ELECTROCHEMICAL CELL FRAME WITH INTEGRATED SEALS

Abstract

An electrochemical cell frame for an electrolysis application utilizing an electrochemical cell is provided. The electrochemical cell frame can include a frame body, an internal sealing member, and an external sealing member. The frame body can be formed from a polymer material. The frame can define an active area, a flow passage, and a port. The active area can be configured to accommodate the electrochemical cell. The flow passage can be configured to direct fluid flow into or out of the active area. The port can be fluidly connected to the flow passage. The internal sealing member can be integrally formed with the frame body and positioned to separate fluid streams within the electrochemical cell. The external sealing member can be integrally formed with the frame body and positioned to militate against fluid leakage from the electrochemical cell.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/745,350, filed on January 15, 2025. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The present technology relates to an electrochemical cell system and, more specifically, to an electrochemical cell frame.

INTRODUCTION

This section provides background information related to the present disclosure which is not necessarily prior art.

Utilizing an electrochemical device for splitting chemical components through electrical current application is an important and valuable part of many industrial processes. The electrochemical device, whether configured in a monopolar or bipolar arrangement, can rely on multiple assembled components to function effectively. The bipolar configuration has gained particular favor in solid-state electrolyte applications where differential pressure operation between half-cell chambers can provide certain operational advantages.

The architectural foundation of the electrochemical systems can rest upon several components working in concert. The electrolyte layer can conduct ions between electrodes, while the cathode and anode layers can facilitate the respective electrochemical reactions. A flow field can direct reactants and products through the electrochemical system, supported by a frame that can contain and direct fluid movement. Most significantly, a sealing component can militate against both external leakage and internal cross-contamination between different chemical species.

Certain approaches in electrochemical device design can involve discrete, separate sealing elements such as one or more gaskets, O-rings, and adhesive systems, working alongside independently manufactured cell frames. Cell frames can employ thermoplastic materials selected for the ability to withstand compressive forces during and after assembly, while the seal can utilize various elastomeric materials chosen for desired sealing properties, integrity requirements, and chemical resistance. The separation of functions into distinct components creates a manufacturing and assembly challenge that persists throughout the industry.

Certain sealing approaches introduce systematic challenges that compound as system complexity increases. The handling and placement of thin, large-area sealing components during assembly can present difficulties. Use of an elastomeric element, while functional, can prove fragile and prone to misalignment during an intricate assembly process. Even minor positioning errors can cascade into complete system malfunction, as proper sealing can depend on exact component registration. The mechanical limitations imposed by a separate sealing system can extend beyond assembly challenges. A gasket-based sealing approach can inherently constrain the operating pressure envelope of the entire system.

Manufacturing considerations further compound operational limitations. Production of a custom gasket, for example, can generate waste material when cut from larger sheets, or alternatively can require expensive specialized equipment for direct fabrication. Precision required for proper sealing function can require tight tolerances between seal thickness and frame groove dimensions, driving up manufacturing costs and complexity. The tolerance requirements often necessitate a thicker seal and a deeper groove than would otherwise be preferred, creating design compromises throughout the system.

Challenges in joining dissimilar materials present additional complications when attempting to integrate sealing and structural functions. Different thermal expansion coefficients and humidity-related dimensional properties can change between frame material and sealing elastomer create ongoing reliability concerns. Commercial membrane material can experience dimensional changes of up to 10% with humidity variations, while maintaining reliable bonds between an elastomeric seal and a metallic structural component can prove difficult. Manufacturing processes that attempt to mold thin seals directly onto metallic substrates face flow challenges that necessitate thicker seal geometries, further compromising system optimization.

As can be appreciated, there can be a need to address several sealing challenges in design of an electrochemical device so that sealing architecture does not limit system performance, increase manufacturing complexity, and constrain operational capabilities. The industry continues to work within a framework where sealing reliability, manufacturing efficiency, assembly simplicity, and operational performance can be in tension with one another. Accordingly, there is a continuing need for an electrochemical cell frame that overcomes limitations in separate frame and seal component architectures while maintaining the reliability and performance characteristics demanded by industrial applications.

SUMMARY

In concordance with the instant disclosure, an electrochemical cell frame that overcomes limitations in separate frame and seal component architectures while maintaining the reliability and performance characteristics demanded by industrial applications, has surprisingly been discovered. The present technology includes articles of manufacture, systems, and processes that relate to electrochemical cells having integrated elastomeric sealing features formed directly into cell frame bodies, manufacturing methods for producing such integrated frame-seal components through molding processes, and electrochemical systems incorporating such components for various electrolysis applications.

In certain embodiments, an electrochemical cell frame for an electrolysis application utilizing an electrochemical cell is provided. The electrochemical cell frame can include a frame body, an internal sealing member, and an external sealing member. The frame body can be formed from a polymer material elastomeric material. The frame can define an active area, a flow passage, and a port. The active area can be configured to accommodate the electrochemical cell. The flow passage can be configured to direct fluid flow into or out of the active area. The port can be fluidly connected to the flow passage. The internal sealing member can be integrally formed with the frame body and positioned to separate fluid streams within the electrochemical cell. The external sealing member can be integrally formed with the frame body and positioned to militate against fluid leakage from the electrochemical cell.

In certain embodiments, an electrochemical cell frame for an electrolysis application utilizing an electrochemical cell. The electrochemical cell frame can include a frame body formed from an elastomeric material. The frame body can define an active area, a flow passage, and a port. The active area can be configured to accommodate the electrochemical cell and can include a cavity centrally disposed within the frame body. The flow passage can be in fluid communication with the active area and can include a channel formed with the frame body.

The port can be in fluid communication with the flow passage and can include a cathode port and an anode port. The electrochemical cell frame can further include an internal sealing member that can be integrally formed with the frame body and positioned to separate fluid streams within the electrochemical cell. An external sealing member can be integrally formed with the frame body and positioned to militate against fluid leakage from the electrochemical cell when the active area accommodates the electrochemical cell. The external sealing member can be disposed between a perimeter of the frame body and the internal sealing member. A membrane sealing member can be positioned to seal around a perimeter of the active area. The elastomeric material can be selected from a group consisting of a fluoroelastomer, a perfluoroelastomer, an ethylene propylene diene monomer rubber, a tetrafluoroethylene/propylene copolymer, and a hydrogenated nitrile butadiene rubber.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a top plan view of an electrochemical cell frame for an anode of an electrochemical cell;

FIG. 2 is a bottom plan view of the electrochemical cell frame for a cathode of an electrochemical cell;

FIG. 3 is a cross-sectional, side elevational view of a frame body of the electrochemical frame cell at an anode port taken at 3—3 of FIG. 1;

FIG. 4 is a cross-sectional, side elevational view of a frame body of the electrochemical frame cell at a cathode port taken at 4—4 of FIG. 2;

FIG. 5 is a flowchart depicting a method of manufacturing an electrochemical cell frame;

FIG. 6 is a flowchart depicting a method of operating an electrochemical cell with an electrochemical cell frame; and

FIG. 7 is a schematic depicting a stack configuration of an electrochemical cell assembly including the electrochemical cell frame and an electrolysis cell.

DETAILED DESCRIPTION

The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and/or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and/or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.

Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.

Disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1–10, or 2–9, or 3–8, it is also envisioned that Parameter X may have other ranges of values including 1–9, 1–8, 1–3, 1–2, 2–10, 2–8, 2–3, 3–10, 3–9, and so on.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The present disclosure provides an electrochemical cell frame 100 for an electrolysis application utilizing an electrochemical cell, shown generally in FIGS. 1-4. The electrochemical cell frame 100 can include a frame body 102, an internal sealing member 104, and an external sealing member 106. As described herein, the electrochemical cell frame 100 serves as a unified structural and sealing component that can facility fluid management and containment within an electrolysis cell 101 while simplifying assembly. The integrated nature of the frame body 102, the internal sealing member 104, and the external sealing member 106 can reduce the need for separate gasket components, reduce assembly complexity, and enable more reliable sealing performance across the various pressure differentials encountered in electrolysis applications.

It should be appreciated that the electrochemical cell frame 100 can be incorporated as a component of an electrochemical cell stack assembly. The electrochemical cell frame 100 can include structural components, described herein, for alignment of multiple electrochemical cell frames 100 that facilitate the electrochemical cell stack assembly and operation of multi-cell electrochemical systems. In a multi-electrochemical cell stack configuration, the structural alignment and assembly features can enable the transmission of compression forces through the entire electrochemical stack assembly while maintaining alignment between adjacent electrochemical cell frames 100 and therefore, electrochemical cells, ensuring sealing engagement of all internal and external sealing components while facilitating controlled disassembly for maintenance when required.

With reference to FIGS. 1-2, the frame body 102 can act as both a mechanical housing for electrochemical components and a primary fluid management system that directs reactant fluids and product fluids throughout the broader electrochemical cell frame 100. The frame body 102 can coordinate interaction between a membrane electrode assembly (MEA), a current collector, a flow field, and any interconnecting elements by providing defined spatial relationships and fluid pathways. The frame body 102 can enable the formation of multi-cell stacks by providing standardized interfaces and sealing surfaces that allow individual electrochemical cells to be assembled in series while maintaining fluid isolation between adjacent cells and militating against external leakage. The integrated frame body 102, internal sealing member 104, and external sealing member 106 can reduce the complexity and reliability issues associated with separate gasket components, thereby simplifying stack assembly and reducing the potential for misalignment or seal failure that could compromise performance.

The frame body 102 can be configured with various shape profiles for specific electrolysis applications. In certain embodiments, the frame body 102 can have a substantially circular cross-section, as shown in FIG. 1, that provides uniform stress distribution during stack compression. The substantially circular cross-section can offer manufacturing advantages by utilizing an injection molding process and can provide optimal material utilization while accommodating circular or oval active areas found in certain electrochemical cells. Alternative cross-sectional shapes can include rectangular, square, or polygonal configurations that can be employed depending on the specific application requirements and stack architecture, with each geometry offering certain advantages in terms of packing efficiency, manifolding, or integration with an existing system. A skilled artisan can select a suitable cross-sectional shape within the scope of the present disclosure.

The frame body 102 can include one or more apertures 108 positioned to receive a coupling means (not shown) such as a bolt, a screw, or another mechanical fastener, for affixing the frame body 102 to an adjacent structure or for placing multiple electrochemical cell frames 100 in series to form an electrochemical stack. The aperture 108 can be one of multiple apertures 102 disposed around a periphery of the frame body 102, outside any active sealing areas, to provide secure mechanical connection points without compromising fluid containment. In certain embodiments, the aperture 108 can be reinforced with a metallic insert or a thickened elastomeric section to distribute clamping forces and militate against deformation under stack compression loads. In a multi-cell stack configuration, the aperture 108 can enable the transmission of compression forces through the entire stack assembly, promoting proper sealing engagement while facilitating disassembly for maintenance when required. A skilled artisan can select a suitable number and configuration of apertures 108 within the scope of the present disclosure.

The frame body 102 can be formed from a material that can provide both structural integrity and chemical compatibility within the electrochemical environment. As an example, the frame body 102 can be formed from a polymer. In certain embodiments, the polymer can include an elastomeric polymer or an elastomeric material such as compositions including a fluoroelastomer (e.g., FKM), a perfluoroelastomer (e.g., FFKM), ethylene propylene diene monomer rubber (EPDM), tetrafluoroethylene/propylene copolymer (e.g., FEPM), and hydrogenated nitrile butadiene rubber (HNBR). In a particular embodiment, FKM can be utilized as the frame material due to chemical resistance to certain corrosive electrolyte environments, thermal stability across certain operating temperature ranges, and compression set resistance that maintains sealing effectiveness over certain operational periods. Material selection for the frame body 102 can directly influence the performance characteristics of both the internal sealing member 104 and external sealing member 106, as the internal sealing member 104 and the external sealing member 106 can be integrally formed from the same polymer as the frame body 102, as described here. Structural material continuity can militate against potential variation points that could arise from dissimilar material interfaces and can promote consistent thermal expansion behavior throughout the electrochemical cell frame 100. The polymer nature of the frame body 102 material can enable the internal sealing member 104 and the external sealing member 106 to conform to surface irregularities and accommodate manufacturing tolerances while maintaining reliable fluid containment under varying pressure and temperature conditions. A skilled artisan can select a suitable polymer for the frame body 102 within the scope of the present disclosure.

In certain embodiments, as shown in FIGS. 3-4, the frame body 102 can include a scaffold 110 that serves as a rigid support structure for the frame body 102, providing enhanced mechanical strength and structural integrity that enables the frame body 102 to withstand the compressive forces and pressure differentials encountered during electrolysis operations. The scaffold 110 can provide the advantage of allowing the frame body 102, the internal sealing member 104, and the external sealing member 106 to be more easily handled during manufacturing and assembly processes while increasing the working pressure capabilities of the electrochemical cell. The scaffold 110 can be constructed from a variety of materials including metallic materials, thermoplastics, or combinations thereof, with metallic substrates being advantageous in certain applications due to the strength-to-weight ratio and resistance to deformation under high pressure conditions. The polymer material of the frame body 102 can encapsulate the scaffold 110 and can permeate through one or more openings (not shown) formed in the scaffold 110, creating a unified component where the polymer material of the frame body 102 mechanically interlocks with the rigid scaffold 110 without requiring adhesion between dissimilar materials. The encapsulation approach can militate against potential failure points that could arise from adhesive bonds between the frame body 102 and the scaffold 110, while enabling the scaffold 110 to be fully integrated within the frame body 102 where the scaffold 110 can provide localized reinforcement in high-stress areas such as around ports and active area boundaries. The scaffold 110 can also serve dual functions in certain embodiments, where the scaffold 110 can act as both the structural support for the frame body 102 and as a bipolar plate for electrical conduction between adjacent electrochemical cells in a stack configuration, thereby reducing overall component count and assembly complexity.

The frame body 102 can include a coating applied to the scaffold 110 to provide enhanced protection in regions that can be exposed to a corrosive environment during electrochemical operation. The coating can be advantageous in embodiments in which the scaffold 110 is formed from metallic material that can be exposed to oxygen and/or electrolyte solutions that can create corrosive conditions that may degrade the scaffold 110 over time. The coating can function as another layer positioned between the scaffold 110 and the frame body 102, creating a protective barrier that militates against direct contact between the electrochemical environment and the underlying scaffold 110. The protective coating can be utilized in applications such as water electrolysis where the anodic environment contains oxygen and acidic or alkaline electrolytes that are known to cause corrosion of metallic components.

The coating can be selected from materials that provide chemical resistance and compatibility with both the scaffold 110 material and the frame body 102, promoting adhesion and long-term durability under the operating conditions encountered in electrolysis applications. For example, the coating can include a ceramic coating, a polymer coating, a metallic coating enhanced corrosion resistance, or a multi-layer coating system that combines different protective mechanisms. A skilled artisan can select a suitable coating within the scope of the present disclosure. The coating can be accomplished through various industrial coating processes such as plasma spraying, chemical vapor deposition, electroplating, or a solution coating method, depending on the specific coating material and substrate requirements. A skilled artisan can select a suitable coating method within the scope of the present disclosure. The integration of the coating can enable the use of cost-effective scaffold 110 material that can otherwise be unsuitable for direct exposure to the electrochemical environment, while also providing additional protection against potential coating defects in the frame body 102 that could otherwise lead to scaffold 110 degradation.

With continued reference to FIGS. 1-2, the frame body 102 can include an active area 112, a flow passage 114, and a port 116. The active area 112, the flow passage 114, and the port 116 can function as an integrated fluid management system that enables electrochemical operation by establishing controlled pathways for reactant delivery and product removal. The active area 112 can serve as the reaction zone where the electrochemical process occurs, housing the MEA and related active components within the electrochemical cell frame 100. The flow passage 114 can provide a fluid transport function by providing one or more channels that connect the active area 112 to the external system, allowing reactants such as water and electrolyte to be directed into the active area 112 while simultaneously enabling products such as hydrogen and oxygen to be removed from the reaction zone. The port 116 can serve as an interface point between individual electrochemical cells and external manifolds, allowing multiple electrochemical cells to be connected in a stack configuration. Together, the active area 112, the flow passage 114, and the port 116 can create a unified fluid management configuration that militates against the need for separate flow distribution hardware while promoting separation of different fluid streams, such as a first fluid stream and a second fluid stream, and maintaining the pressure differential necessary for efficient electrolysis operation, particularly in applications such as dry cathode water electrolysis where distinct anodic and cathodic fluid streams are maintained. It should be appreciated that the first fluid stream and the second fluid streams can be different such that, in operation the first fluid stream can be a reactant stream and the second fluid stream can be a product stream. A skilled artisan can select a suitable fluid stream within the scope of the present disclosure.

As shown in FIGS. 1-2, the active area 112 can be configured as a cavity 118 disposed within the frame body 102 that serves as a housing for the electrochemical cell active components, including the MEA, the current collector, and the flow field structure. The cavity 118 can be centrally disposed within the frame body 102, providing uniform access to reactant streams and current distribution throughout the electrochemical reaction zone. In embodiments in which the frame body 102 has a substantially circular cross-sectional shape, the cavity 118 can include a substantially circular cross-section configuration wherein a perimeter 120 of the active area 112 can be disposed entirely within a perimeter 122 of the frame body 102 and can maintain an active area diameter less than the outer diameter of the frame. The dimensional relationship between the active area 112 and the frame body 102 can be engineered to provide sufficient polymer material for the integrated internal sealing member 104 and external sealing member 106 while maximizing the electrochemically active surface area for performance and efficiency.

With continued reference to FIG. 1, the flow passage 114 include a channel 124 formed within the frame body 102 that can enable controlled fluid flow into and out of the active area 112, facilitating the delivery of reactant fluids and removal of product fluids for continuous electrolysis operation. In certain embodiments, the frame body 102 can include more than one flow passage 114. The flow passage 114 can be positioned to connect the cavity 118 including the active area 112 with the port 116, creating a defined fluid pathway that directs electrolyte, reactants, and products through the electrochemical cell while maintaining separation between different fluid streams. The flow passage 114 can include various cross-sectional areas and geometries to minimize pressure drops while ensuring adequate flow distribution throughout the active area 112, with separate channels 124 that can be provided for anodic streams (e.g., oxygen, in the case of water electrolysis, and electrolyte) and cathodic streams (e.g., hydrogen in the case of water electrolysis, and water vapor in dry cathode operation). It should be appreciated that the electrochemical cell frame 100 can be used in applications other types of electrolysis as well such as CO₂ reduction. The integration of the flow passage 114 within the frame body 102 can militate against the need for separate flow distribution components and can promote alignment with corresponding passages in adjacent cells when assembled into a multi-cell stack configuration.

The port 116 can be configured as an opening 126 positioned in the frame body 102 to provide a fluid communication interface between individual cells and external manifolding systems. The port 116 can be fluidly connected to the corresponding flow passage 114 and can be positioned to align with corresponding ports in adjacent frames when stacked in series, thereby creating continuous manifold channels throughout the stack assembly. It should be appreciated that the openings 126 can be configured for use with the cathode as cathode ports 128 and for use with anode as anode ports 130 depending upon the configuration of the electrochemical cell.

With renewed reference to FIGS. 3-4, the internal sealing member 104 can separate different fluid streams within the electrochemical cell to militate against cross-contamination between distinct fluid environments that can be maintained during electrolysis operation. The internal sealing member 104 can be integrally formed with the frame body 102 from the same polymer material, reducing the need for separate gasket components and promoting material compatibility throughout the frame body 102. The integral formation of the internal sealing member 104 with the frame body 102 can militate against potential failure points that could arise from adhesive bonds or mechanical interfaces between dissimilar materials, while facilitating consistent thermal expansion behavior and chemical resistance properties throughout the electrochemical cell frame 100. The internal sealing member 104 can function within the electrochemical system by creating a fluid-tight barrier that enables differential pressure operation and dry cathode functionality, particularly in applications such as water electrolysis where oxygen and electrolyte streams in the anodic half-cell must be kept separate from hydrogen and water vapor streams in the cathodic half-cell.

As described herein, the internal sealing member 104 can be constructed from the same polymer materials as the frame body, for example, FKM, FFKM, EPDM, FEPM, and HNBR. The material selection can contribute to achieving chemical compatibility with the corrosive electrolysis environment while maintaining sealing effectiveness under the varying pressure and temperature conditions encountered during operation. The polymer nature of the internal sealing member 104 can enable the internal sealing member 104 to conform to surface irregularities and accommodate manufacturing tolerances while providing reliable fluid separation across the pressure differentials that can exist between different fluid streams within the cell. A skilled artisan can select a suitable material for the internal sealing member 104 within the scope of the present disclosure.

The internal sealing member 104 can be disposed on or within the frame body 102 to create a barrier between distinct fluid regions while accommodating the specific flow patterns and pressure requirements of the electrochemical process. The internal sealing member 104 can be positioned to isolate anodic fluid stream from cathodic fluid stream, militating cross-contamination that could reduce cell efficiency. The placement of the internal sealing member 104 can be particularly important in dry cathode water electrolysis applications where the anodic half-cell contains oxygen and electrolyte while the cathodic half-cell contains hydrogen and water vapor, requiring reliable separation to maintain proper cell operation and militate against the formation of explosive gas mixtures.

The internal sealing member 104 can have a circular seal configuration that extends around the perimeter of a designated section of the frame to create a continuous sealing interface that prevents fluid mixing between adjacent regions. The circular geometry can provide optimal sealing effectiveness by eliminating corners or discontinuities that could create potential leak paths, while ensuring uniform stress distribution during compression. The circular seal can be positioned to seal around the perimeter of specific frame sections because this configuration can create complete fluid isolation between different regions of the electrochemical cell, such as separating the anodic active area and associated flow passages from the cathodic active area and associated flow passages. This perimeter sealing approach can be essential for maintaining the distinct fluid environments required for proper electrochemical operation, particularly in applications where cross-contamination could result in reduced efficiency or product quality degradation.

As shown in FIGS. 3-4, the sealing member 104 can include a single projection. However, it should be appreciated that the internal sealing member 104 can include more than one projection configured as a parallel or concentric thin blade to provide redundant sealing and improve reliability in the event of localized seal damage or wear. In certain embodiments, the internal sealing member 104 can be elevated relative the surrounding frame body 102 to facilitate engagement with interfacing components and to accommodate thickness variation between different electrochemical cell stack configurations. The internal sealing member 104 can include a recess or relief area (not shown) that allows for controlled compression during assembly, militating against over-compression that can compromise the internal sealing member 104 while promoting adequate sealing force for reliable fluid containment. The recess can enable the internal sealing member 104 to maintain effective sealing across the range of operating pressures from atmospheric conditions up to certain elevated pressures (e.g., 900 bar), depending on the application requirements and supporting scaffold configuration. In certain embodiments, the internal sealing member 104 can include certain cross-sectional geometries optimized for the particular sealing application alone or in combination with the recess, with considerations for contact stress distribution, compression set resistance, and long-term durability under cyclic loading conditions encountered during electrolyzer operation.

With renewed reference to FIGS. 1-2, the external sealing member 106 can militate against fluid leakage from the electrochemical cell to an external environment, providing an outermost barrier that contains all fluids within the electrochemical cell. The external sealing member 106 can be integrally formed with the frame body 102 from the same polymer material, reducing the need for separate perimeter gasket components. The integral formation of the external sealing member 106 with the frame body 102 can militate against potential failure points that could arise from adhesive bonding or mechanical interfaces between dissimilar materials, while facilitating consistent thermal expansion behavior and chemical resistance properties throughout the electrochemical cell. The external sealing member 106 can function within the electrochemical cell by creating a fluid-tight barrier between the electrochemical cell environment and the external atmosphere, enabling operation even under high pressure conditions.

The external sealing member 106 can be constructed from the same polymer materials as the frame body 102, including FKM, FFKM, EPDM, FEPM, and HNBR, for example. The material selection can allow chemical compatibility with the external sealing member 106 and the various fluid streams within the electrochemical cell, including corrosive electrolytes, reactive gases such as hydrogen and oxygen, and water vapor, while maintaining the effectiveness of the external sealing member 106 under the varying pressure and temperature conditions encountered during operation. The polymer nature of the external sealing member 106 can enable the external sealing member 106 to conform to surface irregularities on interfacing components and accommodate manufacturing tolerances while providing containment of internal fluids and militating against external leakage.

The external sealing member 106 can be positioned in the frame body 102 create an outermost containment barrier that encompasses internal fluid regions and sealing systems within the electrochemical cell. The external sealing member 106 can be disposed between the perimeter 122 of the frame body 102 and the internal sealing member 104, to provide external containment that militates against fluid from escaping the electrochemical cell to the external environment. The positioning of the external sealing member 106 can be advantageous in multi-electrochemical cell stack configurations where multiple electrochemical cells are assembled in series, as the external sealing member 106 creates an interface between adjacent cells that militates against inter-cell leakage while simultaneously militating against external leakage from the entire electrochemical cell stack assembly. The positioning of the external sealing member 106 can also enable the frame body 102 to accommodate the aperture 108 used to compress multi-electrochemical cell stacks, providing sealing around the structural elements without compromising the containment function.

In certain embodiments, the external sealing member 106 can include a circular seal configuration that extends about the perimeter 122 of the frame body 102 to create a continuous sealing interface. The circular geometry can provide sealing effectiveness by lacking corners or discontinuities that could create potential leak paths, while promoting uniform stress distribution during stack compression and minimizing stress concentration points. A skilled artisan can select a suitable geometry for the external sealing member 106 within the scope of the present disclosure. In certain embodiments, the external sealing member 106 can include a projection as shown in FIGS. 3-4. In certain embodiments, the external sealing member 106 can include more than one projection configured as parallel or concentric thin blade to provide redundant sealing and improve reliability in the event of localized seal damage or wear during extended operational periods. The sealing surface of the external sealing member 106 can be elevated above the surface of the frame body 102 to facilitate engagement with interfacing components such as an adjacent cell frame, an end plate, or a bipolar plate, and to accommodate thickness variations between different electrochemical cell stack configurations.

It should be appreciated that the external sealing member 106 can include a recess or relief area (not shown) that can allow for controlled compression during electrochemical cell stack assembly, militating against over-compression. The recess can enable the external sealing member 106 to maintain effective sealing across the range of operating pressures from atmospheric conditions up to about 900 bar, depending on the specific application requirements and scaffold 110 configuration. The external sealing member 106 can also have a cross-sectional geometry to facilitate electrochemical cell stacking and long-term operation, with considerations for contact stress distribution, compression set resistance, and durability under the cyclic loading conditions encountered during electrolyzer startup, shutdown, and pressure cycling operations that are characteristic of industrial electrolysis applications.

With reference to FIG. 1, the frame body 102 can further include a membrane sealing member 132. The membrane sealing member 132 can seal around a perimeter 134 of the active area 110 including the MEA and electrolyte membrane or separator to militate against leaking of reactants around the edge of the electrolyte membrane. In operation, the membrane sealing member 132 can maintain electrochemical operation by facilitating current flow through the active membrane area rather than bypassing around the membrane edges. The membrane sealing member 132 can be integrally formed with the frame body 102 from the same polymer material, reducing the need for separate membrane edge sealing and promoting material compatibility throughout the electrochemical cell. The integral formation can militate against potential failure points that could arise from adhesive bonding or mechanical interfaces between dissimilar materials, while facilitating consistent thermal expansion behavior and chemical resistance properties throughout the MEA. The membrane sealing member 132 can function as an innermost sealing component within the electrochemical cell, where applicable, enabling dry cathode operation and differential pressure to be applied across the anodic/cathodic half-cell chambers by providing reliable edge sealing around MEA.

The membrane sealing member 132 can be constructed from the same polymer materials as the frame body 102, including FKM, FFKM, EPDM, FEPM, and HNBR, for example. A skilled artisan can select a suitable material for the membrane sealing member 132 within the scope of the present disclosure. The polymer nature of the membrane sealing member 132 can enable the membrane sealing member 132 to conform to the membrane surface irregularities and accommodate dimensional changes in the membrane material due to hydration, temperature variation, or mechanical stress, while providing edge containment that militates against current bypass around the perimeter 134 of the MEA.

The present disclosure further provides a method 200 of manufacturing an electrochemical cell frame 100, shown generally in FIG. 5. The method 200 can include a step 202 of forming the frame body 102, as described herein, from a polymer material using a molding process. In certain embodiment, the step 202 of forming the frame body can include a step 204 of positioning the rigid scaffold 110 in a mold cavity used during the molding process to form the frame body 102. The polymer material can be over-molded the around the rigid scaffold 110 such that the polymer material encapsulates at least a portion of the rigid scaffold and forms the frame body 102 in a step 206.

In a step 208, the method 200 can include integrally forming the internal sealing member 104 with the frame body 102 during the molding process and in a step 210, the method can include integrally forming the external sealing member 106 with the frame body 102. In certain embodiments, the method 200 can include a step 212 of integrally forming the membrane sealing member 132 with the frame body 102 during the molding process.

The present disclosure further provides a method 300 of operating an electrochemical cell with an electrochemical cell frame 100, shown generally in FIG. 6. In a step 302, the method 300 can include providing the electrochemical cell frame 100 as described herein. In a step 304, the method can include coupling the electrochemical cell frame 100 to an electrolysis cell 101.

The present disclosure provides an electrochemical cell frame 100 that includes multiple integrated sealing components, thereby reducing the limitations associated with separate frame and seal assemblies. The integrated approach can simplify electrochemical cell stack assembly by reducing component count and the handling requirements associated with thin, fragile gasket materials that are prone to misalignment, tearing, or improper placement during stack construction. The electrochemical cell frame 100 can enable higher operating pressures and improved reliability through the reduction of adhesive bonds between dissimilar materials, while providing tolerance control. Manufacturing advantages can include waste reduction, reduced equipment costs by avoiding the need for expensive custom gasket production machinery, and enhanced flexibility that allows optimal sealing geometries to be formed directly during the molding process without requiring polymer to flow through long, thin features. The integrated sealing mechanisms can facilitate thinner overall electrochemical cell configurations while maintaining robust sealing performance, enable dry cathode operation with reliable differential pressure capabilities, and provide consistent material compatibility throughout the sealing system, thereby delivering improved electrolyzer performance, reduced manufacturing costs, and enhanced operational reliability across diverse electrolysis applications including water electrolysis, ammonia electrolysis, chlor-alkali processes, electrorefining, and chlorate production.

EXAMPLES

Example embodiments of the present technology are provided with reference to the several figures enclosed herewith.

With reference to FIG. 7, an example of an electrochemical cell stack configuration is shown. The electrochemical cell frame 100 can be integrated with an electrolysis cell 101 to form a complete electrochemical cell assembly 400. The electrochemical cell frame 100 can be positioned to encapsulate and seal the active components of the electrolysis cell 101, in certain embodiments. Thee active components can include a membrane electrode assembly (MEA), which can consist of an ion-exchange membrane sandwiched between an anode and a cathode, along with porous transport layers and flow field structures. The polymer seals on the frame can create fluid-tight barriers around the active area, militating against cross-contamination between the anolyte and catholyte compartments while maintaining electrical isolation between adjacent cells. The sealing surfaces of the electrochemical cell frame 100 can engage with the bi-polar plates, which can serve as both electrical conductors and fluid distribution structures, directing water to the anode side and managing the removal of evolved gases.

Multiple electrochemical cell assemblies 400 can be assembled in a stack configuration 500, also shown in FIG. 7 to achieve the desired hydrogen production capacity and operating voltage. In stack configuration 500, individual electrochemical cell assemblies 400 can be stacked in series. The electrochemical cell frame 100 can serve as the anode for one cell and the cathode for the adjacent cell, allowing current to flow through the entire stack configuration 500. The electrochemical cell frame 100 of each stack configuration 500 can align to form continuous fluid manifolds running through the stack configuration 500, enabling the distribution of feed water to each cell and the collection of hydrogen and oxygen gases from the respective compartments.

Additional embodiments can include, for example, the use of the instant invention in a Proton Exchange Membrane (PEM) electrolyzer, an Anion Exchange Membrane (AEM) electrolyzer, or a liquid alkaline electrolyzer. The present disclsoure further contemplates using thicker metal scaffolding within the frame to withstand large pressure differentials between the cell internals and outside atmosphere, as well as use of the present disclosure in electrolyzers operating at pressures from 1 bar up to 900 bar. Additional embodiments include the use of redundant seal features to improve the reliability of the seals, complete coverage of bi-polar plates with non-conductive material to reduce shunt currents in the electrolyte manifold of the stack, and overhang of the frame into the active area to bridge any gap between the frame and electrode, thus militating against the need for a thin membrane to bridge the electrode-frame gap.

In additional embodiments, the present disclosure can include a membrane support feature configured to bridge the gap between an inner diameter of the frame body 102 and the electrode/membrane outer diameter. The membrane support provides structural integrity and maintains alignment of the membrane or separator relative to the frame body 102, ensuring optimal electrochemical performance and militating against membrane displacement during operation. The support feature can be integrally formed with the frame body 102 or provided as a separate component and can accommodate various membrane thicknesses and electrode configurations while maintaining the necessary seal integrity across the assembly.

Further embodiments incorporate an attachment feature for locating and securing various cell components within the electrochemical cell assembly 400. The attachment feature can facilitate positioning and retention of components including, for example, the membrane or separator, anode, anode flow field, cathode, cathode flow field, and bipolar plates (BPP). The attachment feature can include a mechanical interlock, a snap-fit mechanism, an alignment post, a recess, a tab, a groove, or other geometrical element that interface with corresponding features on the electrolysis cell 101. By providing the attachment feature, the assembly process can be simplified, component alignment is improved, and the structural stability of the assembled cell is enhanced.

Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.

Claims

1. An electrochemical cell frame for an electrolysis application utilizing an electrochemical cell, comprising:

a frame body formed from a polymer, the frame body defining an active area, a flow passage, and a port, the active area configured to accommodate the electrochemical cell, the flow passage in fluid communication with the active area, and the port in fluid communication with the flow passage;

an internal sealing member integrally formed with the frame body and positioned to separate fluid streams within the electrochemical cell; and

an external sealing member integrally formed with the frame body and positioned to militate against fluid leakage from the electrochemical cell when the active area accommodates the electrochemical cell.

2. The electrochemical cell frame of claim 1, further including a membrane sealing member positioned to seal around a perimeter of the active area.

3. The electrochemical cell frame of claim 1, wherein the polymer includes an elastomeric material.

4. The electrochemical cell frame of claim 3, wherein the elastomeric material is selected from a group consisting of a fluoroelastomer, a perfluoroelastomer, an ethylene propylene diene monomer rubber, a tetrafluoroethylene/propylene copolymer, and a hydrogenated nitrile butadiene rubber.

5. The electrochemical cell frame of claim 1, wherein the active area includes a cavity disposed within the frame body.

6. The electrochemical cell frame of claim 5, wherein the cavity is centrally disposed within the frame body.

7. The electrochemical cell frame of claim 5, wherein a perimeter of the active area is disposed entirely within a perimeter of the frame body.

8. The electrochemical cell frame of claim 1, wherein the flow passage includes a channel formed within the frame body.

9. The electrochemical cell frame of claim 1, wherein the port includes an opening positioned in the frame body to provide fluid communication between the electrochemical cell and an external manifolding system.

10. The electrochemical cell frame of claim 9, wherein the port is configured to align with a corresponding port in an adjacent frame when the electrochemical cell frame and the adjacent frame are stacked in series.

11. The electrochemical cell frame of claim 1, wherein the port includes a cathode port and an anode port.

12. The electrochemical cell frame of claim 1, wherein the internal sealing member includes more than one parallel blades.

13. The electrochemical cell frame of claim 1, wherein the external sealing member is disposed between a perimeter of the frame body and the internal sealing member.

14. The electrochemical cell frame of claim 1, wherein the external sealing member includes more than one parallel blades.

15. The electrochemical cell frame of claim 1, further including a scaffold at least partially encapsulated by the polymer of the frame body.

16. The electrochemical cell frame of claim 15, wherein the scaffold includes a metallic material.

17. The electrochemical cell frame of claim 1, further including an aperture positioned to receive a coupling means for affixing the frame body to an adjacent structure.

18. The electrochemical cell frame of claim 17, wherein the aperture is comprised by a plurality of apertures disposed around a periphery of the frame body.

19. A method of operating an electrochemical cell with an electrochemical cell frame, comprising:

providing the electrochemical cell frame of claim 1; and

coupling the electrochemical cell frame to an electrolysis cell.

20. An electrochemical cell frame for an electrolysis application utilizing an electrochemical cell, comprising:

a frame body formed from an elastomeric material, the frame body defining an active area, a flow passage, and a port, the active area configured to accommodate the electrochemical cell and including a cavity centrally disposed within the frame body, the flow passage in fluid communication with the active area and including a channel formed with the frame body, and the port in fluid communication with the flow passage and including a cathode port and an anode port;

an internal sealing member integrally formed with the frame body and positioned to separate fluid streams within the electrochemical cell;

an external sealing member integrally formed with the frame body and positioned to militate against fluid leakage from the electrochemical cell when the active area accommodates the electrochemical cell and disposed between a perimeter of the frame body and the internal sealing member; and

a membrane sealing member positioned to seal around a perimeter of the active area,

wherein the elastomeric material is selected from a group consisting of a fluoroelastomer, a perfluoroelastomer, an ethylene propylene diene monomer rubber, a tetrafluoroethylene/propylene copolymer, and a hydrogenated nitrile butadiene rubber.