Abstract: A method of manufacture includes an electrochemical cell structure having a first conductive member and a second conductive member. The first conductive member is spaced from the second conductive member. An adhesive is disposed between the first conductive member and the second conductive member. The adhesive has a solid state and a liquid state. The adhesive is liquefied to form a seal between the first conductive member and the second conductive member.

Abstract: A fuel cell system includes a first electrode-electrolyte assembly having a first electrode coupled to one side of the first electrode-electrolyte assembly and a second electrode coupled to an opposite side of the first electrode-electrolyte assembly and a second electrode-electrolyte assembly having a third electrode coupled to one side of the second electrode-electrolyte assembly and a fourth electrode coupled to an opposite side of the second electrode-electrolyte assembly. A first conduit is in fluid communication with the first electrode and a second conduit is in fluid communication with the fourth electrode and an electrically conductive mesh positioned between the second electrode and the third electrode. Portions of the second and third electrodes engage each other through apertures defined by the mesh. The fuel cell system also includes an electricity source connected to the first and second electrodes; and an electrical circuit connected to the first conduit and the second conduit.

Abstract: A fuel cell system includes a first electrode-electrolyte assembly having a first electrode coupled to one side of the first electrode-electrolyte assembly and a second electrode coupled to an opposite side of the first electrode-electrolyte assembly and a second electrode-electrolyte assembly having a third electrode coupled to one side of the second electrode-electrolyte assembly and a fourth electrode coupled to an opposite side of the second electrode-electrolyte assembly. A first conduit is in fluid communication with the first electrode and a second conduit is in fluid communication with the fourth electrode and an electrically conductive mesh positioned between the second electrode and the third electrode. Portions of the second and third electrodes engage each other through apertures defined by the mesh. The fuel cell system also includes an electricity source connected to the first and second electrodes; and an electrical circuit connected to the first conduit and the second conduit.

Abstract: A method of manufacture includes an electrochemical cell structure having a first conductive member and a second conductive member. The first conductive member is spaced from the second conductive member. An adhesive is disposed between the first conductive member and the second conductive member. The adhesive has a solid state and a liquid state. The adhesive is liquefied to form a seal between the first conductive member and the second conductive member.

Abstract: An electrochemical cell has an anode cavity and a cathode cavity. The anode cavity and the cathode cavity sandwich an electrochemically conductive medium. The anode cavity and/or the cathode cavity have electrically conductive plates assembled using a solid bonding material. Each plate has nesting volumes and protrusions provided in the perimeter seal area. The protrusions of one plate fit into the volumes of an adjacent plate to eliminate the offset introduced by the bonding material thickness.

Abstract: A fluid conduit for use in an electrochemical cell, the fluid conduit comprising a support comprising an elastically deformable material and having a plurality of apertures extending therethrough defining a mesh through which fluid communication can be maintained and a peripheral sealing area; a flow plate positioned adjacent the support, the flow plate including an inlet and an outlet; and a separator positioned adjacent the support. The support, flow plate, and separator are sealingly engaged with one another and cooperate to define a plurality of flow paths in fluid communication with and extending axially between the inlet and the outlet. The support, flow plate, and separator can be comprised of a metallic material coated with an electrically conductive joining compound for providing sealing engagement and electrically conductive communication therebetween.

Abstract: A fuel cell system including an electrode-electrolyte assembly having a first catalytic electrode coupled to one side of the electrode-electrolyte assembly, and a second catalytic electrode coupled to a generally opposite side of the electrode-electrolyte assembly. The fuel cell system includes a first conduit in fluid communication with the first catalytic electrode for delivering fuel to the first catalytic electrode at ambient temperature and a second conduit in fluid communication with the second catalytic electrode for delivering oxidant thereto. The fuel cell system also includes means for providing an electrical potential across the first catalytic electrode, the electrode-electrolyte assembly and the second catalytic electrode and the fuel cell system further includes an electrical load circuit for using an energy output generated across the first catalytic electrode, the electrode-electrolyte assembly and the second catalytic electrode.

Abstract: A fuel cell system comprising a first electrode-electrolyte assembly having a first electrode coupled to one side of thereof and a second electrode coupled to a generally opposite side of the first electrode-electrolyte assembly, and a first conduit for delivering fuel to the first electrode at ambient temperature. The fuel cell system includes a second electrode-electrolyte assembly having a third electrode coupled thereto assembly, and a fourth electrode coupled to a generally opposite side of the second electrode-electrolyte assembly; and a mesh positioned between and in sealing engagement with the second electrode and the third electrode. A second conduit is in fluid communication with the fourth electrode for delivering oxidant thereto. The fuel cell system further includes means for providing an electrical potential across the first electrode-electrolyte assembly and an electrical load circuit for using an energy output generated across the second electrode-electrolyte assembly.

Abstract: A support member is useful for supporting membranes such as solid polymer electrolyte ion exchange membranes such as those used in electrochemical cell applications. The support member has a first lattice pattern on a first side of a single piece of material. A second lattice pattern on a second side of the single piece of material cooperates with the first lattice pattern to establish a plurality of flow passages across the material. Each lattice pattern has a corresponding plurality of recesses that extend partway through the material and overlapping portions of the recesses define the flow passages. In a disclosed example, the monolithic support member lattice patterns are established using chemical etching.

Abstract: A fuel cell system comprising a first electrode-electrolyte assembly having a first electrode coupled to one side of thereof and a second electrode coupled to a generally opposite side of the first electrode-electrolyte assembly, and a first conduit for delivering fuel to the first electrode at ambient temperature. The fuel cell system includes a second electrode-electrolyte assembly having a third electrode coupled thereto assembly, and a fourth electrode coupled to a generally opposite side of the second electrode-electrolyte assembly; and a mesh positioned between and in sealing engagement with the second electrode and the third electrode. A second conduit is in fluid communication with the fourth electrode for delivering oxidant thereto. The fuel cell system further includes means for providing an electrical potential across the first electrode-electrolyte assembly and an electrical load circuit for using an energy output generated across the second electrode-electrolyte assembly.

Abstract: A fluid conduit for use in an electrochemical cell, the fluid conduit comprising a support comprising an elastically deformable material and having a plurality of apertures extending therethrough defining a mesh through which fluid communication can be maintained and a peripheral sealing area; a flow plate positioned adjacent the support, the flow plate including an inlet and an outlet; and a separator positioned adjacent the support. The support, flow plate, and separator are sealingly engaged with one another and cooperate to define a plurality of flow paths in fluid communication with and extending axially between the inlet and the outlet. The support, flow plate, and separator can be comprised of a metallic material coated with an electrically conductive joining compound for providing sealing engagement and electrically conductive communication therebetween.

Abstract: An electrochemical cell has an anode cavity and a cathode cavity. The anode cavity and the cathode cavity sandwich an electrochemically conductive medium. The anode cavity and/or the cathode cavity have electrically conductive plates assembled using a solid bonding material. Each plate has nesting volumes and protrusions provided in the perimeter seal area. The protrusions of one plate fit into the volumes of an adjacent plate to eliminate the offset introduced by the bonding material thickness.

Abstract: A support member is useful for supporting membranes such as solid polymer electrolyte ion exchange membranes such as those used in electrochemical cell applications. The support member has a first lattice pattern on a first side of a single piece of material. A second lattice pattern on a second side of the single piece of material cooperates with the first lattice pattern to establish a plurality of flow passages across the material. Each lattice pattern has a corresponding plurality of recesses that extend partway through the material and overlapping portions of the recesses define the flow passages. In a disclosed example, the monolithic support member lattice patterns are established using chemical etching.

Abstract: A water electrolysis system includes a water electrolysis cell stack having an anode and a cathode. A water storage tank having an outlet is disposed above the cell stack and communicates with an inlet of one of the anode and the cathode of the cell stack for gravity feeding water from the water storage tank to the cell stack. A phase separator is disposed below and in communication with the water storage tank. The phase separator has an inlet for receiving a two phase stream including water and product gas exiting an outlet of the one of the anode and cathode of the cell stack, and includes a conduit having a lower end disposed within the phase separator for receiving water recovered in the phase separator. The conduit has an upper end extending into the water storage tank.

Abstract: An electrochemical cell electrode plate structure, a high-pressure electrochemical cell device, and a method for preparing such devices, are provided. The inventive electrode plate structure comprises a laminar assembly of slotted plate-shaped components that provides more uniform openings or flow passages across the active areas thereof. The inventive high-pressure electrochemical cell device comprises at least one cell made up of both slotted and unslotted plate-shaped components that are free of material deformations typically resulting from the high compressive force employed during final cell assembly. The inventive method for preparing such devices basically involves preparing at least one laminated sub-assembly comprising unslotted component layers for the purpose of consolidating such weaker layers into stronger sub-assemblies prior to a final lamination step.

Abstract: An electrically non-conductive plate structure, for use in high pressure electrochemical cells employing ion-exchange membranes that creep or flow under pressure, is provided. Such plate structures are provided with a means for impeding membrane creep or flow when the cells are subjected to high axial loadings. When two such structures are positioned on either side of an ion-exchange membrane, so as to forcibly contact the surfaces thereof, such structures serve to contain, and thereby form a fluid tight seal with, the membrane while maintaining the electrical integrity of the cell.

Abstract: A graded metal hardware component for an electrochemical cell is shown for mechanically supporting electrochemical cell structures and defining fluid cavities and fluid passages in a cell employing a solid polymer electrolyte membrane. The graded metal hardware component includes a substrate such as stainless steel, a surface layer made of a precious metal such as gold, and a graded boundary layer adjacent to and between the substrate and surface layer, wherein the graded boundary layer is an interdiffusion of the substrate and surface layer so that the graded boundary layer is between 0.5 wt. %-5.0 wt. % of the material making up the substrate, and between 99.5 wt. %-95.0 wt. % of the material making up the surface layer, and the graded boundary layer has a thickness of between 10%-90% of a shortest distance between the substrate and an exterior surface of the surface layer.

Abstract: Accumulated dimensional variations in fuel cells and electrolysis cell assemblies can reduce the efficiency of the assembly and provide leakage paths for fuel and oxidant. A metal compression pad comprised of a metal having an elastic strain of about 3% to about 40% at about 2,500 psig can compensate for component dimensional variations and improve inter-cell conductivity at pressures up to and exceeding about 10,000 psig.

Abstract: Due to the limited structural integrity of the ion exchange membrane, operation at pressure gradients exceeding about 200 psi can cause electrolyzer failure due to the ion exchange membrane being physically forced into the holes of the screen set forming the chamber on the lower pressure side of the ion exchange membrane. Utilizing a porous sheet between the anode electrode and the screen set provides additional structural integrity to the ion exchange membrane and allows simultaneous dual-directional flow of water to the anode electrode while oxygen flows from the anode electrode, thereby allowing high pressure gradient operation.

Abstract: Accumulated dimensional variations in fuel cells and electrolysis cell assemblies can reduce the efficiency of the assembly and provide leakage paths for fuel and oxidant. A metal compression pad comprised of a metal having an elastic strain of about 3% to about 40% at about 2,500 psig can compensate for component dimensional variations and improve inter-cell conductivity at pressures up to and exceeding about 10,000 psig.