FLUID FLOW PATHWAYS IN FLOW FIELDS OF ELECTROCHEMICAL CELLS

Abstract

The following disclosure relates to electrochemical or electrolysis cells and components thereof. More specifically, the following disclosure relates to improved flow fields with fluidic pathways within electrochemical cells. Flow fields comprise channels formed from a first side wall, a second side wall, and a back wall connecting an end of the first side wall with an end of the second side wall with a plurality of perforations in the walls of Outlet channels in the flow fields.

Description

This application claims the benefit of U.S. Provisional Patent Application No. 63/458,202, filed Apr. 10, 2023, which is hereby incorporated by reference in its entirety.

FIELD

The following disclosure relates to electrochemical or electrolysis cells and components thereof. More specifically, the following disclosure relates to improved flow fields with fluidic pathways within electrochemical cells.

BACKGROUND

Hydrogen has been considered as an ideal energy carrier to store renewable energy. Proton exchange membrane water electrolysis (PEMWE) as a means for hydrogen production offers high product purity, fast load response times, small footprints, high efficiencies, and low maintenance efforts. It is regarded as a promising technology, especially when coupled with renewable energy sources.

An electrolysis cell or system uses electrical energy to drive a chemical reaction. For example, water is split to form hydrogen and oxygen. The products may be used as energy sources for later use. In recent years, improvements in operational efficiency have made electrolyzer systems competitive market solutions for energy storage, generation, and/or transport. For example, the cost of generation may be below $10 per kilogram of hydrogen in some cases. Increases in efficiency and/or improvements in operation will continue to drive the installation of electrolyzer systems.

Porous transport layers (PTLs) and gas diffusion layers (GDLs) play important roles in electrochemical cell performance. A PTL, positioned between a membrane and an anode flow field of the electrochemical cell, may assist in transporting water and oxygen on the anode side and in transporting electrons away from the membrane. A GDL, positioned between the membrane and a cathode flow field of the electrochemical cell, may assist in transporting hydrogen on the cathode side of the cell and in transporting electrons towards the membrane.

There remains a desire for improved performance properties within electrochemical cells, including improved fluid transport within the cell.

SUMMARY

In one embodiment, a flow field for an electrochemical cell is described. The flow field includes an inlet to receive fluid, an outlet to transfer fluid out of the electrochemical cell, a plurality of channels, a plurality of lands, and a plurality of perforations. The plurality of channels extends in a direction between the inlet and the outlet. Each channel of the plurality of channels is configured to transfer fluid from the inlet to an adjacent layer of the electrochemical cell, and each channel of the plurality of channels has a first side wall, a second side wall, and a back wall. The back wall connects an end of the first side wall with an end of the second side wall. The plurality of lands extends in the direction between the inlet and the outlet. Each land of the plurality of lands is configured to abut the adjacent layer of the electrochemical cell, and each land of the plurality of lands separates and connects two adjacent channels of the plurality of channels at ends of respective side walls opposite from the back wall of the respective channels. The plurality of perforations is in the first side wall and/or the second side wall of one or more channels of the plurality of channels. Each perforation of the plurality of perforations is configured to transfer fluid from the respective channel to a cavity formed between the flow field and an adjacent flow field for an additional electrochemical cell that abuts the flow field of the electrochemical cell.

In another embodiment, an electrochemical cell is described. The electrochemical cell includes a flow field, a membrane, and an adjacent layer that is positioned between the flow field and the membrane. The flow field includes an inlet to receive fluid, an outlet to transfer the fluid out of the electrochemical cell, and a plurality of channels extending in a direction between the inlet and the outlet. Each channel of the plurality of channels is configured to transfer fluid from the inlet to the adjacent layer, and each channel of the plurality of channels has a first side wall, a second side wall, and a back wall connecting an end of the first side wall with an end of the second side wall. The flow field further includes a plurality of lands extending the direction between the inlet and the outlet. Each land of the plurality of lands is configured to abut the adjacent layer, and each land of the plurality of lands separates and connects two adjacent channels of the plurality of channels at ends of respective side walls opposite from the back wall of the respective channels. In addition, the flow field includes a plurality of perforations in the first side wall and/or the second side wall of one or more channels of the plurality of channels. Each perforation of the plurality of perforations is configured to transfer fluid from the respective channel to a cavity formed between the flow field and an adjacent flow field for an additional electrochemical cell that abuts the flow field of the electrochemical cell.

In another embodiment, an electrochemical system is described. The electrochemical system includes a plurality of electrochemical cells stacked on top of one another. A first electrochemical cell and a second electrochemical cell of the plurality of electrochemical cells include a flow field, a membrane, and an adjacent layer positioned between the flow field and the membrane. The flow field includes an inlet to receive fluid, an outlet to transfer the fluid out of the electrochemical cell, and a plurality of channels extending in a direction between the inlet and the outlet. Each channel of the plurality of channels is configured to transfer fluid from the inlet to the adjacent layer, and each channel of the plurality of channels has a first side wall, a second side wall, and a back wall connecting an end of the first side wall with an end of the second side wall. The flow field further includes a plurality of lands extending in the direction between the inlet and the outlet, and each land of the plurality of lands is configured to abut the adjacent layer. Each land of the plurality of lands separates and connects two adjacent channels of the plurality of channels at ends of respective side walls opposite from the back wall of the respective channels. Furthermore, the flow field includes a plurality of perforations in the first side wall and/or the second side wall of one or more channels of the plurality of channels. Each perforation of the plurality of perforations is configured to transfer fluid from the respective channel to a cavity formed between the flow field of the first electrochemical cell and the flow field of the second electrochemical cell.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments are described herein with reference to the following drawings.

FIG. 1A depicts an example of an electrochemical system including an electrochemical stack having a plurality of electrochemical cells.

FIG. 1B depicts an example of an electrolytic cell.

FIG. 2 depicts an additional example of an electrolytic cell.

FIGS. 3A, 3B, and 3C depict cross-sectional views of an exemplary electrochemical cell with a limited number of flow channels of flow fields depicted for clarity.

FIGS. 4A and 4B depict a side view and a top view, respectively, of portion of such an electrode flow field having a limited number of flow channels and lands depicted for clarity.

FIG. 5 illustrates a section of an interface (e.g., anode interface or cathode interface) of an electrochemical or electrolytic cell including a flow field of the present disclosure.

FIG. 6 illustrates another embodiment of a portion of an electrochemical cell including a flow field of the present disclosure, wherein the flow field includes a plurality of perforations in alternating pattern of locations.

FIG. 7 illustrates, in an exploded view, another example of a portion of an electrochemical cell including a flow field of the present disclosure and a support layer.

FIGS. 8A and 8B illustrate embodiments of portions of electrochemical cells including a flow field of the present disclosure and a support layer, wherein the flow field includes a plurality of perforations in an alternating pattern of locations.

FIG. 9 illustrates an example of an electrochemical system including portions of adjacent electrochemical cells.

FIG. 10 illustrates another example of an electrochemical system including portions of adjacent electrochemical cells.

FIG. 11 illustrates yet another example of an electrochemical system including a support layer positioned between two adjacent electrochemical cells.

FIG. 12 illustrates yet another example of an electrochemical system including a support layer positioned between two adjacent electrochemical cells.

FIG. 13 illustrates another example of an electrochemical system including a support layer positioned between two adjacent electrochemical cells, wherein the support layer has a plurality of perforations.

FIG. 14 illustrates yet another example of an electrochemical system including a support layer positioned between two adjacent electrochemical cells, wherein the support layer has a plurality of perforations.

DETAILED DESCRIPTION

The following disclosure provides an improved flow field for an electrochemical or electrolytic cell for hydrogen gas and oxygen gas production through the splitting of water. A plurality of perforations are present in the improved flow field to provide cavities that may be part of fluid pathways between the flow field and an adjacent layer, cell within a stack, or support layer positioned between adjacent cells of the stack.

The cavities contribute to the flow field performance. The plurality of perforations provide fluid connections to the cavities between the flow field and either an adjacent layer, a support layer, and/or an additional flow field from an additional electrochemical cell within the stack. Utilizing the cavities through the fluid connections created by the plurality of perforations advantageously allow for larger fluidic pathways through the flow fields, which enable lower pressure drops with constant flow rates, enable more area contact between the fluids and the layers of the electrochemical cell (e.g., improving heat transfer between the different layers), and allow for pressure balancing between the outside and inside of the flow field to structurally help the flow field. The plurality of perforations may advantageously facilitate an improved fluid transfer or removal of gas (e.g., gaseous product) from the flow field in comparison with a similar electrochemical cell, not including such perforations in the flow field of the cell.

Furthermore, the plurality of perforations may advantageously create additional fluid flow paths, allowing separate fluid to flow through the cell and improving the electrochemical cell's efficiency.

By improving efficiency of the electrochemical cell, this may advantageously allow for an increase in an amount of reactant water supplied to the membrane/catalyst layer of the cell, therein allowing the cell to operate at higher power levels without a mass transfer limitation occurring. Additionally, improving efficiency of the removal of gaseous products from the cell may advantageously create a more uniform gas-liquid saturation profile throughout the porous layer of the cell. Further, a more uniform gas-liquid saturation profile may advantageously provide a more uniform temperature distribution across the cell.

Electrochemical Cells and Stacks

FIG. 1A depicts an example of an electrochemical system including an electrochemical stack having a plurality of electrochemical cells. In certain examples, the electrochemical stack may contain 50-1000 cells, 50-100 cells, 500-700 cells, or more than 1000 cells. Any number of cells may make up a stack. The electrochemical cells within the electrochemical stack may be configured to operate with 200 mV or less of pure resistive loss when operating at a high current density (e.g., at least 3 Amps/cm², at least 4 Amps/cm², at least 5 Amps/cm², at least 6 Amps/cm², at least 7 Amps/cm², at least 8 Amps/cm², at least 9 Amps/cm², at least 10 Amps/cm², at least 11 Amps/cm², at least 12 Amps/cm², at least 13 Amps/cm², at least 14 Amps/cm², at least 15 Amps/cm², at least 16 Amps/cm², at least 17 Amps/cm², at least 18 Amps/cm², at least 19 Amps/cm², at least 20 Amps/cm², at least 25 Amps/cm², at least 30 Amps/cm², in a range of 1-30 Amps/cm², in a range of 3-20 Amps/cm², in a range of 3-15 Amps/cm², in a range of 3-10 Amps/cm², or in a range of 10-20 Amps/cm²). In additional examples, the amount of water (e.g., deionized (DI) water) transferred to or circulated through each cell of the stack may be in a range of 0.25-1 mL/Amp/cell/min, in a range of 0.25-5 mL/Amp/cell/min, or in a range of 0.5-1 mL/Amp/cell/min.

As illustrated in the system of FIG. 1A, water (H₂O) may be supplied to the anodic inlet of an electrolytic cell stack 12. In some embodiments, only the anodic inlet of the cell stack 12 may receive water. In these embodiments, the cathode side of the cell stack 12 may not receive water (e.g., a dry cathode side may be used). In another embodiment, a cathode inlet may also receive water, wherein the water may be supplied to the cathode inlet to cool the cell stack 12 during electrolysis.

The water supplied to the anodic inlet flows to an anodic inlet manifold that distributes the water to the anode side of the plurality of cells contained with the cell stack 12. In embodiments where water is supplied to the cathode inlet, water supplied to the cathode inlet flows to a cathodic inlet manifold that distributes the water to the cathode side of the plurality of cells in the cell stack 12. In certain examples, the amount of water (e.g., deionized (DI) water) transferred to or circulated through each cell of the stack may be in a range of 0.25-5 mL/Amp/cell/min.

During electrolysis, oxygen (O₂) is produced at the anode side of the electrolytic cells and hydrogen (H₂) is produced at the cathode side of the electrolytic cells. Specifically, a water splitting electrolysis reaction is configured to take place within each individual cell in the cell stack 12. Each cell includes one interface (the anode side of the cell) configured to run an oxygen evolution reaction (OER) and another interface (the cathode side of the cell) configured to run a hydrogen evolution reaction (HER) (such as depicted in FIG. 1B).

During electrolysis, some of the water supplied to the anode side of an electrolytic cell may not be converted into oxygen. Accordingly, a two-phase flow of oxygen and unreacted water is outlet from each of the anode sides of the cells into an anodic outlet manifold 13. The two-phase flow of oxygen and unreacted water flows from out of the cell stack 12 through the anodic outlet manifold 13. This stream within the anodic outlet manifold 13 may be configured to be transferred to a gas detection and conditioning system, such as described in greater detail below, for analysis of the composition within the stream. Specifically, this anodic stream may be analyzed to identify if any undesirable hydrogen gas has leaked (i.e., cross-leaked) across the membranes from the cathode sides of the cells to the anode sides of the cells within the cell stack.

Additionally, in some embodiments, water may be supplied to the cathode side of the cell stack as a coolant. Accordingly, a two-phase flow of hydrogen and water is outlet from each of the cathode sides of the cells to a cathodic outlet manifold 14. The two-phase flow of hydrogen and water flows out of the cell stack 12 through the cathodic outlet manifold 14. Similarly, this particular stream within the cathodic outlet manifold 14 may be configured to be transferred to a gas detection and conditioning system (separate from the anodic gas detection and conditioning system) for analysis of the composition within the stream. Specifically, this cathodic stream may be analyzed to identify if any undesirable oxygen gas has leaked (i.e., cross-leaked) across the membranes from the anode sides of the cells to the cathode sides of the cells within the cell stack.

FIG. 1B depicts an example of an electrochemical or electrolytic cell for hydrogen gas and oxygen gas production through the splitting of water. The electrolytic cell includes a cathode, an anode, and a membrane positioned between the cathode and anode. The membrane may be a catalyst coated membrane (CCM) such as a proton exchange membrane (PEM). Proton Exchange Membrane (PEM) electrolysis involves the use of a solid electrolyte or ion exchange membrane. Within the water splitting electrolysis reaction, one interface runs an oxygen evolution reaction (OER) while the other interface runs a hydrogen evolution reaction (HER). For example, the anode reaction is H₂O→2H⁺+½O₂+2e and the cathode reaction is 2H⁺+2e→H₂.

FIG. 2 depicts an additional example of an electrochemical or electrolytic cell.

Specifically, FIG. 2 depicts a portion of an electrochemical cell 200 having a cathode flow field 202, an anode flow field 204, and a membrane 206 positioned between the cathode flow field 202 and the anode flow field 204.

In certain examples, the membrane 206 may be a catalyst coated membrane (CCM) having a cathode catalyst layer 205 and/or an anode catalyst layer 207 positioned on respective surfaces of the membrane 206. As used throughout this disclosure, the term “membrane” may refer to a catalyst coated membrane (CCM) having such catalyst layers.

In certain examples, additional layers may be present within the electrochemical cell 200. For example, one or more additional layers 208 may be positioned between the cathode flow field 202 and membrane 206. In certain examples, this may include a gas diffusion layer (GDL) 208 positioned between the cathode flow field 202 and membrane 206. This may be advantageous in providing a hydrogen diffusion barrier adjacent to the cathode on one side of the multi-layered membrane to mitigate hydrogen crossover to the anode side. In other words, the GDL is responsible for the transport of gaseous hydrogen to the cathode side flow field. For a wet cathode PEM operation, liquid water transport across the GDL is needed for heat removal in addition to heat removal from the anode side.

In certain examples, the GDL is made from a carbon paper or woven carbon fabrics. The GDL is configured to allow the flow of hydrogen gas to pass through it. The thickness of the GDL may be within a range of 100-1000 microns, for example. As used herein, a “thickness” by which a film is characterized refers to the distance, or median measured distance, between the top and bottom faces of a film in a direction perpendicular to the plane of the film layer. As used herein, the top and bottom faces of a film refer to the sides of the film extending in a parallel direction of the plane of the film having the largest surface area.

The thickness may affect the mass transport within the cell as well as the durability/deformability and electrical/thermal conductivity of the GDL. In other words, a thinner GDL may provide better mass transport, lower resistance, and a reduction in durability (e.g., greater chance for localized deformation).

Similarly, one or more additional layers 210 may be present in the electrochemical cell between the membrane 206 and the anode flow field 204. In certain examples, this may include a porous transport layer (PTL) positioned between the membrane 206 (e.g., the anode catalyst layer 207 of the catalyst coated membrane 206) and the anode flow field 204.

In certain examples, the PTL is made from a titanium (Ti) mesh/felt or Ti sinter.

As used herein, a Ti mesh/felt may refer to a structure created from microporous Ti fibers. The Ti felt structure may be sintered together by fusing some of the fibers together. Ti felt may be made by a special laying process and a special ultra-high temperature vacuum sintering process. The Ti felt may have an excellent three-dimensional network, porous structure, high porosity, large surface area, uniform pore size distribution, special pressure, and corrosion resistance, and may be rolled and processed.

Similar to the GDL, the PTL is configured to allow the transportation of the reactant water to the anode catalyst layers, remove produced oxygen gas, and provide good electrical conductivity for effective electron conduction. In other words, liquid water flowing in the anode flow field is configured to permeate through the PTL to reach the CCM. Further, gaseous byproduct oxygen is configured to be removed from the PTL to the flow fields. In such an arrangement, liquid water functions as both reactant and coolant on the anode side of the cell.

The thickness of the PTL may be within a range of 100-1000 microns, for example. The thickness may affect the mass transport within the cell as well as the durability/deformability and electrical/thermal conductivity of the PTL. In other words, a thinner PTL may provide better mass transport and a reduction in durability (e.g., greater chance for localized deformation).

In some examples, an anode catalyst coating layer may be positioned between the anode flow field 204 and the PTL.

The cathode flow field 202 and anode flow field 204 of the cell may individually include a flow field plate composed of metal, carbon, or a composite material having a set of channels machined, stamped, or etched into the plate to allow fluids to flow inward toward the membrane or out of the cell.

FIGS. 3A, 3B, and 3C depict examples of an electrochemical or electrolytic cell, wherein examples of flow fields are depicted. In these particular examples, the electrochemical cell includes a cathode flow field 302, cathode flow channels 303, an anode flow field 304, anode flow channels 305, and a membrane 306 positioned between the cathode and the anode. Additionally, the electrochemical cell 300 includes a gas diffusion layer 308 positioned between the catalyst coated membrane 306 and the cathode flow channels 303. Further, a porous transport layer 310 is positioned between the catalyst coated membrane 306 and the anode flow channels 305.

In the particular example depicted in FIGS. 3A and 3B, the cathode and anode flow fields are arranged to provide a cross-fluid flow. In such a cross-fluid arrangement, the fluid flow through the cathode flow channels is arranged perpendicular to the fluid flow through the anode flow channels. Specifically, FIG. 3A depicts the cross-sectional view of the electrochemical cell with the cathode flow channels displayed, while FIG. 3B depicts the cross-sectional view of the electrochemical cell rotated 90 degrees to display the anode flow channels.

In alternative examples, the flow fields may have a co-flow configuration or a counter-flow configuration. FIG. 3C depicts such an alternative example, wherein the channels and lands of the anode flow field are parallel with the channels and lands of the cathode flow field, therein allowing for a co-flow or a counter-flow configuration. For example, in a co-flow configuration, the flow of fluid through the anode flow field channels is in the same direction as the flow of fluid through the cathode flow field channels. In a counter-flow configuration, the flow of fluid through the anode flow field channels is in an opposite direction as the flow of fluid through the cathode flow field channels.

The orientation or configuration of fluid flow between the anode flow field and cathode flow field may be advantageous in adjusting or controlling the pressure distribution or temperature distribution within the electrochemical cell.

Regarding these anode and cathode flow fields depicted in FIGS. 3A-3C, such flow fields may be configured to have paths of channels and land. The channels are configured for directing the flow of water and gas, while the lands are configured to contact an adjacent layer of the electrochemical cell (e.g., the GDL or PTL). FIGS. 3A-3C depict examples of cells having three cathode flow channels and three anode flow channels, respectively. The number of flow channels are depicted for simplicity of a design, and in potential commercial use, may include many more flow channels. As such, the disclosure is not limited to such configurations as depicted in FIGS. 3A-3C.

FIGS. 4A and 4B depict a side view and a top view, respectively, of such an electrode flow field having a plurality of channels and lands. In this particular example, the flow field includes three parallel channels and four lands, wherein each channel is positioned between adjacent lands.

There are challenges with how the flow field is arranged within an electrochemical cell, such as the arrangement depicted in FIGS. 4A and 4B. Specifically, challenges exist with providing optimal fluid flow and heat distribution within the cell to provide better performance and reduce risks of hotspots. The cell performance depends more on the flow configuration, in particular, as current density increases. Flow field designs that lead to poor liquid reactant supply to the catalyst layers suffer from mass transport overpotential. Transport overpotentials increase with increasing current density which is simultaneously accompanied with increasing cell temperature due to the additional heat dissipation due to increased transport overpotential. Ensuring sufficient reactant flow rate is necessary to minimize mass transport losses and avoid cell failures, especially for higher current density operations.

Additionally, inadequate liquid reactant flow in porous layers may lead to an accumulation of generated gas. Flow field design is therefore important in achieving sufficient water flow for gas removal to prevent dehydration issues. Increasing flow rate improves gas-liquid exchange in the porous layers, but also increases the pumping power cost and downstream separation costs due to larger sized equipment to deal with the increased volume. Nevertheless, increasing the flow rate in conventional flow fields such as those involving parallel channels connecting inlet and outlet ports (manifolds) does not guarantee sufficient flow rates in porous layers for effective gas removal, in particular for high current density operations.

Further, inadequate fluidic pathways in flow field design may lead to high pressure drops and inefficient heat transfer. Thus, designing larger fluidic pathways through the flow fields would enable lower pressure drops with the same flow rates, and enable more area contact between the fluids and the flow field (e.g., improving heat transfer).

Furthermore, increasing the current density for a fixed flow rate may lead to significant increases in the gas fractions inside the porous transport layers. This increase in gas fraction occurs concurrently with the increase in mass transport overpotential. As used herein, “stoic ratio” is a non-dimensional metric comparing amount of liquid water supply with respect to the operational current density. An ideal stoic ratio provides sufficient water supply for the electrolysis reaction and effective gas removal. Below a critical stoic ratio, the rate of gas generation exceeds the rate of gas removal, which hinders the reactant liquid water from reaching the reaction sites. Even at low gas fractions, if the bubbles remain stagnant as opposed to a dynamic regime, local hot spots may arise. Therefore, having a design that achieves a threshold stoic ratio is important in mitigating increasing cell temperatures. Stoic ratio also depends on cell hardware and flow field geometry. Designs facilitating reduction in stoic ratio is important not only for cell performance but also from balance of plant perspective. Also, lower water flow rates allow for lower pumping and auxiliary/separation unit sizing for the plant design, therein helping reduce green hydrogen cost.

During proton exchange membrane water electrolysis (PEMWE), an oxygen evolution reaction (OER) may occur on an anode interface or side of an electrochemical or electrolytic cell and a hydrogen evolution reaction (HER) may occur on a cathode interface or side of the cell. For an oxygen evolution reaction (OER) occurring at an anode interface (e.g., at an anode catalyst layer), water is a reactant and may be in a liquid phase. In some examples, water may be provided to a cathode interface of the cell, e.g., as a cooling source for the cathode side of the cell.

FIG. 5 illustrates a section of one interface (e.g., anode interface or cathode interface) of an electrochemical or electrolytic cell including a flow field of the present disclosure. The segment of the electrochemical cell 500 depicted in FIG. 5 includes a flow field 502, a membrane 504, and an adjacent layer 506. The adjacent layer 506 may be a porous transport layer or a gas diffusion layer.

In this embodiment, the flow field 502 is a formed piece having a plurality of lands 508 and a plurality of channels 510 that are connected with the adjacent layer 506 (e.g., the adjacent porous transport layer or gas diffusion layer). As depicted in FIG. 5, the flow field 502 includes an outlet configured to transport fluid, e.g., water and any hydrogen gas (cathode) or oxygen gas (anode) produced in the water-splitting reaction at the membrane, out of the flow field 502 and cell 500. In certain examples, the flow field 502 (e.g., on the anode side of the cell) may also include an inlet configured to receive water to flow into the flow field 502 of the cell 500.

As illustrated in FIG. 5, the flow field 502 includes four channels 510 and five lands 508; however, the present disclosure is not limited thereto. Each of the plurality of channels 510 include a first side wall 512, a second side wall 514, and a back wall 516 that connects the first side wall 512 with an end of the second side wall 514. Each of the plurality of lands 508 is configured to abut the adjacent layer 506 of the electrochemical cell 500. Each land of the plurality of lands 508 separates and connects two adjacent channels of the plurality of channels 510 at the ends of respective side walls 512 and 514, opposite from the back walls 516 of the respective channels 510.

As mentioned above, the channels 510 are configured to convey a flow of fluid. The channels 510 may be configured to both convey a flow of fluid into the adjacent layer 506 and receive a flow of fluid from the adjacent layer 506. For example, when the flow field 502 is an anode flow field, the channels 510 may be configured to both convey a flow of water (e.g., from an inlet of the flow field 502) into the adjacent layer 506 (e.g., porous transport layer) and receive a flow of oxygen and water from the adjacent layer 506 (e.g., porous transport layer) from the water splitting reaction at the membrane (not illustrated) and convey the oxygen and water to an outlet of the anode flow field 502.

In another example, when the flow field 502 is a cathode flow field, the channels 510 may be configured to receive a flow of hydrogen (and, in some cases, water) from the adjacent layer 506 (e.g., the gas diffusion layer) from the water splitting reaction at the membrane and convey the hydrogen (and potentially water) to an outlet of the flow field 502. In other examples, when the flow field 502 is a cathode flow field, the channels 510 may be configured to both convey a flow of water (e.g., from an inlet of the flow field 502) into the adjacent layer 506 (e.g., the gas diffusion layer) and receive a flow of hydrogen (and, e.g., water) from the gas diffusion layer and convey the hydrogen (and, e.g., water) to an outlet of the cathode flow field.

The adjacent layer 506 may be a porous transport layer (PTL) (e.g., PTL 210, 310) or a gas diffusion layer (GDL) (e.g., GDL 208, 308). The adjacent layer 506 may be disposed between the flow field 502 and a catalyst layer (not illustrated). The adjacent layer 506 may be configured to convey fluid. For example, the adjacent layer 506 may be configured to convey a flow of fluid from the channels 510 of the flow field 502 to the catalyst layer and/or convey a flow of fluid from the catalyst layer to the channels 510 of the flow field 502. For example, when the adjacent layer 506 is a PTL, the adjacent layer 506 may be configured to convey a flow of liquid water from the channels 510 of the flow field 502 to the catalyst layer and convey a flow of gaseous oxygen from the catalyst layer to the channels 510 of the flow field 502. In another example, when the adjacent layer 506 is a gas diffusion layer, the adjacent layer 506 may be configured to convey a flow of gaseous hydrogen from the catalyst layer to the channels 510 of the flow field 502.

The catalyst layer may refer to an anode catalyst layer (e.g., anode catalyst layer 207) or a cathode analyst layer (e.g., cathode catalyst layer 205). The catalyst layer may be a catalyst for facilitating the water splitting reaction occurring on a given interface of the electrochemical cell 500. For example, when the catalyst layer is an anode catalyst layer, the catalyst layer may be a catalyst for the oxygen evolution reaction (OER) occurring at the anode interface of the electrochemical cell. In another example, when the catalyst layer is a cathode catalyst layer, the catalyst layer may be a catalyst for the hydrogen evolution reaction (HER) occurring at the cathode interface of the electrochemical cell 500. Gaseous products (e.g., hydrogen, oxygen) may be produced at or near the catalyst layer.

The membrane (e.g., proton exchange membranes) 504 may be disposed between an anode catalyst layer and a cathode catalyst layer of the electrochemical cell 500. The proton exchange membrane 504 may be configured to convey or transport protons from the anode interface of the electrochemical cell 500 to the cathode interface of the electrochemical cell 500. In some examples, the proton exchange membrane 504 may be a catalyst coated membrane and include the anode catalyst layer and/or the cathode catalyst layer.

As depicted in FIG. 5, the flow field 502 includes a plurality of perforations 518. The plurality of perforations 518 may be included in the first side wall 512 and/or in the second side wall 514 of one or more channels of the plurality of channels 510. The plurality of perforations 518 is configured to transfer fluid from the channels 510 to cavities 520 formed between the flow field 502 of the electrochemical cell 500 and an adjacent flow field 550 of a portion of an additional electrochemical cell (further described below) that abuts the flow field 502 of the electrochemical cell 500. As noted above, the plurality of perforations is advantageous in providing fluidic pathways in the flow field. For example, the channels 510 may be configured to receive a flow of hydrogen (and, in some cases, water) from the adjacent layer 506. The plurality of perforations 518 create a fluid connection with formed cavities 520, thus larger fluidic pathways are provided to enable lower pressure drops while maintaining constant flow rates through the flow field 502. Furthermore, the larger fluid pathways provide more surface area contact between the fluids and the flow field 502 (e.g., improving heat transfer), and allow for pressure balancing for improving the structural design of the flow field 502.

Each perforation of the plurality of perforations 518 may be any shape or size to advantageously provide a fluid connection between the channels 510 and the cavities 520. The shape and/or size of the plurality of perforations 518 may be configurable, and may be selected based on the type of electrochemical cell, flow field of the electrochemical cell, flow rate of reactant supplied to the electrochemical cell, power of the electrochemical cell, number of cells in an electrochemical cell stack, and the like. For example, the perforations 518 may be formed in any geometric shape, such as a circle, an oval, a square, a rectangle, a triangle, or any polygon. Furthermore, the size of the perforations 518 may be configured to provide an amount of fluid transfer (e.g., flow rate and/or pressure drop) between the respective channels 510 to the respective cavities 520, which are formed between the flow field 502 of the electrochemical cell 500 and the adjacent flow field 550 of a portion an additional electrochemical cell. In this configuration, the perforations 518 are circular; however, as mentioned herein, the perforations 518 may be any shape.

Furthermore, the number of perforations per each side wall may vary and are not limited to the illustrated embodiments. As illustrated in FIG. 5, at least eleven perforations of the plurality of perforations 518 are provided on each respective side wall 512 and 514 of each channel of the plurality of channels 510. However, any number of perforations may be provided on each respective side wall.

Additionally, the plurality of perforations may include repeating perforations on a first side wall and/or a second sidewall in a predictable manner. In other words, the perforations may be positioned in a regular (e.g., constant) pattern on the first side wall and/or a second side wall of a channel of the plurality of channels. For instance, as illustrated in FIG. 5., the plurality of perforations 518 are evenly spaced apart from one another on the first side wall 512 and the second side wall 514 of each respective channel of the plurality of channels 510. Furthermore, the plurality of perforations 518 may be level with one another so that neither perforation is positioned longitudinally higher or lower than the other on a respective side wall.

In another configuration, the plurality of perforations may include repeating perforations on a first side wall and/or a second sidewall in a random or unpredictable manner. In other words, the perforations may be positioned in an irregular (e.g., non-constant) pattern on the first side wall and/or a second side wall of a channel of the plurality of channels. For example, the perforation may be unequally spaced apart. Furthermore, the perforations may be unlevel with one another so that one perforation of the plurality of perforations may be positioned longitudinally higher/lower than the other on a respective side wall. Additionally, each of the sidewalls of the plurality of channels may have a different amount of perforations.

Further, in some embodiments, the perforations may be positioned on less than all of the side walls of the channels within the flow field (e.g., 50% of the side walls, 25% of the side walls, etc.) (discussed further below with reference to FIG. 6, for example). In some examples, perforations may be positioned only on the first side wall or only on the second side wall of each channel. In other examples, perforations may be positioned only on every other first side wall, or only on every other second side wall of the plurality of channels of the flow field.

As mentioned above, the plurality of perforations is advantageous because it allows for much larger fluidic pathways through the flow fields, which enable lower pressure drops with constant flow rates, enable more area contact between the fluids and the layers of the electrochemical cell (e.g., improving heat transfer between the different layers), and allow for pressure balancing between the outside and inside of the flow field to help the flow field structurally.

FIG. 6 illustrates another embodiment of a flow field of the present disclosure for a section of one interface (e.g., anode interface or cathode interface) of an electrochemical or electrolytic cell. Referring to FIG. 6, the plurality of perforations 518 are arranged in an alternating pattern of locations in the electrochemical cell 600. For instance, the plurality of perforations 518 is positioned in an alternating pattern of locations on a first side wall 512 of one respective channel 522 of the plurality of channels 510 and a second side wall 514 of an adjacent channel 524 of the plurality of channels 510 such that fluid is configured to flow into every other cavity 520 that formed between the flow field 502 and the adjacent flow field 550. Furthermore, as mentioned above, the plurality of perforations may also include irregular and regular patterns while positioned in alternating pattern locations. Multiple configurations of an electrochemical cell including the flow field of the present disclosure are possible and may be selected based on the type of electrochemical cell, the flow field of the electrochemical cell, the flow rate of reactant supplied to the electrochemical cell, the power of the electrochemical cell, the number of cells in an electrochemical cell stack, and the like.

Providing the plurality of perforations to alternate channels, as illustrated in FIG. 6, allows for the plurality of cavities 520 to be shared by the adjacent electrochemical cells (e.g., with different fluids as well). In other words, fluid transport from the anode flow field of the electrochemical cell 600 may flow into every other cavity 520, while fluid transport from the adjacent cathode flow field 550 of a portion of the adjacent electrochemical cell may flow into the remaining cavities 520. Allowing the fluid from either or both sides of the flow field to enter the formed cavities 520 of the flow field has many advantages. For example, a flow field with alternating perforations can allow the flow field to be smaller at the same flow rate and with the same pressure drop as an alternative flow field that is larger and that does not use the formed cavities through the fluid connections created by the perforations. This could enable a smaller flow field in total area or thickness. Also, fluid in the formed cavities may have an additional contact area for heat transfer to the flow field. Allowing fluid to enter the formed cavities may also balance pressure differences across the flow field, enabling thinner materials or other design ideas that would otherwise not withstand the difference in pressure.

FIG. 7 illustrates, in an exploded view, another example of a section of one interface (e.g., anode interface or cathode interface) of an electrochemical or electrolytic cell including the flow field of the present disclosure and a support layer. The electrochemical cell 700 includes the flow field 502, the membrane layer 504, the adjacent layer 506, and the support layer 702. In this example, the support layer 702 is positioned between the flow field 502 of the electrochemical cell 700 and the adjacent flow field 550 of the adjacent electrochemical cell.

The adjacent layer 506 may be a porous transport layer or a gas diffusion layer. As mentioned above, the flow field 502 includes a plurality of lands 508 and a plurality of channels 510. Each of the plurality of channels 510 includes a first side wall 512, a second side wall 514, and a back wall 516 that connects the first side wall 512 with an end of the second side wall 514. Each of the plurality of lands 508 of the flow field 502 abut the adjacent layer 506. The support layer 702 abuts the flow field 502 on an opposite side of the flow field 502 from the adjacent layer 506. Specifically, the support layer 702 abuts the back walls 516 of each respective channel 510 of the flow field 502, therein providing cavities 704 between the plurality of lands 508 and the support layer 702.

The positioning of the support layer 702 between two flow fields of two adjacent electrochemical cells may be advantageous in allowing each flow field to have perforations for each channel of the respective flow field, allowing fluid to flow into the respective cavities 704 between the flow field 502 and the support layer 702. The support layer 702 provides a barrier between the two different sets of cavities, preventing cross-over or mixing/contamination of different fluids between the respective cavities of the adjacent cells (e.g., oxygen gas from the anode flow field of one cell and hydrogen gas from the cathode flow field of the adjacent cell).

Further, the support layer 702 may advantageously provide structural support to the electrochemical cell or stack.

The configuration of the support layer 702 is variable. In certain examples, such as depicted in FIG. 7, the support layer 702 may be a plate (e.g., flat plate) structure. In other examples, the support layer may have at least one three-dimensional (3D) surface, such as a surface with ridges or bumps in the surface. In some cases, the support layer may have one 3D surface configured to abut the flow field of the first electrochemical cell, while the other opposing surface is a flat, two-dimensional surface configured to abut the second, opposite flow field of the second electrochemical cell. In other examples, the support layer includes two 3D surfaces, wherein one 3D surface is configured to abut the flow field of the first electrochemical cell, while the other 3D surface of the support layer is configured to abut the second, opposite flow field of the second electrochemical cell.

The support layer 702 may be made from any number of different materials. In certain examples, the material or composition of the support layer may be a material configured to provide structural support for the cell or system. In some examples, the support layer may be made of a plastic, polymer, carbon, or stainless steel.

In certain examples, the thickness of the support layer may be within a range of 1-1000 microns, 10-1000 microns, 100-1000 microns, or 1-100 microns, for example.

As mentioned above, the flow field 502 includes a plurality of perforations 518 and the flow field 502 may be any of the different flow field configurations mentioned above. For instance, the flow field 502 may have any con figuration of the plurality of perforations 518 and is not limited to one.

FIG. 8A illustrates another embodiment of the flow field 502 of the present disclosure for a portion of an electrochemical cell with a support layer 802 depicting a different flow field configuration from the example depicted in FIG. 7. Specifically, FIG. 8A illustrates a portion of an electrochemical cell 800 including the flow field 502, the membrane 504, the adjacent layer 506, and a support layer 802. The flow field 502 includes a plurality of perforations 518 arranged in an alternating pattern of locations. In other words, a plurality of perforations 518 are positioned on less than all of the side walls of the flow field channels to provide an irregular pattern. In this configuration, the plurality of perforations 518 are arranged in every other channel 510 (e.g., skipping a land 508 and a channel 510).

In yet another embodiment, a plurality of perforations (e.g., holes) 808 may be provided in the support layer 802. FIG. 8B illustrates an example of a portion of an electrochemical cell 800 that includes a support layer 802 with perforations 808 to fluidly communicate with cavities 820. Cavities 820 are formed between the plurality of lands 508 and the support layer 802. The support layer 802 having the plurality of perforations 808 advantageously provides structural support to the flow field 502 and electrochemical cell 800 and further provides greater fluidic pathways between cavities of the flow field 502 and cavities of the adjacent flow field 550 of the adjacent electrochemical cell.

FIG. 9 illustrates an example of an electrochemical system 900 including a portion of a first electrochemical cell 901 and its interaction with an adjacent portion of a second electrochemical cell 950. The electrochemical system 900 may include a plurality of electrochemical cells equal to or more than the two cells depicted in FIG. 9 stacked on top of one another (e.g., connecting, abutting, or the like) in the electrochemical system to provide an electrochemical stack. As depicted in FIG. 9, the first electrochemical cell 901 and a second electrochemical cell 950 of the plurality of electrochemical cells are stacked on top of one another. In other words, a portion of the first electrochemical cell 901 (i.e., a cathode side of the electrochemical cell 901) is stacked on top of a portion of the second electrochemical cell 950 (i.e., an anode side of the electrochemical cell 950) such the respective flow fields 502 of the first electrochemical cell 901 is abutting the flow field 502 of the second electrochemical cell 950.

Each cell of the electrochemical cells 901 and 950 include their own flow fields, membrane, and adjacent layer. As depicted in FIG. 9, the portion of the first electrochemical cell 901 includes flow field 902, membrane 904, and adjacent layer 906. The portion of the second electrochemical cell 950 includes flow field 952, membrane 954, and adjacent layer 956. The flow fields 902 and 952 of each respective electrochemical cell may have a same configuration as the flow fields described above. The adjacent layers 906 and 956 of the respective cells may be porous transport layers or gas diffusion layers positioned between the respective flow fields and membranes. In this configuration, in the first electrochemical cell 901, the flow field 902 may be a cathode flow field, and the adjacent layer 906 may be a gas diffusion layer. In the second electrochemical cell 950, the flow field 952 may be an anode flow field, and the adjacent layer 956 may be a porous transport layer.

The flow field 902 of the first electrochemical cell 901 is configured to abut the flow field 952 of the second electrochemical cell 950. In other words, the back walls 516 of respective channels 510 of the flow field 952 abut respective back walls 516 of the flow field 902. Thus, cavities 910 are provided between the lands and the side walls 512 and 514 of the channels 510 of the flow field 902 of the first electrochemical cell 901 and the lands 508 and the side walls 512 and 514 of the channels 510 of the flow field 952 of the second electrochemical cell 950.

By positioning the two flow fields of the two adjacent cells together in this configuration, the formed cavities can be utilized through the fluid connections created by the plurality of perforations. Different orientations or configurations of fluid flow can be possible. The formed cavities between the bonded flow fields may lower pressure drops while maintaining constant flow rates and provide additional contact areas for heat transfer. Furthermore, allowing fluid to enter the formed cavities can balance pressure differences across the formed plate, enabling thinner materials or other design ideas that would otherwise not withstand the different pressures.

As mentioned above, the flow fields of one or both of the electrochemical cells may include a plurality of perforations 518 such as any of the different flow field configurations mentioned above.

Furthermore, the plurality of perforations may alternate between the abutting flow fields. For instance, the flow field 952 of the second electrochemical cell 950 may include the plurality of perforations 518, while flow field 902 of the first electrochemical cell 901 may include no perforations, as illustrated in FIG. 9.

In another embodiment, the flow field 902 of the first electrochemical cell 901 may include the plurality of perforations 518, while flow field 952 of the second electrochemical cell 950 may include no perforations. Any number of configurations may be possible, and the disclosure is not limited to one.

In another embodiment, the plurality of perforations may alternate channels 510 between respective flow fields of the first and second electrochemical cells such as to accommodate different fluids.

For example, FIG. 10, illustrates an additional example of an electrochemical system 1000 that includes a portion of a first electrochemical cell 901 and its interaction with an adjacent portion of a second electrochemical cell 950. In this example, the plurality of perforations 518 in the flow fields 902 and 952 of the first and second electrochemical cells 901 and 950, respectively, may alternate channels of the flow field 902 of the first electrochemical cell 901 and may also alternate channels of the flow field 952 of the second electrochemical cell 950.

For instance, the flow field 902 of the first electrochemical cell has perforations 518 in only one channel 510 such that fluid from channel 510 of the flow field 902 may communicate with cavities 910. Additionally, the flow field 952 of the second electrochemical cell has perforations 518 in one channel 510 such that fluid from the flow field 952 may communicate with respective cavities 910. Thus, the cavities 910 (i.e., formed between the lands 508 of the flow field 902 of the first electrochemical cell 901 and the flow field 952 of the second electrochemical cell 950) may be configured to alternate flow between the first electrochemical cell 901 and the second electrochemical cell 950. This configuration is advantageous because a separate fluid may flow through and alternate between cavities 910, preventing cross-over or mixing/contamination of different fluids between the respective cavities of the adjacent cells (e.g., oxygen gas from the anode flow field of one cell and hydrogen gas from the cathode flow field of the adjacent cell). It should be noted that any configuration of perforations is possible to alternate fluid between the first and second electrochemical cells.

Furthermore, in yet another embodiment, the plurality of perforations for a respective flow field may include irregular or regular patterns, as mentioned above.

FIG. 11 illustrates yet another example of an electrochemical system 1100 depicting a portion of a first electrochemical cell 1101 and a portion of a second electrochemical cell 1150 and a support layer 1112 positioned between the two cells. In this configuration, two electrochemical cells are depicted; however any number of electrochemical cells may be stacked on one another in an electrochemical system to provide an electrochemical stack.

The electrochemical cells 1101 and 1150 of the system 1100 are stacked on top of one another with the support layer 1112 positioned between the two cells, separating the two electrochemical cells 1101 and 1150 in the system 1100.

The first electrochemical cell 1101 includes flow field 1102, membrane 1104, and adjacent layer 1106. The second electrochemical cell 1150 includes flow field 1152, membrane 1154, and adjacent layer 1156. The flow fields 1102 and 1152 of each respective electrochemical cell may have in a same configuration flow field 502 described above. The adjacent layer 1106 and 1156 may be a porous transport layer or a gas diffusion layer positioned between the respective flow fields and membranes. In this configuration, in the first electrochemical cell 1101, the flow field 1102 may be a cathode flow field, and the adjacent layer 1106 may be a gas diffusion layer. In the second electrochemical cell 1150, the flow field 1152 may be an anode flow field, and the adjacent layer 1156 may be a porous transport layer.

As depicted in FIG. 11, the flow field 1102 of the first electrochemical cell 1101 abuts a first surface of the support layer 1112. Specifically, the back walls 516 of the channels 510 of the flow field 1102 of the first electrochemical cell 1101 abut the support layer 1112. Cavities 1110 are provided in the volume formed between the first surface of the support layer 1112 and the lands 508 and the side walls 512 and 514 of the channels 510 of the flow field 1102 of the first electrochemical cell 1101.

Furthermore, the flow field 1152 of the second electrochemical cell 1150 abuts the second, opposite surface of the support layer 1112. In other words, the back walls 516 of each respective channel 510 of the flow field 1152 of the second electrochemical cell 1150 abut the support layer 1112. Thus, cavities 1114 are provided in the volume formed between the second surface of the support layer 1112 and the lands 508 and the side walls 512 and 514 of the channels of the flow field 1152 of the second electrochemical cell 1150. The multiple cavities advantageously provide for alternative fluidic pathways, thus allowing more than one fluid to pass through the bonded flow plates.

As mentioned above, the flow fields may include a plurality of perforations 518 and each flow field 1102 and 1152 of each respective electrochemical cell 1101 and 1150 may include any of the different flow field configurations mentioned above.

In another embodiment, the flow fields of only one of the first or second electrochemical cells may include a plurality of perforations 518, while the flow field of the other electrochemical cell may include no perforations.

In another embodiment, as illustrated in FIG. 12, both flow fields 1102 and 1152 of the first electrochemical cell 1101 and the second electrochemical cell 1150 of the system 1200 include the plurality of perforations 518. For instance, the presence of the support layer 1112 advantageously allows for each flow field of the adjacent electrochemical cells to include a plurality of perforations 518. In other words, the flow field 1102 of the first electrochemical cell 1101 includes a plurality of perforations 518, and the flow field 1152 of the second electrochemical cell 1150 also includes its own plurality of perforations 518. The support layer 1112 advantageously allows fluid flowing in respective cavities 1110 and 1114 of respective flow fields to be separated from each other.

In another embodiment, as illustrated in FIG. 13, an electrochemical system 1300 includes a support layer 1112 positioned between two adjacent cells, wherein the support layer 1112 includes a plurality of perforations 1316. The system 1300 depicts a portion of the first electrochemical cell 1101 and a portion of the second electrochemical cell 1150 of a plurality of electrochemical cells. In this configuration, the flow field 1152 of the second electrochemical cell 1150 has the plurality of perforations 518, while the flow field 1102 of the first electrochemical cell 1101 has no perforations. The plurality of perforations 1316 are configured to fluidly connect the cavities 1110 of the first electrochemical cell 1101 with the cavities 1114 of the second electrochemical cell 1150. This is advantageous because the support layer provides structural support, and also provides fluid communication between the cavities of the first and second electrochemical cells.

In yet another embodiment, as illustrated in FIG. 14, the plurality of perforations may alternate between channels 510 of respective flow fields of a portion of the first electrochemical cell and a portion of the second electrochemical cell such as to accommodate different fluids within alternating cavity areas between the cells. Referring to FIG. 14, the plurality of perforations 518 may alternate channels of the flow field 1102 of the first electrochemical cell 1101 and may also alternate channels of the flow field 1152 of the second electrochemical cell 1150. Furthermore, the support layer 1112 may be positioned in between the two electrochemical cells to provide structural support.

In this configuration, the flow field 1102 of the first electrochemical cell 1101 has perforations 518 in one channel and the flow field 1152 of the second electrochemical cell 1150 has perforations 518 in two separate channels. The perforations alternate channels 510 between the first and second electrochemical cells. For instance, the cavities 1110 (i.e., formed between the lands 508 of the flow field 1102 of the first electrochemical cell 1101 and the support layer 1112) are fluidly connected with the channel 510 of flow field 1102 having the plurality perforation 518. The cavities 1110, on each side of the channel 510 having the plurality of perforation 518 of flow field 1102, are fluidly connected by perforations 1316 with respective cavities 1114 of the flow field 1152. Similarity, the cavities 1114 (i.e., formed between the lands 508 of the flow field 1152 of the second electrochemical cell 1150 and the support layer 1112) are fluidly connected with the channel 510 having the plurality perforation 518 of the flow field 1152. The cavities 1114, on each side of the channel 510 having the plurality of perforation 518 of flow field 1152, are fluidly connected by perforations 1316 with respective cavities 1110 of the flow field 1102. Thus, the perforations 518 alternate channels 510 between the first and second electrochemical cells. This configuration is advantageous because a separate fluids may utilize alternating cavities 1110 and 1114, therein preventing cross-over or mixing/contamination of different fluids between the respective cavities of the adjacent cells (e.g., oxygen gas from the anode flow field of one cell and hydrogen gas from the cathode flow field of the adjacent cell).

Furthermore, as mentioned above, the plurality of perforations for a respective flow field may include irregular and regular patterns while being positioned in alternating pattern locations, as mentioned above. As illustrated in FIG. 10, the flow fields of both the first electrochemical cell 901 and the second electrochemical cell 950 include a respective plurality of perforations in a regular pattern that are not alternating pattern locations. Any number of configurations may be possible, and the disclosure is not limited to one.

One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, are apparent to those of skill in the art upon reviewing the description.

As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

As used herein, “for example,” “for instance,” “such as,” or “including” are meant to introduce examples that further clarify more general subject matter. Unless otherwise expressly indicated, such examples are provided only as an aid for understanding embodiments illustrated in the present disclosure and are not meant to be limiting in any fashion. Nor do these phrases indicate any kind of preference for the disclosed embodiment.

The Abstract of the Disclosure is provided to comply with 37 C.F.R. § 1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.

It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the disclosure. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the disclosure.

Claims

1. A flow field for an electrochemical cell, the flow field comprising:

a plurality of channels configured to transfer fluid to an adjacent layer of the electrochemical cell, wherein each channel of the plurality of channels comprises a first side wall, a second side wall, and a back wall connecting an end of the first side wall with an end of the second side wall;

a plurality of lands configured to abut the adjacent layer of the electrochemical cell, wherein each land of the plurality of lands separates and connects two adjacent channels of the plurality of channels at ends of respective side walls opposite from the back wall of the respective channels; and

a plurality of perforations in the first side wall and/or the second side wall of one or more channels of the plurality of channels, wherein each perforation of the plurality of perforations is configured to transfer fluid from the respective channel to a cavity formed between the flow field and an adjacent flow field of an additional electrochemical cell configured to abut the flow field of the electrochemical cell,

wherein the plurality of perforations is positioned in a pattern of locations such that fluid is configured to flow into every other cavity formed between the flow field and the adjacent flow field.

2.-4. (canceled)

5. The flow field of claim 1, wherein the plurality of perforations provides larger fluidic pathways to enable lower pressure drops while maintaining constant flow rates through the flow field.

6.-7. (canceled)

8. An electrochemical cell comprising:

a flow field;

a membrane; and

an adjacent layer is positioned between the flow field and the membrane,

wherein the flow field comprises: a plurality of channels configured to transfer fluid to the adjacent layer, wherein each channel of the plurality of channels comprises a first side wall, a second side wall, and a back wall connecting an end of the first side wall with an end of the second side wall; a plurality of lands configured to abut the adjacent layer, wherein each land of the plurality of lands separates and connects two adjacent channels of the plurality of channels at ends of respective side walls opposite from the back wall of the respective channels; and a plurality of perforations in the first side wall and/or the second side wall of one or more channels of the plurality of channels, wherein each perforation of the plurality of perforations is configured to transfer fluid from the respective channel to a cavity formed between the flow field and an adjacent flow field of an additional electrochemical cell configured to abut the flow field of the electrochemical cell, wherein the plurality of perforations is positioned in a pattern of locations such that fluid is configured to flow into every other cavity formed between the flow field and the adjacent flow field.

9. The electrochemical cell of claim 8, further comprising:

a support layer abutting to the flow field on an opposite side of the flow field from the adjacent layer of the electrochemical cell,

wherein the support layer abuts the back wall of each channel of the flow field, therein providing the cavities between side walls of the plurality of channels and the support layer.

10. The electrochemical cell of claim 9, wherein the support layer has a plurality of perforations configured to transfer fluid between the cavities and the adjacent flow field of the additional electrochemical cell.

11. The electrochemical cell of claim 9, wherein the support layer is a flat plate.

12. The electrochemical cell of claim 9, wherein the support layer comprises at least one three-dimensional surface configured to abut the back wall of each channel of the flow field.

13.-15. (canceled)

16. The electrochemical cell of claim 8, wherein the flow field is an anode flow field of the electrochemical cell, and

wherein the adjacent layer is a porous transport layer.

17. The electrochemical cell of claim 8, wherein the flow field is a cathode flow field of the electrochemical cell, and

wherein the adjacent layer is a gas diffusion layer.

18. The electrochemical cell of claim 8, wherein the plurality of perforations provides larger fluidic pathways to enable lower pressure drops while maintaining constant flow rates through the flow field.

19. The electrochemical cell of claim 8, wherein the electrochemical cell is configured to operate with 200 mV or less of pure resistive loss when operating at a current density of at least at least 3 Amps/cm2.

20. The electrochemical cell of claim 8, wherein the electrochemical cell is configured to transfer 0.25-1 ml of water through the electrochemical cell per Amp per min.

21. An electrochemical system comprising:

a plurality of electrochemical cells stacked on top of one another,

wherein a first electrochemical cell and a second electrochemical cell of the plurality of electrochemical cells each comprises: a flow field; a membrane; and an adjacent layer positioned between the flow field and the membrane, wherein the flow field comprises: a plurality of channels configured to transfer fluid to the adjacent layer, wherein each channel of the plurality of channels comprises a first side wall, a second side wall, and a back wall connecting an end of the first side wall with an end of the second side wall; a plurality of lands configured to abut the adjacent layer, wherein each land of the plurality of lands separates and connects two adjacent channels of the plurality of channels at ends of respective side walls opposite from the back wall of the respective channels; and a plurality of perforations in the first side wall and/or the second side wall of one or more channels of the plurality of channels, and

wherein the plurality of perforations of the first electrochemical cell is configured to transfer fluid from the plurality of channels of the flow field of the first electrochemical cell to cavities formed between the flow field of the first electrochemical cell and the flow field of the second electrochemical cell,

wherein the plurality of perforations of the second electrochemical cell is configured to transfer fluid from the plurality of channels of the flow field of the second electrochemical cell to additional, separate cavities formed between the flow field of the second electrochemical cell and the flow field of the first electrochemical cell, and

wherein the plurality of perforations of the first electrochemical cell and the plurality of perforations of the second electrochemical cell are positioned in patterns of locations such that fluid from the first electrochemical cell is configured to flow into every other cavity formed between the flow field of the first electrochemical cell and the flow field of the second electrochemical cell and fluid from the second electrochemical cell is configured to flow into every other cavity formed between the flow field of the second electrochemical cell and the flow field of the first electrochemical cell in which the fluid from the first electrochemical cell is not flowing.

22. The electrochemical system of claim 21, further comprising:

a support layer positioned between the flow field of the first electrochemical cell and the flow field of the second electrochemical cell,

wherein the support layer abuts the back wall of each channel of the flow field of the first electrochemical cell, and

wherein the support layer abuts the back wall of each channel of the flow field of the second electrochemical cell.

23. The electrochemical system of claim 22, wherein the support layer has a plurality of perforations configured to transfer fluid between the cavities of the flow field of the first electrochemical cell and the cavities of the flow field of the second electrochemical cell.

24.-26. (canceled)

27. The electrochemical system of claim 21, wherein the flow field of the first electrochemical cell is an anode flow field, and

wherein the adjacent layer is a porous transport layer.

28. The electrochemical system of claim 27, wherein the flow field of the second electrochemical cell is a cathode flow field, and

wherein the adjacent layer is a gas diffusion layer.

29. The electrochemical system of claim 21, wherein the plurality of perforations provides larger fluidic pathways to enable lower pressure drops while maintaining constant flow rates through the field.

30. The electrochemical system of claim 21, wherein the flow field of the first electrochemical cell has the plurality of perforations, the flow field of the second electrochemical cell has the plurality of perforations, or a combination thereof.

31. The electrochemical system of claim 21, wherein the flow field of the first electrochemical cell directly abuts the flow field of the second electrochemical cell.