Abstract: A method of manufacturing electrochemical cell stacks of different sizes or configurations is disclosed in which a first planar module having a first planar size and configuration is assembled from a first inventory of parts including planar modular parts having mating surfaces along connectable ends. The planar modular parts are connected in a co-planar configuration to form the first planar module having the first size and configuration. A second inventory of parts including planar modular parts in common with the first inventory is identified, and a second planar module having a different planar size or configuration than the first planar module is assembled from the second inventory. The first and second planar modules are assembled with other planar modules and component to form electrochemical stacks corresponding to the planar size and configuration of the respective first or second planar module.

Abstract: An electrochemical cell stack is disclosed having a plurality of stacked planar electrochemical cell modules, a first end plate at a first end of the stacked planar modules, and a second end plate at a second end of the stacked planar modules. Also included in the stack is an intermediate planar module disposed between adjacent electrochemical cells in the stack. In some aspects, the intermediate module includes a cavity disposed internally within the intermediate module that is in fluid communication with a fluid source at a pressure higher than the operating pressure of the electrochemical cell stack on either side of the intermediate module. In some aspects, the electrochemical cell stack includes an electrically conductive process liquid in fluid communication with a plurality of electrochemical cells in the stack, and the intermediate planar module includes an electrically non-conductive channel in fluid communication with the electrically conductive process liquid.

Abstract: A method of manufacturing electrochemical cell stacks of different sizes or configurations is disclosed in which a first planar module having a first planar size and configuration is assembled from a first inventory of parts including planar modular parts having mating surfaces along connectable ends. The planar modular parts are connected in a co-planar configuration to form the first planar module having the first size and configuration. A second inventory of parts including planar modular parts in common with the first inventory is identified, and a second planar module having a different planar size or configuration than the first planar module is assembled from the second inventory. The first and second planar modules are assembled with other planar modules and component to form electrochemical stacks corresponding to the planar size and configuration of the respective first or second planar module.

Abstract: A system is disclosed for providing hydrogen that includes a first PEM electrochemical cell or stack including a membrane electrode assembly that includes an inlet for a first gas that comprises hydrogen in fluid communication with the anode side of the first electrochemical cell or cell stack, and an outlet in fluid communication with the cathode side of the first electrochemical cell or stack. A second electrochemical cell or cell stack includes a water inlet in fluid communication with the anode side of the second electrochemical cell or cell stack, and an outlet in fluid communication with the cathode side of the second electrochemical cell or cell stack. A controller is configured to operate the first electrochemical cell or cell stack as a primary hydrogen source and to controllably operate the second electrochemical cell or cell stack as a secondary hydrogen source.

Abstract: An electrochemical cell stack is disclosed having a plurality of stacked planar electrochemical cell modules, a first end plate at a first end of the stacked planar modules, and a second end plate at a second end of the stacked planar modules. Also included in the stack is an intermediate planar module disposed between adjacent electrochemical cells in the stack. In some aspects, the intermediate module includes a cavity disposed internally within the intermediate module that is in fluid communication with a fluid source at a pressure higher than the operating pressure of the electrochemical cell stack on either side of the intermediate module. In some aspects, the electrochemical cell stack includes an electrically conductive process liquid in fluid communication with a plurality of electrochemical cells in the stack, and the intermediate planar module includes an electrically non-conductive channel in fluid communication with the electrically conductive process liquid.

Abstract: A system is disclosed for providing hydrogen that includes a first PEM electrochemical cell or stack including a membrane electrode assembly that includes an inlet for a first gas that comprises hydrogen in fluid communication with the anode side of the first electrochemical cell or cell stack, and an outlet in fluid communication with the cathode side of the first electrochemical cell or stack. A second electrochemical cell or cell stack includes a water inlet in fluid communication with the anode side of the second electrochemical cell or cell stack, and an outlet in fluid communication with the cathode side of the second electrochemical cell or cell stack. A controller is configured to operate the first electrochemical cell or cell stack as a primary hydrogen source and to controllably operate the second electrochemical cell or cell stack as a secondary hydrogen source.

Abstract: A compression member for an electrochemical cell stack is provided. The compression member includes a first surface including a plurality of raised portions, a second surface including a substantially flat surface, and an edge defined by the first surface and the second surface. The plurality of raised portions is aligned to define a plurality of receiving areas. The plurality of raised portions and the plurality of receiving areas are configured such application of an axial compressive force spreads the plurality of raised portions into the plurality of receiving areas. The edge includes a portion configured to receive an electrochemical cell terminal therethrough. The compression member is formed of electrically non-conductive materials.

Abstract: An electrochemical cell includes a first electrode, a second electrode, and a proton exchange membrane disposed between and in intimate contact with the electrodes. The proton exchange membrane is configured to be integral with a frame structure and includes a substrate disposed in contiguous contact with the frame structure and a proton exchange material disposed at the substrate.

Abstract: An electrochemical cell includes a first electrode, a second electrode, a proton exchange membrane disposed between and in intimate contact with the electrodes, and a pressure pad disposed in electrical communication with the first electrode. The pressure pad is compatible with the cell environment and is configured to support the electrodes and the membrane. The pressure pad includes an electrically conductive member and a compression member disposed at the electrically conductive member. A method of maintaining compression within the cell includes disposing the electrically conductive member and the compression member at the first electrode, applying a load at the cell to compress the cell components, and maintaining electrical communication through the electrically conductive member.

Abstract: An electrochemical cell capable of operating in pressure differentials exceeding about 2,000 psi, using a porous electrode. The porous electrode comprises a catalyst adsorbed on or in a porous support that is disposed in intimate contact and fluid communication with the electrolyte membrane.

Abstract: A compression member for an electrochemical cell stack is provided. The compression member includes a first surface including a plurality of raised portions, a second surface including a substantially flat surface, and an edge defined by the first surface and the second surface. The plurality of raised portions is aligned to define a plurality of receiving areas. The plurality of raised portions and the plurality of receiving areas are configured such application of an axial compressive force spreads the plurality of raised portions into the plurality of receiving areas. The edge includes a portion configured to receive an electrochemical cell terminal therethrough. The compression member is formed of electrically non-conductive materials.

Abstract: A compression member for an electrochemical cell stack is provided. The compression member includes a first surface including a plurality of raised portions, a second surface including a substantially flat surface, and an edge defined by the first surface and the second surface. The plurality of raised portions is aligned to define a plurality of receiving areas. The plurality of raised portions and the plurality of receiving areas are configured such application of an axial compressive force spreads the plurality of raised portions into the plurality of receiving areas. The edge includes a portion configured to receive an electrochemical cell terminal therethrough. The compression member is formed of electrically non-conductive materials.

Abstract: An electrochemical cell in which the cell frame is integrated with the flow field support member defining a contiguous surface includes an electrode, a proton exchange membrane and a flow field support member disposed at the electrode, a cell frame disposed at the flow field support member, and a membrane support element disposed intermediate the flow field support member and the frame. A resilient seal may be disposed at the cell frame. A method of integrating the frame with the flow field support member includes disposing the membrane support element in a gap between the frame and the flow field support member and melting the membrane support element into the frame and the flow field support member to form a contiguous surface. A method of sealing a flow field of the cell includes disposing a resilient seal at the cell frame.

Abstract: An electrochemical cell includes a first electrode, a second electrode, and a proton exchange membrane disposed between and in intimate contact with the electrodes. The proton exchange membrane is configured to be integral with a frame structure and includes a substrate disposed in contiguous contact with the frame structure and a proton exchange material disposed at the substrate.

Abstract: An electrochemical cell capable of operating in pressure differentials exceeding about 2,000 psi, using a porous electrode. The porous electrode comprises a catalyst adsorbed on or in a porous support that is disposed in intimate contact and fluid communication with the electrolyte membrane.

Abstract: An integral screen/frame assembly for use in an electrochemical cell for supporting and facilitating the hydration of a solid membrane. The screen/frame assembly is comprised of planar screen layers having the frame disposed about the periphery of those layers such that the frame bonds the layers together.

Abstract: An electrochemical cell capable of operating in pressure differentials exceeding about 2,000 psi, using a porous electrode. The porous electrode comprises a catalyst adsorbed on or in a porous support that is disposed in intimate contact and fluid communication with the electrolyte membrane.

Abstract: One embodiment of a method of operating an electrochemical cell system comprises: flowing supply water to an anode electrode of an electrolysis cell, applying a first current density to the electrolysis cell, electrolyzing the supply water at the anode electrode wherein hydrogen ions and a first portion water migrate to a cathode electrode of the electrolysis cell, collecting the first portion of water in a chamber in fluid communication with the cathode electrode, monitoring a first portion water level in the chamber, when the first portion water level attains a first selected level, decreasing the supply water flow to the anode electrode a sufficient amount to draw the first portion water from the chamber to the anode electrode, and electrolyzing the first portion water.

Abstract: The unique cell frame of the present invention comprises an integral protector portion. This protector portion comprises a rigid or flexible lip on the membrane side of the cell frame. In an assembled cell stack, the membrane assembly is disposed between two cell frames on the side of the cell frames having the protector portion. Screen assemblies are disposed on the opposite side of the cell frame such that the screen assemblies rest on the protector portion, within the cell frame. The protector portion prevents the edge of the screen assemblies from pinching, cutting, or otherwise damaging the membrane.

Abstract: The present invention relates to a unique electrochemical cell stack which employs an electrically conductive pressure pad. The pressure pad is composed of material compatible with the electrochemical cell environment and is disposed on the high pressure side of the membrane assembly, in intimate contact with the high pressure side screen pack.