator 114, as shown in FIG. 1B. The coolant used to cool said water may also be subsequently fed to the water polishing heat exchanger 146 via a coolant input 127 for polishing. The coolant is then output back to the deionized water heat exchanger 172 for cooling the water therein.

After the water is output from the deionized water polishing heat exchanger 146 and subsequently to the deionized water resin tank 148, a portion of the water may be fed to deionized water high pressure feed pumps 160. Another portion of the water may be fed to a deionized water pressure control valve 152, as shown in FIG. 1C. The portion of the water that is fed to the deionized water pressure control valve 152 flows through a recirculation fluidic connection 154 that allows the water to flow back to the deionized water tank 140 for continued polishing.

In some embodiments, the electrolysis systems 110 may increase deionized water skid for polishing water flow to flush out ions within the water at a faster rate. The portion of the water that is fed to the deionized water high pressure feed pumps 160 is then output to a deionized water feed 164, which then flows into the oxygen separator 114 for recirculation and eventual reusage in the electrolyzer cell stacks 111, 112. This process may then continuously repeat.

The electrolysis systems 110 described herein, may be used in stationary and/or immovable power systems, such as industrial applications and power generation plants. The electrolysis systems 110 may also be implemented in conjunction with other electrolysis systems 110.

The present electrolysis systems 110 may be comprised in mobile applications. The electrolysis systems 110 may be in a vehicle or a powertrain. The vehicle or powertrain comprising the electrolysis systems 110 may be an automobile, a pass car, a bus, a truck, a train, a locomotive, an aircraft, a light duty vehicle, a medium duty vehicle, or a heavy-duty vehicle.

The present disclosure provides a reinforced electrolyzer assembly 10 including an electrolyzer cell 12, a frame 14, and a mechanical reinforcement system 16, as shown in FIG. 2A. The electrolyzer cell 12 may be the cell 180 described above.

The mechanical reinforcement system 16 mechanically reinforces, strengthens, and/or supports a membrane 22 of the electrolyzer cell 12 outside of an active area 32 of the membrane 22, as shown in FIG. 2A. In traditional electrolyzer cells, membranes may become compromised, damaged, and/or weakened for various reasons. This compromising, damaging, and/or weakening may lead to electrical shorting. Specifically, non-active areas of the membrane may be compromised, damaged, and/or weakened, thereby forming an unintended low-resistance path between a gas diffusion layer and a porous transport layer (i.e., a short circuit). Shorting leads to a diminished lifetime of traditional electrolyzer cells.

Compromised mechanical strength of the membrane in traditional electrolyzer cells may stem from high stresses on the membrane, high temperatures, high reactant/byproduct concentrations, gaps between frames and the gas diffusion layer/porous transport layer (as discussed in more detail below), sharp edges of the gas diffusion layer/porous transport layer, and/or unprotected portions of the membrane (i.e., the non-active area) at hydrogen and water ports. Thus, the mechanical reinforcement system 16 disclosed herein reinforces, supports, and/or strengthens the membrane 22 outside of the active area 32 to thereby reduce or minimize the risk of shorting so that the lifetime of the electrolyzer cell 12 is extended.

Compromised mechanical strength of the membrane in traditional electrolyzer cells may also lead to high crossover of hydrogen gas into oxygen gas through the membrane. A volume fraction of hydrogen in oxygen (HTO) represents the concentration of hydrogen gas in oxygen gas due to crossover through the membrane. A compromised, damaged, and/or weakened membrane may lead to higher HTO. Thus, strengthening, supporting, and/or reinforcing the membrane 22 using the mechanical reinforcement system 16 minimizes or mitigates HTO.

The electrolyzer cell 12 includes a gas diffusion layer 18, a porous transport layer 20, and the membrane 22, as shown in FIG. 2A. The gas diffusion layer 18 and the porous transport layer 20 are spaced apart from one another along a first axis A1. The membrane 22 is located between the gas diffusion layer 18 and the porous transport layer 20. The gas diffusion layer 18 may be the gas diffusion layer 182 as described above. The porous transport layer 20 may be the porous transport layer 183 as described above. The membrane 22 may be the membrane electrode assembly (MEA) 181 as described above. The membrane 22, as referred to herein, is illustratively defined as a catalyst coated membrane (CCM) including a membrane coated with two electrodes (an anode catalyst and a cathode catalyst).

The membrane 22 is located between the gas diffusion layer 18 and the porous transport layer 20 relative to the first axis A1, as shown in FIG. 2A. Illustratively, the membrane 22 is formed to include the active area 32 that interfaces entirely with the gas diffusion layer 18 and the porous transport layer 20 and a non-active area 34 located on each side of the active area 32 relative to a second axis A2 that is perpendicular to the first axis A1. Portions of the non-active area 34 of the membrane 22 do not overlap with or interface with the gas diffusion layer 18 and the porous transport layer 20.

The gas diffusion layer 18 includes a first wall 18A and a second wall 18B opposite the first wall 18A relative to the first axis A1, as shown in FIG. 2A. Once the reinforced electrolyzer assembly 10 is assembled, the first wall 18A contacts and/or engages the membrane 22. In some embodiments, the gas diffusion layer 18 is formed to define a first step 24 that extends inwardly from the first wall 18A toward the second wall 18B and a second step 26 that extends inwardly from the first wall 18A toward the second wall 18B, as shown in FIGS. 3 and 4. The steps 24, 26 are spaced apart from one another relative to the second axis A2. Illustratively, the steps 24, 26 are formed on opposite terminal ends of the gas diffusion layer 18 such that the steps 24, 26 are open in two directions (one direction that faces toward the membrane 22 and another direction along the second axis A2). The steps 24, 26 do not overlap with the active area 32 of the membrane 22, and instead, overlap with the non-active area 34 of the membrane 22.

The porous transport layer 20 includes a first wall 20A and a second wall 20B opposite the first wall 20A relative to the first axis A1, as shown in FIG. 2A. Once the reinforced electrolyzer assembly 10 is assembled, the first wall 20A contacts and/or engages the membrane 22. In some embodiments, the porous transport layer 20 is formed to define a first step 28 that extends inwardly from the first wall 20A toward the second wall 20B and a second step 30 that extends inwardly from the first wall 20A toward the second wall 20B. The steps 28, 30 are spaced apart from one another relative to the second axis A2. Illustratively, the steps 28, 30 are formed on opposite terminal ends of the porous transport layer 20 such that the steps 28, 30 are open in two directions (one direction that faces toward the membrane 22 and another direction along the second axis A2). The steps 28, 30 do not overlap with the active area 32 of the membrane 22, and instead, overlap with the non-active area 34 of the membrane 22.

The gas diffusion layer 18 has a first length L1, as shown in FIG. 2B. The gas diffusion layer 18 has a first thickness T1 defined between the first wall 18A and the second wall 18B above the active area 32 of the membrane 22 (i.e., not the portion of the gas diffusion layer 18 defining the steps 24, 26). The steps 24, 26 both have a second thickness T2 and a second length L2, as shown in FIG. 2B.

The porous transport layer 20 has a third length L3, as shown in FIG. 2B. The porous transport layer 20 has a third thickness T3 defined between the first wall 20A and the second wall 20B below the active area 32 of the membrane 22 (i.e., not the portion of the porous transport layer 20 defining the steps 28, 30). The steps 28, 30 both have a fourth thickness T4 and a fourth length L4, as shown in FIG. 2B.

The membrane 22 has a fifth length L5, as shown in FIG. 2B. The membrane 22 has a fifth thickness T5. In some embodiments, the fifth length L5 of the membrane 22 is greater than the third length L3 of the porous transport layer 20 and the first length L1 of the gas diffusion layer 18. In some embodiments, the third length L3 of the porous transport layer 20 is greater than the first length L1 of the gas diffusion layer 18. In some embodiments, the second length L2 of the steps 24, 26 of the gas diffusion layer 18 and the fourth length L4 of the steps 28, 30 of the porous transport layer 20 are the same.

In some embodiments, the second length L2 and the fourth length L4 of the steps 24, 26, 28, 30 are about 3 mm to about 7 mm, including any range or specific number comprised therein. In some embodiments, the second length L2 and the fourth length L4 of the steps 24, 26, 28, 30 are about 4 mm to about 6 mm, including any range or specific number comprised therein. In some embodiments, the second length L2 and the fourth length L4 of the steps 24, 26, 28, 30 are about 5 mm. The term “about” used in the context of millimeters is defined as plus or minus 1 mm.

In some embodiments, the first thickness T1 of the gas diffusion layer 18 is equal to the third thickness T3 of the porous transport layer 20, as shown in FIG. 2B. It will be understood that these thicknesses are post-assembly thicknesses, and the thicknesses may be different pre-assembly. For example, pre-assembly, the thickness of the gas diffusion layer 18 may be greater than the thickness of the porous transport layer 20. The compression of the layers 18, 20 during assembly may change the thicknesses.

In some embodiments, the first thickness T1 of the gas diffusion layer 18 is greater than the second thickness T2 of the steps 24, 26, and the third thickness T3 of the porous transport layer 20 is greater than the fourth thickness T4 of the steps 28, 30, as shown in FIG. 2B. In some embodiments, the fifth thickness T5 of the membrane 22 is less than the first thickness T1 of the gas diffusion layer 18 and the third thickness T3 of the porous transport layer 20. In some embodiments, the fifth thickness T5 of the membrane 22 is greater than the second thickness T2 of the steps 24, 26 and the fourth thickness T4 of the steps 28, 30.

In some embodiments, the second thickness T2 of the steps 24, 26 and the fourth thickness T4 of the steps 28, 30 are about 10 μm to about 75 μm, including any range or specific number comprised therein. In some embodiments, the second thickness T2 of the steps 24, 26 and the fourth thickness T4 of the steps 28, 30 are about 30 μm. The term “about” used in the context of microns is defined as plus or minus 5 μm.

The frame 14 includes an upper frame 36 arranged above the membrane 22 and a lower frame 38 arranged below the membrane 22 relative to the first axis A1, as shown in FIGS. 2A and 7. The membrane 22 is located between the upper frame 36 and the lower frame 38. The upper and lower frames 36, 38 overlap with the non-active area 34 of the membrane 22 and do not overlap with the active area 32 of the membrane 22.

The upper frame 36 includes a first upper plate 40 and a second upper plate 42, as shown in FIGS. 2A and 7. The first upper plate 40 and the second upper plate 42 are spaced apart from one another relative to the second axis A2. The gas diffusion layer 18 is located between the first upper plate 40 and the second upper plate 42. A first gap G1 is formed between the first upper plate 40 and the gas diffusion layer 18, and a second gap G2 is formed between the gas diffusion layer 18 and the second upper plate 42. The first upper plate 40 and the second upper plate 42 both have a sixth thickness T6, as shown in FIG. 2B. The first upper plate 40 and the second upper plate 42 both have a sixth length L6.

The lower frame 38 includes a first lower plate 44 and a second lower plate 46, as shown in FIGS. 2A and 7. The first lower plate 44 and the second lower plate 46 are spaced apart from one another relative to the second axis A2. The porous transport layer 20 is located between the first lower plate 44 and the second lower plate 46. A third gap G3 is formed between the first lower plate 44 and the porous transport layer 20, and a fourth gap G4 is formed between the porous transport layer 20 and the second lower plate 46. The first lower plate 44 and the second lower plate 46 both have a seventh thickness T7, as shown in FIG. 2B. The first lower plate 44 and the second lower plate 46 both have a seventh length L7.

In some embodiments, the sixth length L6 of the first and second upper plates 40, 42 is greater than the seventh length L7 of the first and second lower plates 44, 46, as shown in FIGS. 2B and 5. In some embodiments, the sixth thickness T6 and the seventh thickness T7 are the same. In some embodiments, the sixth thickness T6 and the seventh thickness T7 are less than the first thickness T1 of the gas diffusion layer 18 and the third thickness T3 of the porous transport layer 20. In some embodiments, the sixth thickness T6 and the seventh thickness T7 are greater than the second thickness T2 of the steps 24, 26 of the gas diffusion layer 18 and the fourth thickness T4 of the steps 28, 30 of the porous transport layer 20.

In some embodiments, the first gap G1, the second gap G2, the third gap G3, and the fourth gap G4 are the same. In some embodiments, the first gap G1, the second gap G2, the third gap G3, and the fourth gap G4 are each about 0.1 mm to about 0.3 mm, including any range or specific number comprised therein. In some embodiments, the first gap G1, the second gap G2, the third gap G3, and the fourth gap G4 are each about 0.25 mm. In traditional electrolyzer assemblies, these gaps are at least about 0.5 mm. A relatively large gap (such as the gaps in traditional electrolyzer assemblies) may lead to the membrane extruding inside the gaps. In other words, a relatively large gap results in membrane deformation. Thus, shortening the gaps G1, G2, G3, G4 leads to more support and reinforcement of the membrane 22 and a minimized risk of membrane 22 deformation.

In some embodiments, the frame 14 is formed of polyethylene naphthalate (PEN). In some embodiments, the frame 14 is formed of polyethylene terephthalate (PET), such as biaxially oriented polyethylene terephthalate (BOPET). The frame 14 interfaces with bipolar plates 15, 17 arranged above and below the frame 14 relative to the first axis A1, as shown in FIG. 2A. The bipolar plates 15, 17 may be the bipolar plates 184, 185 as described above.

The mechanical reinforcement system 16 is configured to increase a mechanical stability of the membrane 22 of the electrolyzer cell 12 outside of the active area 32 of the membrane 22 so that shorting is minimized, damage to the membrane 22 is reduced, and HTO is limited, among other benefits. The mechanical reinforcement system 16 includes an upper reinforcement layer 48 arranged between the upper frame 36 and the non-active area 34 of the membrane 22 relative to the first axis A1 and a lower reinforcement layer 50 arranged between the non-active area 34 of the membrane 22 and the lower frame 38 relative to the first axis A1, as shown in FIGS. 2A and 7.

The upper reinforcement layer 48 does not overlap with the active area 32 of the membrane 22, as shown in FIG. 2A. Illustratively, the upper reinforcement layer 48 includes a first upper reinforcement portion 52 and a second upper reinforcement portion 54 spaced apart from the first upper reinforcement portion 52 relative to the second axis A2. The first upper reinforcement portion 52 is located in and/or extends into the first step 24 of the gas diffusion layer 18, as shown in FIGS. 2A, 5, and 6. The first upper reinforcement portion 52 is coupled to and/or adhered to the first upper plate 40 and the first step 24 of the gas diffusion layer 18.

The second upper reinforcement portion 54 is located in and/or extends into the second step 26 of the gas diffusion layer 18, as shown in FIG. 2A. The second upper reinforcement portion 54 is coupled to and/or adhered to the second upper plate 42 and the second step 26 of the gas diffusion layer 18.

The first and second upper reinforcement portions 52, 54 both have an eighth length L8, as shown in FIG. 2B. The eighth length L8 is greater than the sixth length L6 of the first and second upper plates 40, 42. The first and second upper reinforcement portions 52, 54 both have an eighth thickness T8. The eighth thickness T8 is less than the first thickness T1 of the gas diffusion layer 18, less than the sixth thickness T6 of the first and second upper plates 40, 42, and less than the fifth thickness T5 of the membrane 22. Illustratively, the eighth thickness T8 is the same as the second thickness T2 of the steps 24, 26 of the gas diffusion layer 18. In illustrative embodiments, a sum of the sixth thickness T6 of the first and second upper plates 40, 42 and the eighth thickness T8 of the first and second upper reinforcement portions 52, 54 is equal to the first thickness T1 of the gas diffusion layer 18.

In some embodiments, a terminal end of the first and second upper reinforcement portions 52, 54 nearest the active area 32 of the membrane 22 is a first distance D1 from the active area 32 of the membrane 22, as shown in FIG. 2B. In some embodiments, the first distance D1 is about 0.5 mm to about 1.5 mm, including any range or specific number comprised therein. In some embodiments, the first distance D1 is about 1 mm.

In some embodiments, the overlap between the first upper reinforcement portion 52 and the gas diffusion layer 18 (i.e., a length of the first upper reinforcement portion 52 located in the first step 24) and the overlap between the second upper reinforcement portion 54 and the gas diffusion layer 18 (i.e., a length of the second upper reinforcement portion 54 located in the second step 26) is about 3 mm to about 7 mm, including any range or specific number comprised therein. In some embodiments, the overlap is about 4 mm to about 6 mm, including any range or specific number comprised therein. In some embodiments, the overlap is about 5 mm. In other words, in some embodiments, the overlap may be the same as the second length L2 of the steps 24, 26.

In some embodiments, the eighth thickness T8 of the first and second upper reinforcement portions 52, 54 is about 10 μm to about 75 μm, including any range or specific number comprised therein. In some embodiments, the eighth thickness T8 of the first and second upper reinforcement portions 52, 54 is about 30 μm.

The lower reinforcement layer 50 does not overlap with the active area 32 of the membrane 22, as shown in FIG. 2A. Illustratively, the lower reinforcement layer 50 includes a first lower reinforcement portion 56 and a second lower reinforcement portion 58 spaced apart from the first lower reinforcement portion 56 relative to the second axis A2. The first lower reinforcement portion 56 is located in and/or extends into the first step 28 of the porous transport layer 20, as shown in FIGS. 2A, 5, and 6. The first lower reinforcement portion 56 is coupled to and/or adhered to the first lower plate 44 and the first step 28 of the porous transport layer 20.

The second lower reinforcement portion 58 is located in and/or extends into the second step 30 of the porous transport layer 20, as shown in FIG. 2A. The second lower reinforcement portion 58 is coupled to and/or adhered to the second lower plate 46 and the second step 30 of the porous transport layer 20.

The first and second lower reinforcement portions 56, 58 both have a ninth length L9, as shown in FIG. 2B. The ninth length L9 is greater than the seventh length L7 of the first and second lower plates 44, 46. The ninth length L9 is less than the eighth length L8 of the first and second upper reinforcement portions 52, 54.

The first and second lower reinforcement portions 56, 58 both have a ninth thickness T9. The ninth thickness T9 is less than the third thickness T3 of the porous transport layer 20, less than the seventh thickness T7 of the first and second lower plates 44, 46, and less than the fifth thickness T5 of the membrane 22. Illustratively, the ninth thickness T9 is the same as the fourth thickness T4 of the steps 28, 30 of the porous transport layer 20. In illustrative embodiments, a sum of the seventh thickness T7 of the first and second lower plates 44, 46 and the ninth thickness T9 of the first and second lower reinforcement portions 56, 58 is equal to the third thickness T3 of the porous transport layer 20. Illustratively, the ninth thickness T9 of the first and second lower reinforcement portions 56, 58 is the same as the eight thickness T8 of the first and second upper reinforcement portions 52, 54.

In some embodiments, a terminal end of the first and second lower reinforcement portions 56, 58 nearest the active area 32 of the membrane 22 is a second distance D2 from the active area 32 of the membrane 22, as shown in FIG. 2B. In some embodiments, the second distance D2 is about 2 mm to about 3.5 mm, including any range or specific number comprised therein. In some embodiments, the second distance D2 is about 2.75 mm. The first and second lower reinforcement portions 56, 58 are farther away from the active area 32 of the membrane 22 than the first and second upper reinforcement portions 52, 54 (i.e., the first distance D1 is less than the second distance D2).

In some embodiments, the overlap between the first lower reinforcement portion 56 and the porous transport layer 20 (i.e., a length of the first lower reinforcement portion 56 located in the first step 28) and the overlap between the second lower reinforcement portion 58 and the porous transport layer 20 (i.e., a length of the second lower reinforcement portion 58 located in the second step 30) is about 3 mm to about 7 mm, including any range or specific number comprised therein. In some embodiments, the overlap is about 4 mm to about 6 mm, including any range or specific number comprised therein. In some embodiments, the overlap is about 5 mm. In other words, in some embodiments, the overlap may be the same as the fourth length L4 of the steps 28, 30.

In illustrative embodiments, the overlap of the lower reinforcement portions 56, 58 and the porous transport layer 20 and the overlap of the upper reinforcement portions 52, 54 and the gas diffusion layer 18 are the same. The larger the overlap, the more area available for the upper and lower reinforcement layers 48, 50 to securely adhere to the gas diffusion layer 18 and the porous transport layer 20.

In some embodiments, the ninth thickness T9 of the first and second lower reinforcement portions 56, 58 is about 10 μm to about 75 μm, including any range or specific number comprised therein. In some embodiments, the ninth thickness T9 of the first and second lower reinforcement portions 56, 58 is about 30 μm.

As shown in FIG. 2B, the offset between the first upper reinforcement portion 52 and the first lower reinforcement portion 56 and the offset between the second upper reinforcement portion 54 and the second lower reinforcement portion 58 are both a third distance D3. In some embodiments, the third distance D3 is about 1 mm to about 3 mm, including any range or specific number comprised therein. In some embodiments, the third distance D3 is about 2 mm. In some embodiments, the third distance D3 is at least 2 mm. The offset between the first upper reinforcement portion 52 and the first lower reinforcement portion 56 and the offset between the second upper reinforcement portion 54 and the second lower reinforcement portion 58 helps to distribute local stresses.

In some embodiments, the reinforced electrolyzer assembly 10 may further include a plurality of seals 60, as shown in FIG. 2A. The plurality of seals 60 is configured to seal between layers of the reinforced electrolyzer assembly 10. As shown in FIG. 2B, the first gap G1 and the second gap G2 are both a fourth distance D4 away from an adjacent seal of the plurality of seals 60. In some embodiments, the fourth distance D4 is about 3 mm to about 6 mm, including any range or specific number comprised therein. In some embodiments, the fourth distance D4 is about 3 mm to about 4.5 mm, including any range or specific number comprised therein. In some embodiments, the fourth distance D4 is about 3.75 mm.

As shown in FIG. 2B, the third gap G3 and the fourth gap G4 are both a fifth distance D5 away from an adjacent seal of the plurality of seals 60. In some embodiments, the fifth distance D5 is about 1 mm to about 3 mm, including any range or specific number comprised therein. In some embodiments, the fifth distance D5 is about 2 mm.

Illustratively, the upper and lower reinforcement layers 48, 50 comprise a polyimide film or a polyimide tape. In some embodiments, the upper and lower reinforcement layers 48, 50 comprise Kapton. In some embodiments, the upper and lower reinforcement layers 48, 50 comprise other polyimide films with specific advantageous properties, such as, but not limited to, Upilex or Kaptrex. In some embodiments, the upper and lower reinforcement layers 48, 50 comprise an adhesive material such that the upper and lower reinforcement layers 48, 50 adhere to and/or bind to the respective upper and lower frames 36, 38, the gas diffusion layer 18, and/or the porous transport layer 20. In some embodiments, the upper and lower reinforcement layers 48, 50 comprise a polyimide film and an adhesive material.

To manufacture the reinforced electrolyzer assembly 10, the gas diffusion layer 18, the upper frame 36, and the upper reinforcement layer 48 are aligned with one another. The upper reinforcement layer 48 is adhered to the gas diffusion layer 18 and the upper frame 36 to form a first component 62, as shown in FIG. 5. The upper reinforcement layer 48 is adhered to a first wall of the upper frame 36 and the first wall 18A of the gas diffusion layer 18. The upper reinforcement layer 48 may be temperature sensitive and/or pressure sensitive such that a particular temperature and/or pressure is applied to form the first component 62. In some embodiments, the particular temperature and/or pressure may be applied via a hot press, a cold press, a mechanical press, rollers, etc.

The porous transport layer 20, the lower frame 38, and the lower reinforcement layer 50 are aligned with one another. The lower reinforcement layer 50 is adhered to the porous transport layer 20 and the lower frame 38 to form a second component 64, as shown in FIG. 5. The lower reinforcement layer 50 is adhered to a first wall of the lower frame 38 and the first wall 20A of the porous transport layer 20. The lower reinforcement layer 50 may be temperature sensitive and/or pressure sensitive such that a particular temperature and/or pressure is applied to form the second component 64. In some embodiments, the particular temperature and/or pressure may be applied via a hot press, a cold press, a mechanical press, rollers, etc.

The first component 62 and the second component 64 are aligned with the membrane 22, as shown in FIGS. 5 and 6, to locate the membrane 22 between the upper reinforcement layer 48 of the first component 62 and the lower reinforcement layer 50 of the second component 64. The first component 62 and the second component 64 are coupled to the membrane 22 so that the upper reinforcement layer 48 and the lower reinforcement layer 50 extend along the non-active area 34 of the membrane 22 to form the reinforced electrolyzer assembly 10.

In some embodiments, the method of manufacturing includes compressing a portion of the gas diffusion layer 18 such that the gas diffusion layer 18 is formed to define the first step 24 and the second step 26. In some embodiments, the method of manufacturing includes compressing a portion of the porous transport layer 20 such that the porous transport layer 20 is formed to define the first step 28 and the second step 30.

The reinforcement layers 48, 50 allow for an easier manufacturing process as compared to traditional manufacturing processes. Because the first component 62 and the second component 64 are formed via the adhesive reinforcement layers 48, 50, three components are coupled together (the first component 62, the second component 64, and the membrane 22) instead of seven components to form the reinforced electrolyzer assembly 10.

The upper and lower reinforcement layers 48, 50 may act as an electrical insulator among layers of the reinforced electrolyzer assembly 10. The upper and lower reinforcement layers 48, 50 protect the membrane 22 outside the active area 32 from different stresses, such as high flow rates of water and hydrogen, excessive local stresses, local heat, and/or local stresses at the gaps G1, G2, G3, G4, among others.

The present disclosure provides an alternative reinforced electrolyzer assembly 210. FIG. 8 illustrates another embodiment of a reinforced electrolyzer assembly 210 that is substantially similar to the reinforced electrolyzer assembly 10. In the absence of disclosure to the contrary, the features and components of the reinforced electrolyzer assembly 10 are applicable and present for the reinforced electrolyzer assembly 210.

As shown in FIG. 8, a gas diffusion layer 218 and a porous transport layer 220 are swapped relative to the arrangement shown in FIG. 2A. The dimensions disclosed in relation to FIG. 2B apply with equal weight to the reinforced electrolyzer assembly 210 with the gas diffusion layer 218 and the porous transport layer 220 dimensions being swapped.

The reinforced electrolyzer assembly 210 includes an electrolyzer cell 212, a frame 214, and a mechanical reinforcement system 216, as shown in FIG. 8. The electrolyzer cell 212 includes the gas diffusion layer 218, the porous transport layer 220, and a membrane 222. The gas diffusion layer 218 and the porous transport layer 220 are spaced apart from one another along a first axis A1. The membrane 222 is located between the gas diffusion layer 218 and the porous transport layer 220.

Illustratively, the membrane 222 is formed to include an active area 232 that interfaces entirely with the gas diffusion layer 218 and the porous transport layer 220 and a non-active area 234 located on each side of the active area 232 relative to a second axis A2 that is perpendicular to the first axis A1. Portions of the non-active area 234 of the membrane 222 do not overlap with or interface with the gas diffusion layer 218 and the porous transport layer 220.

The gas diffusion layer 218 includes a first wall 218A and a second wall 218B opposite the first wall 218A relative to the first axis A1, as shown in FIG. 8. In some embodiments, the gas diffusion layer 218 is formed to define a first step 224 that extends inwardly from the first wall 218A toward the second wall 218B and a second step 226 that extends inwardly from the first wall 218A toward the second wall 218B, as shown in FIG. 8. The steps 224, 226 are spaced apart from one another relative to the second axis A2.

The porous transport layer 220 includes a first wall 220A and a second wall 220B opposite the first wall 220A relative to the first axis A1, as shown in FIG. 8. In some embodiments, the porous transport layer 220 is formed to define a first step 228 that extends inwardly from the first wall 220A toward the second wall 220B and a second step 230 that extends inwardly from the first wall 220A toward the second wall 220B. The steps 228, 230 are spaced apart from one another relative to the second axis A2.

The gas diffusion layer 218 has a first length L1, as shown in FIG. 8. The porous transport layer 220 has a third length L3. In some embodiments, the third length L3 of the porous transport layer 220 is less than the first length L1 of the gas diffusion layer 218.

The frame 214 includes an upper frame 236 arranged above the membrane 222 and a lower frame 238 arranged below the membrane 222 relative to the first axis A1, as shown in FIG. 8. The upper frame 236 includes a first upper plate 240 and a second upper plate 242. The porous transport layer 220 is located between the first upper plate 240 and the second upper plate 242.

The lower frame 238 includes a first lower plate 244 and a second lower plate 246, as shown in FIG. 8. The gas diffusion layer 218 is located between the first lower plate 244 and the second lower plate 246.

The mechanical reinforcement system 216 includes an upper reinforcement layer 248 arranged between the upper frame 236 and the non-active area 234 of the membrane 222 relative to the first axis A1 and a lower reinforcement layer 250 arranged between the non-active area 234 of the membrane 222 and the lower frame 238 relative to the first axis A1, as shown in FIG. 8. Illustratively, the upper reinforcement layer 248 includes a first upper reinforcement portion 252 and a second upper reinforcement portion 254 spaced apart from the first upper reinforcement portion 252 relative to the second axis A2. The first upper reinforcement portion 252 is located in and/or extends into the first step 228 of the porous transport layer 220, as shown in FIG. 8. The first upper reinforcement portion 252 is coupled to and/or adhered to the first upper plate 240 and the first step 228 of the porous transport layer 220.

The second upper reinforcement portion 254 is located in and/or extends into the second step 230 of the porous transport layer 220, as shown in FIG. 8. The second upper reinforcement portion 254 is coupled to and/or adhered to the second upper plate 242 and the second step 230 of the porous transport layer 220.

Illustratively, the lower reinforcement layer 250 includes a first lower reinforcement portion 256 and a second lower reinforcement portion 258 spaced apart from the first lower reinforcement portion 256 relative to the second axis A2. The first lower reinforcement portion 256 is located in and/or extends into the first step 224 of the gas diffusion layer 218, as shown in FIG. 8. The first lower reinforcement portion 256 is coupled to and/or adhered to the first lower plate 244 and the first step 224 of the gas diffusion layer 218.

The second lower reinforcement portion 258 is located in and/or extends into the second step 226 of the gas diffusion layer 218, as shown in FIG. 8. The second lower reinforcement portion 258 is coupled to and/or adhered to the second lower plate 246 and the second step 226 of the gas diffusion layer 218.

The present disclosure provides an alternative reinforced electrolyzer assembly 310. FIG. 9 illustrates another embodiment of a reinforced electrolyzer assembly 310 that is substantially similar to the reinforced electrolyzer assembly 10. In the absence of disclosure to the contrary, the features and components of the reinforced electrolyzer assembly 10 are applicable and present for the reinforced electrolyzer assembly 310. The dimensions disclosed in relation to FIG. 2B apply with equal weight to the reinforced electrolyzer assembly 310 unless otherwise stated.

The reinforced electrolyzer assembly 310 includes an electrolyzer cell 312, a frame 314, and a mechanical reinforcement system 316, as shown in FIG. 9. The electrolyzer cell 312 includes a gas diffusion layer 318, a porous transport layer 320, and a membrane 322. The gas diffusion layer 318 and the porous transport layer 320 are spaced apart from one another along a first axis A1. The membrane 322 is located between the gas diffusion layer 318 and the porous transport layer 320.

The gas diffusion layer 318 includes a first wall 318A and a second wall 318B opposite the first wall 318A relative to the first axis A1, as shown in FIG. 9. The gas diffusion layer 318 is illustratively formed without steps. However, during compression of the reinforced electrolyzer assembly 310, pseudo steps 324, 326 are formed in the gas diffusion layer 318. In other words, the gas diffusion layer 318 is formed as a single component without steps, and compression of the gas diffusion layer 318 during assembly forms the pseudo steps 324, 326.

The porous transport layer 320 includes a first wall 320A and a second wall 320B opposite the first wall 320A relative to the first axis A1, as shown in FIG. 9. The porous transport layer 320 is illustratively formed without steps. However, during compression of the reinforced electrolyzer assembly 310, pseudo steps 328, 330 are formed in the porous transport layer 320. In other words, the porous transport layer 320 is formed as a single component without steps, and compression of the porous transport layer 320 during assembly forms the pseudo steps 328, 330.

In illustrative embodiments, a second thickness T2 of the pseudo steps 324, 326 and a fourth thickness T4 of the pseudo steps 328, 330 are about 10 μm to about 25 μm, including any range or specific number comprised therein.

The frame 314 includes an upper frame 336 arranged above the membrane 322 and a lower frame 338 arranged below the membrane 322 relative to the first axis A1, as shown in FIG. 9. The membrane 322 is located between the upper frame 336 and the lower frame 338.

The mechanical reinforcement system 316 includes an upper reinforcement layer 348 arranged between the upper frame 336 and a non-active area of the membrane 322 relative to the first axis A1 and a lower reinforcement layer 350 arranged between the non-active area of the membrane 322 and the lower frame 338 relative to the first axis A1, as shown in FIG. 9. Illustratively, the upper reinforcement layer 348 includes a first upper reinforcement portion 352 and a second upper reinforcement portion 354 spaced apart from the first upper reinforcement portion 352 relative to the second axis A2.

Before compression of the reinforced electrolyzer assembly 310, a gap may be formed between the first wall 318A of the gas diffusion layer 318 and the membrane 322 relative to the first axis A1. During compression of the reinforced electrolyzer assembly 310, the first upper reinforcement portion 352 causes and/or forces the gas diffusion layer 318 to deform to form the pseudo first step 324 and the second upper reinforcement portion 354 causes and/or forces the gas diffusion layer 318 to deform to form the pseudo second step 326. In other words, the compression causes the gas diffusion layer 318 to deform and fill the gap between the first wall 318A of the gas diffusion layer 318 and the membrane 322.

The first and second upper reinforcement portions 352, 354 both have an eighth thickness T8, as shown in FIG. 9. Illustratively, the eighth thickness T8 is the same as the second thickness T2 of the pseudo steps 324, 326 of the gas diffusion layer 318. In some embodiments, the eighth thickness T8 of the first and second upper reinforcement portions 352, 354 is about 10 μm to about 25 μm, including any range or specific number comprised therein. As compared to the reinforced electrolyzer assemblies 10, 210, the reinforced electrolyzer assembly 310 has relatively thin first and second upper reinforcement portions 352, 354 such that steps do not have to be formed in the gas diffusion layer 318 prior to compression.

Illustratively, the lower reinforcement layer 350 includes a first lower reinforcement portion 356 and a second lower reinforcement portion 358 spaced apart from the first lower reinforcement portion 356 relative to the second axis A2, as shown in FIG. 9. Before compression of the reinforced electrolyzer assembly 310, a gap may be formed between the first wall 320A of the porous transport layer 320 and the membrane 322 relative to the first axis A1. During compression of the reinforced electrolyzer assembly 310, the first lower reinforcement portion 356 causes and/or forces the porous transport layer 320 to deform to form the pseudo first step 328 and the second lower reinforcement portion 358 causes and/or forces the porous transport layer 320 to deform to form the pseudo second step 330. In other words, the compression causes the porous transport layer 320 to deform and fill the gap between the first wall 320A of the porous transport layer 320 and the membrane 322.

The first and second lower reinforcement portions 356, 358 both have a ninth thickness T9. Illustratively, the ninth thickness T9 is the same as the fourth thickness T4 of the pseudo steps 328, 330 of the porous transport layer 320. Illustratively, the ninth thickness T9 of the first and second lower reinforcement portions 356, 358 is the same as the eight thickness T8 of the first and second upper reinforcement portions 352, 354.

In some embodiments, the ninth thickness T9 of the first and second lower reinforcement portions 356, 358 is about 10 μm to about 25 μm, including any range or specific number comprised therein. As compared to the reinforced electrolyzer assemblies 10, 210, the reinforced electrolyzer assembly 310 has relatively thin first and second lower reinforcement portions 356, 358 such that steps do not have to be formed in the porous transport layer 320 prior to compression.

The present disclosure provides an alternative reinforced electrolyzer assembly 410. FIGS. 10 and 11 illustrate another embodiment of a reinforced electrolyzer assembly 410 that is substantially similar to the reinforced electrolyzer assembly 10, 210, 310. In the absence of disclosure to the contrary, the features and components of the reinforced electrolyzer assembly 10, 210, 310 are applicable and present for the reinforced electrolyzer assembly 410. The dimensions disclosed in relation to FIG. 2B apply with equal weight to the reinforced electrolyzer assembly 410 unless otherwise stated.

The reinforced electrolyzer assembly 410 includes an electrolyzer cell 412, a frame 414, and a mechanical reinforcement system 416, as shown in FIG. 10. The electrolyzer cell 412 may be the cell 180 described above.

The mechanical reinforcement system 416 mechanically reinforces, strengthens, and/or supports a membrane 422 of the electrolyzer cell 412 outside of an active area 432 of the membrane 422, as shown in FIG. 10. The electrolyzer cell 412 includes a gas diffusion layer 418, a porous transport layer 420, and the membrane 422. The gas diffusion layer 418 and the porous transport layer 420 are spaced apart from one another along a first axis A1. The membrane 422 is located between the gas diffusion layer 418 and the porous transport layer 420.

The frame 414 includes an upper frame 436 arranged above the membrane 422 and a lower frame 438 arranged below the membrane 422 relative to the first axis A1, as shown in FIGS. 10 and 11. The membrane 422 is located between the upper frame 436 and the lower frame 438. The upper and lower frames 436, 438 overlap with a non-active area 434 of the membrane 422 and do not overlap with the active area 432 of the membrane 422.

The upper frame 436 includes a first upper plate 440 and a second upper plate 442, as shown in FIG. 10. The first upper plate 440 and the second upper plate 442 are spaced apart from one another relative to a second axis A2. The gas diffusion layer 418 is located between the first upper plate 440 and the second upper plate 442.

The lower frame 438 includes a first lower plate 444 and a second lower plate 446, as shown in FIG. 10. The first lower plate 444 and the second lower plate 446 are spaced apart from one another relative to the second axis A2. The porous transport layer 420 is located between the first lower plate 444 and the second lower plate 446.

In some embodiments, the frame 414 is formed of polyethylene naphthalate (PEN). In some embodiments, the frame 414 is formed of polyethylene terephthalate (PET), such as biaxially oriented polyethylene terephthalate (BOPET).

The mechanical reinforcement system 416 is configured to increase a mechanical stability of the membrane 422 of the electrolyzer cell 412 outside of the active area 432 of the membrane 422 so that shorting is minimized, damage to the membrane 422 is reduced, and HTO is limited, among other benefits. The mechanical reinforcement system 416 includes a lower reinforcement layer 450 arranged between the non-active area 434 of the membrane 422 and the lower frame 438 relative to the first axis A1, as shown in FIGS. 10 and 11.

The lower reinforcement layer 450 does not overlap with the active area 432 of the membrane 422, as shown in FIG. 10. Illustratively, the lower reinforcement layer 450 includes a first lower reinforcement portion 456 and a second lower reinforcement portion 458 spaced apart from the first lower reinforcement portion 456 relative to the second axis A2. The first lower reinforcement portion 456 is coupled to and/or adhered to the first lower plate 444 and the porous transport layer 420. The second lower reinforcement portion 458 is coupled to and/or adhered to the second lower plate 446 and the porous transport layer 420.

It will be understood that the mechanical reinforcement system 416 can, alternatively to the lower reinforcement layer 450, include an upper reinforcement layer (such as the upper reinforcement layer 48). The inclusion of only one of the upper and lower reinforcement layers 450 allows for more direct contact between the membrane 422 and the frames 436, 438 as compared to the reinforced electrolyzer assembly 10, 210, 310.

Illustratively, the lower reinforcement layer 450 comprises a polyimide film or a polyimide tape. In some embodiments, the lower reinforcement layer 450 comprises Kapton. In some embodiments, the lower reinforcement layer 450 comprises other polyimide films with specific advantageous properties, such as, but not limited to, Upilex or Kaptrex. In some embodiments, the lower reinforcement layer 450 comprises an adhesive material such that the lower reinforcement layer 450 adheres to and/or binds to the lower frame 438 and/or the porous transport layer 420. In some embodiments, the lower reinforcement layer 450 comprises a polyimide film 451 and an adhesive material 453. In some embodiments, the lower reinforcement layer 450 comprises polyethylene naphthalate (PEN) 451 and an adhesive material 453.

In some embodiments, the polyimide film 451 and/or the PEN 451 has a thickness of about 20 μm to about 30 μm, including any specific number or range of numbers comprised therein. In some embodiments, the polyimide film 451 and/or the PEN 451 has a thickness of about 25 μm. In some embodiments, the adhesive material 453 has a thickness of about 2 μm to about 4 μm, including any specific number or range of numbers comprised therein. In some embodiments, the adhesive material 453 has a thickness of about 3 μm.

The adhesive material 453 may be temperature sensitive and/or pressure sensitive such that a particular temperature and/or pressure is applied to adhere the lower reinforcement layer 450 to the lower frame 438 and/or the porous transport layer 420. In some embodiments, the particular temperature and/or pressure may be applied via a hot press, a cold press, a mechanical press, rollers, etc.

The present disclosure provides an alternative reinforced electrolyzer assembly 510. FIGS. 12-16 illustrate another embodiment of a reinforced electrolyzer assembly 510 that is substantially similar to the reinforced electrolyzer assembly 10, 210, 310, 410. In the absence of disclosure to the contrary, the features and components of the reinforced electrolyzer assembly 10, 210, 310, 410 are applicable and present for the reinforced electrolyzer assembly 510. The dimensions disclosed in relation to FIG. 2B apply with equal weight to the reinforced electrolyzer assembly 510 unless otherwise stated.

The present disclosure provides a reinforced electrolyzer assembly 510 including an electrolyzer cell 512, a frame 514, and a mechanical reinforcement system 516, as shown in FIG. 12. The electrolyzer cell 512 may be the cell 180 described above.

The mechanical reinforcement system 516 mechanically reinforces, strengthens, and/or supports a membrane 522 of the electrolyzer cell 512 outside of an active area 532 of the membrane 522, as shown in FIG. 12. The electrolyzer cell 512 includes a gas diffusion layer 518, a porous transport layer 520, and the membrane 522, as shown in FIG. 12. The gas diffusion layer 518 and the porous transport layer 520 are spaced apart from one another along a first axis A1. The membrane 522 is located between the gas diffusion layer 518 and the porous transport layer 520.

Illustratively, the membrane 522 is formed to include the active area 532 that interfaces entirely with the gas diffusion layer 518 and the porous transport layer 520 and a non-active area 534 located on each side of the active area 532 relative to a second axis A2 that is perpendicular to the first axis A1. Portions of the non-active area 534 of the membrane 522 do not overlap with or interface with the gas diffusion layer 518 and the porous transport layer 520.

The gas diffusion layer 518 includes a first wall 518A and a second wall 518B opposite the first wall 518A relative to the first axis A1, as shown in FIG. 13. Once the reinforced electrolyzer assembly 510 is assembled, the first wall 518A contacts and/or engages the membrane 522. The gas diffusion layer 518 is illustratively formed without steps. However, during compression of the reinforced electrolyzer assembly 510, pseudo steps 524 are formed in the gas diffusion layer 518. In other words, the gas diffusion layer 518 is formed as a single component without steps, and compression of the gas diffusion layer 518 during assembly forms the pseudo steps 524.

The porous transport layer 520 includes a first wall 520A and a second wall 520B opposite the first wall 520A relative to the first axis A1, as shown in FIG. 13. Once the reinforced electrolyzer assembly 510 is assembled, the first wall 520A contacts and/or engages the membrane 522. The porous transport layer 520 is illustratively formed without steps. However, during compression of the reinforced electrolyzer assembly 510, pseudo steps 528 are formed in the porous transport layer 520. In other words, the porous transport layer 520 is formed as a single component without steps, and compression of the porous transport layer 520 during assembly forms the pseudo steps 528.

The frame 514 includes an upper frame 536 arranged above the membrane 522 and a lower frame 538 arranged below the membrane 522 relative to the first axis A1, as shown in FIGS. 12 and 13. The membrane 522 is located between the upper frame 536 and the lower frame 538. The upper and lower frames 536, 538 overlap with the non-active area 534 of the membrane 522 and do not overlap with the active area 532 of the membrane 522.

The upper frame 536 includes a first upper plate 540 and a second upper plate 542, as shown in FIG. 12. The first upper plate 540 and the second upper plate 542 are spaced apart from one another relative to the second axis A2. The gas diffusion layer 518 is located between the first upper plate 540 and the second upper plate 542. A first gap G1, as shown in FIG. 13, is formed between the first upper plate 540 and the gas diffusion layer 518 and between the gas diffusion layer 518 and the second upper plate 542.

The lower frame 538 includes a first lower plate 544 and a second lower plate 546, as shown in FIG. 12. The first lower plate 544 and the second lower plate 546 are spaced apart from one another relative to the second axis A2. The porous transport layer 520 is located between the first lower plate 544 and the second lower plate 546. A third gap G3, as shown in FIG. 13, is formed between the first lower plate 544 and the porous transport layer 520 and between the porous transport layer 520 and the second lower plate 546.

In some embodiments, the first gap G1 and the third gap G3 are the same. In some embodiments, the first gap G1 and the third gap G3 are each about 0.1 mm to about 0.3 mm, including any range or specific number comprised therein. In some embodiments, the first gap G1 and the third gap G3 are each about 0.25 mm.

In some embodiments, the frame 514 is formed of polyethylene naphthalate (PEN). In some embodiments, the frame 514 is formed of polyethylene terephthalate (PET), such as biaxially oriented polyethylene terephthalate (BOPET). The frame 514 interfaces with bipolar plates 515, 517 arranged above and below the frame 514 relative to the first axis A1, as shown in FIGS. 12 and 13.

The mechanical reinforcement system 516 includes an upper reinforcement layer 548 arranged between the upper frame 536 and the non-active area 534 of the membrane 522 relative to the first axis A1 and a lower reinforcement layer 550 arranged between the non-active area 534 of the membrane 522 and the lower frame 538 relative to the first axis A1, as shown in FIGS. 12 and 13.

The upper reinforcement layer 548 and the lower reinforcement layer 550 do not overlap with the active area 532 of the membrane 522, as shown in FIG. 13. As shown in FIGS. 12 and 14, the upper reinforcement layer 548 and the lower reinforcement layer 550 substantially match a contour of manifolds 555 of the membrane 522, the upper frame 536, the lower frame 538, and the bipolar plates 515, 517. In other words, the upper reinforcement layer 548 and the lower reinforcement layer 550 substantially match a shape of a gasket seal 560, as shown in FIG. 14. In this way, the upper reinforcement layer 548 and the lower reinforcement layer 550 extend entirely around each of the six manifolds 555. As compared to the upper reinforcement layer 48 and the lower reinforcement layer 50, the upper reinforcement layer 548 and the lower reinforcement layer 550 use less material as the upper reinforcement layer 548 and the lower reinforcement layer 550 do not cover an entirety of the upper frame 536 and the lower frame 538. Thus, the upper reinforcement layer 548 and the lower reinforcement layer 550 have a different shape than the upper frame 536 and the lower frame 538.

Illustratively, the upper reinforcement layer 548 includes a first upper reinforcement portion 552 and a second upper reinforcement portion 554 spaced apart from the first upper reinforcement portion 552 relative to the second axis A2. The first upper reinforcement portion 552 is located in and/or extends into the first pseudo step 524 of the gas diffusion layer 518. The first upper reinforcement portion 552 is coupled to and/or adhered to the first upper plate 540 and the first pseudo step 524 of the gas diffusion layer 518.

The second upper reinforcement portion 554 is located in and/or extends into the second pseudo step of the gas diffusion layer 518. The second upper reinforcement portion 554 is coupled to and/or adhered to the second upper plate 542 and the second pseudo step of the gas diffusion layer 518.

In some embodiments, a terminal end of the first and second upper reinforcement portions 552, 554 nearest the active area 532 of the membrane 522 is a first distance D1 from the active area 532 of the membrane 522, as shown in FIG. 13. In some embodiments, the first distance D1 is about 3 mm to about 3.5 mm, including any range or specific number comprised therein. In some embodiments, the first distance D1 is about 3.25 mm.

In some embodiments, the overlap between the first upper reinforcement portion 552 and the gas diffusion layer 518 (i.e., a length of the first upper reinforcement portion 552 located in the first pseudo step 524) and the overlap between the second upper reinforcement portion 554 and the gas diffusion layer 518 (i.e., a length of the second upper reinforcement portion 554 located in the pseudo second step) is about 1.5 mm to about 3.5 mm, including any range or specific number comprised therein. In some embodiments, the overlap is about 2.5 mm.

The lower reinforcement layer 550 does not overlap with the active area 532 of the membrane 522, as shown in FIG. 12. Illustratively, the lower reinforcement layer 550 includes a first lower reinforcement portion 556 and a second lower reinforcement portion 558 spaced apart from the first lower reinforcement portion 556 relative to the second axis A2, as shown in FIG. 14. The first lower reinforcement portion 556 is located in and/or extends into the first pseudo step 528 of the porous transport layer 520. The first lower reinforcement portion 556 is coupled to and/or adhered to the first lower plate 544 and the first pseudo step 528 of the porous transport layer 520.

The second lower reinforcement portion 558 is located in and/or extends into the second pseudo step of the porous transport layer 520. The second lower reinforcement portion 558 is coupled to and/or adhered to the second lower plate 546 and the second pseudo step of the porous transport layer 520.

In some embodiments, a terminal end of the first and second lower reinforcement portions 556, 558 nearest the active area 532 of the membrane 522 is a second distance D2 from the active area 532 of the membrane 522, as shown in FIG. 13. In some embodiments, the second distance D2 is about 4 mm to about 6 mm, including any range or specific number comprised therein. In some embodiments, the second distance D2 is about 5 mm. The first and second lower reinforcement portions 556, 558 are farther away from the active area 532 of the membrane 522 than the first and second upper reinforcement portions 552, 554 (i.e., the first distance D1 is less than the second distance D2).

In some embodiments, the overlap between the first lower reinforcement portion 556 and the porous transport layer 520 (i.e., a length of the first lower reinforcement portion 556 located in the first pseudo step 528) and the overlap between the second lower reinforcement portion 558 and the porous transport layer 520 (i.e., a length of the second lower reinforcement portion 558 located in the second pseudo step) is about 1.5 mm to about 3.5 mm, including any range or specific number comprised therein. In some embodiments, the overlap is about 2.5 mm.

In illustrative embodiments, the overlap of the lower reinforcement portions 556, 558 and the porous transport layer 520 and the overlap of the upper reinforcement portions 552, 554 and the gas diffusion layer 518 are the same.

As shown in FIG. 13, the offset between the first upper reinforcement portion 552 and the first lower reinforcement portion 556 and the offset between the second upper reinforcement portion 554 and the second lower reinforcement portion 558 are both a third distance D3. In some embodiments, the third distance D3 is about 0.5 mm to about 3 mm, including any range or specific number comprised therein. In some embodiments, the third distance D3 is about 1.75 mm.

In some embodiments, the reinforced electrolyzer assembly 510 may further include a plurality of seals 560, as shown in FIG. 13-15B. The plurality of seals 560 is configured to seal between layers of the reinforced electrolyzer assembly 510. As shown in FIG. 13, the first gap G1 is a fourth distance D4 away from an adjacent seal of the plurality of seals 560. In some embodiments, the fourth distance D4 is about 3 mm to about 5 mm, including any range or specific number comprised therein. In In some embodiments, the fourth distance D4 is about 4 mm.

As shown in FIG. 13, the third gap G3 is a fifth distance D5 away from an adjacent seal of the plurality of seals 560. In some embodiments, the fifth distance D5 is about 1.25 mm to about 3.25 mm, including any range or specific number comprised therein. In some embodiments, the fifth distance D5 is about 2.25 mm.

As shown in FIGS. 14, 15A, and 15B, the gasket seal 560 is positioned on the lower reinforcement layer 550. Though shown with one gasket seal 560, it will be understood that another gasket seal 560 is positioned on the upper reinforcement layer 548. In this way, the discussion of the gasket seal 560 and the lower reinforcement layer 550 applies with equal weight to another gasket seal 560 and the upper reinforcement layer 548. Outside of the active area 532 of the membrane 522 (i.e., outside of the porous transport layer 520 and/or in areas surrounding the manifolds 555), a first extension E1 and a second extension E2 of the lower reinforcement layer 550 are defined, as shown in FIG. 15A. The first extension E1 is a portion of the lower reinforcement layer 550 that extends beyond the gasket seal 560 on a first lateral side thereof, and the second extension E2 is a portion of the lower reinforcement layer 550 that extends beyond the gasket seal 560 on a second lateral side thereof. In illustrative embodiments, the first extension E1 is equal to the second extension E2. In some embodiments, the first and second extensions E1, E2 are about 0.1 mm to about 3 mm, including any specific number or range of numbers comprised therein. In some embodiments, the first and second extensions E1, E2 are about 1 mm to about 2.5 mm, including any specific number or range of numbers comprised therein. In some embodiments, the first and second extensions E1, E2 are about 2 mm.

Inside of the active area 532 of the membrane 522 (i.e., inside of the porous transport layer 520), a third extension E3 and a fourth extension E4 of the lower reinforcement layer 550 are defined, as shown in FIG. 15B. The third extension E3 is a portion of the lower reinforcement layer 550 that extends beyond the gasket seal 560 on the first lateral side thereof, and the fourth extension E4 is a portion of the lower reinforcement layer 550 that extends beyond the gasket seal 560 on the second lateral side thereof to overlap with the porous transport layer 520. In illustrative embodiments, the third extension E3 is less than the fourth extension E4. In some embodiments, the third extension E3 is about 0.1 mm to about 1 mm, including any specific number or range of numbers comprised therein. In some embodiments, the third extension E3 is about 0.5 mm. In some embodiments, the fourth extension E4 is about 1 mm to about 4 mm, including any specific number or range of numbers comprised therein. In some embodiments, the fourth extension E4 is about 2.5 mm to about 4 mm, including any specific number or range of numbers comprised therein.

The fourth extension E4 is illustratively greater than the first and second extensions E1, E2. The larger fourth extension E4 provides overlap protection of the membrane 522 against the porous transport layer 520.

As previously described, the upper and lower reinforcement layers 548, 550 are smaller than the upper and lower reinforcement layers 48, 50 such that the upper and lower reinforcement layers 548, 550 do not match a shape of the frames 536, 538. Thus, the upper and lower reinforcement layers 548, 550 are cutback. As shown in FIG. 16, the cutback design of the upper and lower reinforcement layers 548, 550 allow the membrane 522 to directly contact the frames 536, 538 because the upper and lower reinforcement layers 548, 550 do not match the shape of the frames 536, 538. In this way, the membrane 522 directly contacts the frames 536, 538 and the upper and lower reinforcement layers 548, 550.

Due to the cutback design of the upper and lower reinforcement layers 548, 550, the membrane 522 encapsulates the upper and lower reinforcement layers 548, 550. After the reinforced electrolyzer assembly 510 is compressed, the upper and lower reinforcement layers 548, 550 will be embedded in the membrane 522, as shown in FIG. 16, such that the upper and lower reinforcement layers 548, 550 are trapped by the membrane 522 and prevented from extruding laterally. Thus, the membrane 522 helps to maintain a position of the upper and lower reinforcement layers 548, 550. The cutback design of the upper and lower reinforcement layers 548, 550 allows for more direct contact between the membrane 522 and the frames 536, 538 as compared to the reinforced electrolyzer assembly 10, 210, 310.

Illustratively, the upper and lower reinforcement layers 548, 550 comprise a polyimide film or a polyimide tape. In some embodiments, the upper and lower reinforcement layers 548, 550 comprise Kapton. In some embodiments, the upper and lower reinforcement layers 548, 550 comprise other polyimide films with specific advantageous properties, such as, but not limited to, Upilex or Kaptrex. In some embodiments, the upper and lower reinforcement layers 548, 550 comprise an adhesive material such that the upper and lower reinforcement layers 548, 550 adhere to and/or bind to the respective upper and lower frames 536, 538, the gas diffusion layer 518, and/or the porous transport layer 520. In some embodiments, the upper and lower reinforcement layers 548, 550 comprise a polyimide film 551 and an adhesive material 553.

In some embodiments, the upper and lower reinforcement layers 548, 550 comprise polyethylene naphthalate (PEN) 551 and an adhesive material 553.

In some embodiments, the polyimide film 551 and/or the PEN 551 has a thickness of about 8 μm to about 16 μm, including any specific number or range of numbers comprised therein. In some embodiments, the polyimide film 551 and/or the PEN 551 has a thickness of about 12 μm. In some embodiments, the adhesive material 553 has a thickness of about 2 μm to about 4 μm, including any specific number or range of numbers comprised therein. In some embodiments, the adhesive material 553 has a thickness of about 3 μm.

The following described aspects of the present invention are contemplated and non-limiting:

• • A first aspect of the present invention relates to a reinforced electrolyzer assembly. The reinforced electrolyzer assembly includes an electrolyzer cell, a frame, and a mechanical reinforcement system. The electrolyzer cell includes a gas diffusion layer, a porous transport layer spaced apart from the gas diffusion layer along a first axis, and a membrane located between the gas diffusion layer and the porous transport layer. The membrane is formed to include an active area and a non-active area located on each side of the active area of the membrane along a second axis that is perpendicular to the first axis. The frame includes an upper frame arranged above the non-active area of the membrane relative to the first axis and a lower frame arranged below the non-active area of the membrane relative to the first axis. The mechanical reinforcement system is configured to increase a mechanical stability of the membrane of the electrolyzer cell outside of the active area of the membrane so that shorting is minimized. The mechanical reinforcement system includes at least one of an upper reinforcement layer arranged between the upper frame and the non-active area of the membrane relative to the first axis and a lower reinforcement layer arranged between the non-active area of the membrane and the lower frame relative to the first axis.
  • A second aspect of the present invention relates to a method of forming a reinforced electrolyzer assembly. The method includes aligning a gas diffusion layer and an upper frame with one another to form a first component; aligning a porous transport layer, a lower frame, and a lower reinforcement layer with one another; adhering the lower reinforcement layer to the porous transport layer and the lower frame to form a second component, wherein the lower reinforcement layer is adhered to a first wall of the lower frame and a first wall of the porous transport layer; aligning the first component and the second component with a membrane to locate the membrane between the first component and the lower reinforcement layer of the second component; and coupling the first component and the second component to the membrane so that the lower reinforcement layer extends along a non-active area of the membrane to form the reinforced electrolyzer assembly.
  • A third aspect of the present invention relates to a method of forming a reinforced electrolyzer assembly. The method includes aligning a gas diffusion layer, an upper frame, and an upper reinforcement layer with one another; adhering the upper reinforcement layer to the gas diffusion layer and the upper frame to form a first component, wherein the upper reinforcement layer is adhered to a first wall of the upper frame and a first wall of the gas diffusion layer; aligning a porous transport layer and a lower frame with one another to form a second component; aligning the first component and the second component with a membrane to locate the membrane between the upper reinforcement layer of the first component and the second component; and coupling the first component and the second component to the membrane so that the upper reinforcement layer extends along a non-active area of the membrane to form the reinforced electrolyzer assembly.

In the first aspect of the present invention, the gas diffusion layer may include a first wall and a second wall opposite the first wall relative to the first axis. In the first aspect of the present invention, the gas diffusion layer may define a first step that extends inwardly from the first wall toward the second wall and a second step that extends inwardly from the first wall toward the second wall in spaced apart relation to the first step relative to the second axis.

In the first aspect of the present invention, the upper reinforcement layer may extend into the first step and the second step of the gas diffusion layer. In the first aspect of the present invention, the porous transport layer may include a first wall and a second wall opposite the first wall relative to the first axis. In the first aspect of the present invention, the porous transport layer may define a first step that extends inwardly from the first wall toward the second wall and a second step that extends inwardly from the first wall toward the second wall in spaced apart relation to the first step relative to the second axis. In the first aspect of the present invention, the lower reinforcement layer may extend into the first step and the second step of the porous transport layer.

In the first aspect of the present invention, the upper reinforcement layer may include a first upper reinforcement portion located in the first step of the gas diffusion layer and a second upper reinforcement portion spaced apart from the first upper reinforcement portion relative to the second axis and located in the second step of the gas diffusion layer. In the first aspect of the present invention, the lower reinforcement layer may include a first lower reinforcement portion located in the first step of the porous transport layer and a second lower reinforcement portion spaced apart from the first lower reinforcement portion relative to the second axis and located in the second step of the porous transport layer.

In the first aspect of the present invention, the first upper reinforcement portion and the second upper reinforcement portion may both have a first length defined along the second axis. In the first aspect of the present invention, the first lower reinforcement portion and the second lower reinforcement portion may both have a second length defined along the second axis. In the first aspect of the present invention, the first length is different than the second length.

In the first aspect of the present invention, the first upper reinforcement portion, the second upper reinforcement portion, the first lower reinforcement portion, and the second lower reinforcement portion may each have a first thickness defined along the first axis. In the first aspect of the present invention, the first step and the second step of the gas diffusion layer and the first step and the second step of the porous transport layer may each have the first thickness. In the first aspect of the present invention, the first step and the second step of the gas diffusion layer and the first step and the second step of the porous transport layer may each have a length, and the length may be about 2 mm to about 6 mm.

In the first aspect of the present invention, the upper frame may include a first upper plate and a second upper plate spaced apart from the first upper plate relative to the second axis to locate the gas diffusion layer between the first upper plate and the second upper plate. In the first aspect of the present invention, the lower frame may include a first lower plate and a second lower plate spaced apart from the first lower plate relative to the second axis to locate the porous transport layer between the first lower plate and the second lower plate.

In the first aspect of the present invention, a first gap may be formed between the first upper plate and the gas diffusion layer relative to the second axis, a second gap may be formed between the gas diffusion layer and the second upper plate relative to the second axis, a third gap may be formed between the first lower plate and the porous transport layer relative to the second axis, and a fourth gap may be formed between the porous transport layer and the second lower plate relative to the second axis. In the first aspect of the present invention, the first gap, the second gap, the third gap, and the fourth gap may each be about 0.1 mm to about 0.3 mm.

In the first aspect of the present invention, the upper reinforcement layer may include a first upper reinforcement portion located between the first upper plate and the non-active area of the membrane and a second upper reinforcement portion located between the second upper plate and the non-active area of the membrane. In the first aspect of the present invention, the lower reinforcement layer may include a first lower reinforcement portion located between the non-active area of the membrane and the first lower plate and a second lower reinforcement portion located between the non-active area of the membrane and the second lower plate.

In the first aspect of the present invention, the gas diffusion layer may have a first thickness above the active area of the membrane, the first upper reinforcement portion and the second upper reinforcement portion may have a second thickness, and the first upper plate and the second upper plate may have a third thickness. In the first aspect of the present invention, the first thickness may be greater than the third thickness, and the third thickness may be greater than the second thickness.

In the second aspect of the present invention, the step of aligning the gas diffusion layer and the upper frame to form the first component may include aligning the gas diffusion layer, the upper frame, and an upper reinforcement layer and adhering the upper reinforcement layer to a first wall of the gas diffusion layer and a first wall of the upper frame. In the second aspect of the present invention, the method may further comprise compressing a portion of the gas diffusion layer such that the gas diffusion layer is formed to define a first step and a second step spaced apart from the first step, the first step and the second step extending inwardly from the first wall of the gas diffusion layer toward a second wall of the gas diffusion layer opposite the first wall.

In the second aspect of the present invention, the method may further comprise compressing a portion of the porous transport layer such that the porous transport layer is formed to define a first step and a second step spaced apart from the first step, the first step and the second step extending inwardly from the first wall of the porous transport layer toward a second wall of the porous transport layer. In the second aspect of the present invention, the lower reinforcement layer may comprise an adhesive material and polyethylene naphthalate.

In the third aspect of the present invention, the step of aligning the porous transport layer and the lower frame with one another to form the second component may include aligning the porous transport layer, the lower frame, and a lower reinforcement layer and adhering the lower reinforcement layer to a first wall of the porous transport layer and a first wall of the lower frame. In the third aspect of the present invention, the method may further comprise compressing a portion of the porous transport layer such that the porous transport layer is formed to define a first step and a second step spaced apart from the first step, the first step and the second step extending inwardly from the first wall of the porous transport layer toward a second wall of the porous transport layer opposite the first wall.

In the third aspect of the present invention, the method may further comprise compressing a portion of the gas diffusion layer such that the gas diffusion layer is formed to define a first step and a second step spaced apart from the first step, the first step and the second step extending inwardly from the first wall of the gas diffusion layer toward a second wall of the gas diffusion layer.

The features illustrated or described in connection with one exemplary embodiment may be combined with any other feature or element of any other embodiment described herein. Such modifications and variations are intended to be included within the scope of the present disclosure. Further, a person skilled in the art will recognize that terms commonly known to those skilled in the art may be used interchangeably herein.

The above embodiments are described in sufficient detail to enable those skilled in the art to practice what is claimed and it is to be understood that logical, mechanical, and electrical changes may be made without departing from the spirit and scope of the claims. The detailed description is, therefore, not to be taken in a limiting sense.

As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the presently described subject matter are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Specified numerical ranges of units, measurements, and/or values comprise, consist essentially or, or consist of all the numerical values, units, measurements, and/or ranges including or within those ranges and/or endpoints, whether those numerical values, units, measurements, and/or ranges are explicitly specified in the present disclosure or not.

Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terms “first,” “second,” “third” and the like, as used herein do not denote any order or importance, but rather are used to distinguish one element from another. The term “or” is meant to be inclusive and mean either or all of the listed items. In addition, the terms “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect.

Moreover, unless explicitly stated to the contrary, embodiments “comprising,” “including,” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property. The term “comprising” or “comprises” refers to a composition, compound, formulation, or method that is inclusive and does not exclude additional elements, components, and/or method steps. The term “comprising” also refers to a composition, compound, formulation, or method embodiment of the present disclosure that is inclusive and does not exclude additional elements, components, or method steps.

The phrase “consisting of” or “consists of” refers to a compound, composition, formulation, or method that excludes the presence of any additional elements, components, or method steps. The term “consisting of” also refers to a compound, composition, formulation, or method of the present disclosure that excludes the presence of any additional elements, components, or method steps.

The phrase “consisting essentially of” or “consists essentially of” refers to a composition, compound, formulation, or method that is inclusive of additional elements, components, or method steps that do not materially affect the characteristic(s) of the composition, compound, formulation, or method. The phrase “consisting essentially of” also refers to a composition, compound, formulation, or method of the present disclosure that is inclusive of additional elements, components, or method steps that do not materially affect the characteristic(s) of the composition, compound, formulation, or method steps.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” and “substantially” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances, the modified term may sometimes not be appropriate, capable, or suitable.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used individually, together, or in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the subject matter set forth herein without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the disclosed subject matter, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter described herein should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

This written description uses examples to disclose several embodiments of the subject matter set forth herein, including the best mode, and also to enable a person of ordinary skill in the art to practice the embodiments of disclosed subject matter, including making and using the devices or systems and performing the methods. The patentable scope of the subject matter described herein is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.