Method for manufacturing a component for an electrochemical cell, and an electrochemical cell and a cell stack

Abstract

Components for an electrochemical cell are formed by an additive manufacturing process. The additive manufacturing process can be repeated to produce a fuel cell stack.

Description

Technical Field

[0001] Apparatus and methods relate to producing one or more electrochemical cells, battery components by additive manufacturing or 3D printing techniques. The components may include one or more separators or any MEA components that may together form a bipolar plate assembly and / or a membrane electrode assembly (MEA). The method may include: using doped, impregnated or coated polymers to provide conductive properties to the components, and applying electromagnetic or other energy sources to induce welding, for producing a more robust and electrically isotropic structure in three dimensions. Background Art

[0002] Electrochemical cells (e.g., fuel cells) generate electricity through chemical reactions. A common reaction in a fuel cell consists of a reaction between hydrogen and oxygen, which produces water and releases an electrical charge. Typically, each cell only produces a small amount of voltage. To increase the voltage for efficient operation, the cells are connected in series in a fuel cell stack.

[0003] A fuel cell typically includes at least one MEA, and in the case of two MEAs, at least one bipolar plate assembly that can separate the two MEAs. The MEA can include multiple layers, wherein the number of layers depends on the MEA to be constructed. In one embodiment, the MEA can be a 5-layer MEA that includes a polymer electrolyte membrane sandwiched between an anode catalyst layer and a cathode catalyst layer. The outer surface of each catalyst layer is defined by a gas diffusion layer.

[0004] The bipolar plate assembly generally includes an anode separator and a cathode separator. The bipolar plate assembly is located between two MEAs. The function of the bipolar plate assembly is to deliver fuel (e.g., hydrogen and oxygen) to adjacent MEAs, provide mechanical support for the MEAs, and may also have the function of cooling the MEAs. The anode separator and the cathode separator may be connected together to form a closed cooling channel.

[0005] The MEAs may be alternated with bipolar plate assemblies to create a fuel cell stack. In some cases, there are many MEAs, which are alternated with many bipolar plate assemblies to create a fuel cell stack so that the stack can generate enough electrical energy to operate efficiently.

[0006] The separator is typically made of a conductive metal, carbon, or polymer composite. The separator provides electrical conduction from one MEA to an adjacent MEA. As described above, the separator may include channels to provide a medium (e.g., reactants of fuel and oxygen) to feed the reaction as well as a cooling fluid. The MEA and separator may together form a battery. The separator provides structural support for the battery.

[0007] The separators can be machined from solid blocks of graphite, which has the advantage of isotropic electrical properties. However, this process is expensive and time-consuming.

[0008] The separators can also be produced by adding materials (e.g., graphite flakes) to a polymer in a mold. Unfortunately, the graphite flakes are typically oriented only in the xy plane and not in the z direction through the layer, so the separators are not electrically isotropic. Metal powders can be added to the material, but this adds weight and makes the separators heavier. Prior art designs can use polymers with high graphite filler content, which ultimately reduces the moldability of the material.

[0009] Typically, separators are made by stamping or molding processes, with metal sheets typically being stamped and polymer sheets typically being molded. The process involves expensive tooling and is limited to producing a single-sheet design unless expensive retooling is performed. Therefore, unless new tooling is created, manufacturers are typically limited to making fuel cells of a single shape or size. The standard shape / size commonly used for fuel cells is a square or rectangular shape, which in some cases, such as in a vehicle, does not fit well into the available space.

[0010] Prior art fuel cells also require many gaskets to seal the multiple fluid channels. Each gasket increases the cost of the fuel cell, and each gasket represents a failure mode of the fuel cell.

[0011] Prior art fuel cells also require bulky clamping mechanisms to make the seal effective and reduce electrical resistance between the MEA components and the separator.

[0012] It would be advantageous to have a method for making an electrochemical cell without the disadvantages associated with prior art methods. Summary of the invention

[0013] A method for manufacturing an electrochemical cell component, the method may include the following steps: providing an additive manufacturing device for producing a 3D object, the additive manufacturing device including: a support platform having a building area for producing a three-dimensional object on the support platform; and a movable deposition device for depositing a flowable conductive material on the building area; heating the conductive material to a temperature higher than a first temperature using a heating device, thereby providing the deposition device with a flowable conductive material, the flowable material solidifying at a temperature lower than a second temperature; moving the movable deposition device to deposit the flowable conductive material on the building area of ​​the support platform in sequence, thereby producing a component for an electrochemical cell, the component having at least one channel for medium transmission.

[0014] Another aspect of the method may be that the conductive material is a carbon loaded thermoplastic or thermoset material.

[0015] Another aspect of the method can be that the carbon-loaded thermoplastic material is a carbon-coated thermoplastic filament.

[0016] Another aspect of the method may be that the cross-sectional area of ​​the channel varies as a function of deposition.

[0017] Another aspect may be that the method includes using an apparatus to print a plurality of channels in a part and one or more manifolds in communication with the channels.

[0018] Another aspect may be that the method includes an activation step to cure the conductive material.

[0019] Another aspect of the method may be to print the channel as a zigzag channel that runs along the length of a component face from one side of the face to an opposite side of the face.

[0020] Another aspect of the method may be to print the component to include a first opening at one end of the tortuous channel and in fluid communication with the tortuous channel, and a second opening at the other end of the tortuous channel and in fluid communication with the tortuous channel.

[0021] Another aspect of the method may be printing the component to include an anode separator, a cathode separator, and / or a bipolar plate.

[0022] Another aspect of the method may be to print the bipolar plate to include two active surfaces on opposite sides of the plate, wherein one active surface faces the anode electrode cell and the opposite side faces the cathode electrode cell.

[0023] Another aspect of the method may be: printing the component to include an anode separator having an anode separator tortuous channel printed on one side of the anode separator, and also including: adding an electrically insulating material around the anode separator, placing a membrane electrode assembly on the anode separator, and printing a cathode separator with an initial flowable deposition material on the membrane electrode assembly and the electrically insulating material, wherein the cathode separator is printed with a first cathode plate tortuous channel on a first side and a second cathode plate tortuous channel on a second side.

[0024] Another aspect of the method may include applying energy to one or more of the anode separator, the cathode separator, the electrical insulation material, or the membrane electrode assembly.

[0025] Another aspect of the method may be that the energy causes the anode separator to become flowable, thereby causing the membrane electrode assembly to be embedded in the anode separator.

[0026] In addition, a method for manufacturing a fuel cell stack includes: providing an additive manufacturing device for producing 3D objects, the additive manufacturing device including: a support platform for supporting the manufacture of three-dimensional objects thereon; heating a conductive material to a temperature higher than a first temperature, thereby providing a flowable conductive material to a deposition mechanism, the flowable material solidifying at a temperature lower than a second temperature; depositing the flowable material layer by layer according to a data file to produce a first separator supported on the support platform, the first separator being deposited to have at least one channel to allow a medium to be transmitted therethrough; placing a membrane electrode assembly on the deposited first separator in contact with at least one channel of the first separator; so that a non-conductive material is located on the first separator that does not extend from the membrane electrode assembly; depositing a layer of flowable material on the layer to produce a second separator, the second separator having at least one channel on a side facing the membrane electrode assembly and having at least one channel generated by the deposited material on a side opposite to the membrane electrode assembly formed by the deposited material, wherein both channels are used to transmit the medium; and applying energy to one or more individual layers during deposition.

[0027] Another aspect of the method may be that the energy is heat that is added to at least the non-conductive material to soften it, thereby causing the membrane electrode assembly to be at least partially embedded therein.

[0028] Another aspect of the method can be that the conductive material is a carbon coated thermoplastic filament.

[0029] Another aspect of the method may be to apply plasma or microwave energy to the individual layers during deposition.

[0030] Another aspect of the method may be to deposit the at least one channel to include a plurality of tortuous channels running across the first separator face from one side to an opposite side of the face along the length of the first separator face.

[0031] Another aspect of the method may be that the first separator is deposited to include a first opening at one end of the plurality of tortuous channels and in fluid communication with the plurality of tortuous channels, and a second opening at another end of the tortuous channels and in fluid communication with the tortuous channels.

[0032] Another aspect of the method may be that one or more manifolds printed in the first and second baffles are printed with a variable cross-section to vary the flow rate of the fluid in the manifold.

[0033] Another aspect of the method may be embedding the fastener retainer into the first bulkhead or the second bulkhead.

[0034] Another aspect of the method may be to embed the sensor in the first separator or the second separator.

[0035] Another aspect of the method may include positioning a permeation barrier in the second separator between at least one channel on a side facing the membrane electrode assembly and at least one channel on a side opposite the membrane electrode assembly.

[0036] A method of manufacturing an electrochemical cell may include printing a component of the electrochemical cell using an additive manufacturing device. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 A perspective view showing one embodiment of a 3D printing or fused filament fabrication apparatus that can be used to produce structures of the present disclosure;

[0038] Figure 2 An embodiment of an initial layer of an embodiment of an anode separator is depicted, wherein the anode separator is Figure 1 Print on your device;

[0039] Figure 3 Depicts one embodiment of a printed anode separator having a Figure 1 Print on your device;

[0040] Figure 3A Depicted along Figure 3 An embodiment of a cross section of the center line 3-3;

[0041] Figure 4 depicts one embodiment of an electrically insulating material located or printed on a printed anode separator;

[0042] Figure 5 depicts one embodiment of a membrane electrode assembly positioned or printed on a printed anode separator and electrical insulation material;

[0043] Figure 6 Depicted Figure 5 An embodiment of a membrane electrode assembly, wherein the membrane electrode assembly is mounted on the printed anode separator and the electrical insulating material;

[0044] Fig. 6A An embodiment of a membrane electrode assembly having a gas diffusion layer is depicted;

[0045] Figure 7 One embodiment of an initial layer of a cathode separator to be printed is depicted;

[0046] Fig. 7A depicts one embodiment of a permeable layer added to a cathode separator;

[0047] Figure 8 Depicts one embodiment of another layer of a printed cathode separator having a Figure 1Print on your device;

[0048] Fig. 9 Depicts one embodiment of another layer of a printed cathode separator having a Figure 1 Print on your device;

[0049] Fig.10 One embodiment of an external manifold for an electrochemical cell is depicted;

[0050] Fig.11 depicts embodiments of internal manifold cross-sectional shapes;

[0051] Fig.12 One embodiment of an external fluid manifold is depicted; and

[0052] Fig.13 Another embodiment of a printed frame with a manifold is depicted, wherein the frame houses components of an electrochemical cell. DETAILED DESCRIPTION OF THE INVENTION

[0054] It should be understood that, unless explicitly stated to the contrary, the embodiments disclosed herein may take various alternative orientations and step sequences. It should also be understood that the specific devices and processes shown in the accompanying drawings and described in the following specification are merely exemplary embodiments of the present inventive concept. Therefore, specific dimensions, directions, or other physical characteristics associated with the disclosed embodiments should not be considered limiting.

[0055] In one embodiment, a fuel cell component and / or one or more fuel cells are produced by an additive manufacturing process. The structures and methods described herein are primarily directed to producing fuel cells by an additive manufacturing method. However, it is understood that the method can be used to selectively manufacture all or part of one or more fuel cell components, which can be single or combined. In addition, all or part of one or more fuel cells can be manufactured using the method. A method for manufacturing a fuel cell component, which can also be part of a fuel cell, will be described below.

[0056] Reference Figure 1 , schematically depicting one embodiment of the method. The fuel cell components can be produced using a fused filament fabrication (FFF) apparatus 20 and process. Although an FFF apparatus 20 and process are described and depicted, other additive manufacturing apparatus and processes can be used. The processes include, but are not limited to: fused deposition molding, selective laser sintering, selective laser melting, electron beam melting, and object layering manufacturing.

[0057] FFF forms structures by laying down or depositing molten or flowable materials layer by layer, which bond together to form a 3D structure. Figure 1 In one embodiment of the FFF apparatus 20 shown, a material in the form of a solid filament 22 is fed from a coil (not shown) at room temperature via a roller 24 or other advancement device to a heater or heating element 26, which changes the material into a molten or flowable form. The temperature at which the change occurs may be a first temperature. The temperature at which the material is solid may be a second temperature, wherein the second temperature is lower than the first temperature. Subsequently, the material is extruded onto a substrate or platform 30 by a deposition device or mechanism (e.g., a nozzle) 28. The material from the filament 26 will be referred to herein as material 26.

[0058] The material 26 can be a thermoplastic that is solid at room temperature but becomes flowable when heated. In one embodiment, the material 26 is a carbon doped or impregnated thermoplastic material. In another embodiment, the material 26 can be, for example, a carbon coated filament such as those available from Essentium Materials, 5880 Imperial Loop Dr #10, College Station, TX 77845. Thermosetting materials 26 can also be used. The material can also be, for example, a solid oxide or a ceramic material.

[0059] The deposition device 28 may be mounted on one or more movable arms 32 or tracks, and may move on the platform 30 in the xy plane to deposit layers of material 26, and vertically in the z direction to add layers to previously deposited layers, all under the control of a computer 34. Alternatively, the substrate or platform 30 may be moved under computer control, or both the deposition mechanism and the platform may be moved under computer control, thereby moving in the x, y, and z planes. The speed of the deposition device may also be controlled (e.g., by the computer 34), including stopping and starting deposition, to form all types of 3D structures.

[0060] The desired structure to be manufactured can be defined in a computer-aided design (CAD) file or other file readable by the computer 34, and the structure can be defined layer by layer in as fine detail as desired. The layers can include components of the fuel cell (e.g., each layer is a component), or each component can include multiple layers.

[0061] Although the present description begins with printing the anode separator 36, the process is not limited to starting with the separator 36. Instead, as can be understood above, any of the components of the fuel cell can be printed in any order. However, it is more cost-effective and simpler to print in sequence substantially from one end of the fuel cell to the other end of the fuel cell so that all or most of the fuel cell components can be printed together. It is also possible to print a bipolar plate, the bipolar plate comprising: one surface facing the anode electrode cell and another surface facing the cathode electrode cell.

[0062] Figure 2 Depicted Figure 1 The apparatus of claim 1, wherein one embodiment of an anode separator 36 has been printed. The anode separator 36 may have a square or rectangular perimeter or shape, but the apparatus and method are not limited to such shapes. Rather, it is preferred to print the anode separator 36 in a shape other than a square or rectangular shape because it allows the separator 36, and any resulting fuel cell stack, to adapt to the unconventional shapes of a vehicle or other storage device.

[0063] Figure 2 Depicted may be the initial deposition of material 22 or substrate layer may include one or more layers of anode separator 36. The substrate layer may or may not provide fluid channels, which will be described in further detail below. In the illustrated embodiment, no channels are provided, so the substrate layer may have a planar upper surface 38 and a planar lower surface 40.

[0064] During the initial deposition step, the contour or perimeter 42 of the anode separator 36 may be established. Figure 2 It can be seen that the periphery 42 of the anode separator 36 is not square or rectangular. Instead, Figure 2 The partition 36 in the embodiment has an irregular shape. In addition, one or more reactant supply ports 44 and / or outlet ports 46 may be first located in the partition 36 via a deposition method.

[0065] Figure 3 One embodiment of a completed anode separator 36 printed by an additive process is depicted. In this embodiment, the shape of the separator 36 has been further defined, and the supply / outlet ports 44, 46 are also further defined. Further defined is that the ports 44, 46 extend through the plate 36 from one side of the plate 36 to the other side of the plate 36. The depth of the ports 44, 46 is defined by the amount of material 22 added to the plate 36 by the printing process. Figure 3A As shown, the cross-section of the ports 44, 46 can be circular, or can be other shapes besides circular. During the printing process, the shape of each port 44, 46 can change, so the shape of each individual port 44, 46 can change, or the shape of multiple ports 44, 46 in the plate 36 can change relative to each other.

[0066] Additionally, during the additive printing process, after the base layer is printed, one or more channels 48 may be printed in the plate 36. More specifically, as Figure 3As shown, a plurality of channels 48 may extend from one port 44, 46 to another port 44, 46 on one side or face 52 of the plate 36. The channels 48 may extend or meander at least over a central region 50 of the face 52. The channels 48 may be closed on three sides and have an open top side. The channels 48 may be formed or printed directly in the face 52, and the channels 48 may include grooves or continuous depressions in the face 52.

[0067] Although the drawings depict one embodiment of the direction, number, shape and length of the channels 48, the method is not limited to these directions, numbers, shapes and lengths. For example, channels 48 of different widths, depths, sizes and shapes can be printed simultaneously on the face 52. Of course, while this printing is being performed, the plates 36 and / or ports 44, 46 are printed.

[0068] The channels 48 may carry media, such as reactants, cooling fluids, and products of the fuel cell reactions. Although the individual channels 48 are depicted as being separated from one another, they may be in fluid communication via the ports 44 , 46 .

[0069] All of the aforementioned information regarding layers / boards, channels and ports may be stored in the aforementioned data files or in separate data files in or in communication with the computer 34 .

[0070] A gas diffusion layer (GDL) may be printed on the anode separator 36. The gas diffusion layer may be printed using the same or different material 22 as used to print the anode separator 36. The GDL is not shown in the figure.

[0071] The GDL essentially acts as an electrode, facilitating diffusion of reactants across the catalyst layer. The surface area and porosity of the GDL allows reactants to transfer from channels in the anode separator 36 and cathode separator (described below) to the catalyst region of the membrane.

[0072] Information about the material, shape, size, and feature locations of the GDL may be stored in the above-mentioned data file or in a separate data file in or in communication with the computer 34 .

[0073] In one embodiment, the GDL may include a carbon fiber mat or paper that functions as a gas diffusion layer and has catalyst particles thereon. In one embodiment, the carbon fiber mat or paper with or without catalyst may be printed or deposited by the FFF apparatus 20. If no catalyst is present in the deposited material, the catalyst may be applied after the second step.

[0074] Figure 4An electrically insulating material 54 is depicted as being located on the anode separator 36. In the illustrated embodiment, the material 54 is located directly on the face 52 of the anode separator 36 and around the perimeter 42 of the plate 36. The perimeter 42 may include an area that includes the ports 44, 46 and, in some cases, may include the inside of the ports 44, 46, such as into a portion of the central region 50. Preferably, the material 54 is continuous and uniform in its location, size, and shape. The electrically insulating material 54 has a predetermined thickness and forms a pocket 56 inside its inner edge 58. In other words, the electrically insulating material 54 may extend from the perimeter 42 of the anode separator 36 on the plate 36, wherein it may extend around and beyond the ports 44, 46 to a predetermined location inside the ports 44, 46. The continuous inner edge 58 of the electrically insulating material 54 defines a boundary of an exposed area 60 of the face 54 of the anode separator 36, where the electrically insulating material 54 is absent.

[0075] Electrically insulating material 54 insulates anode separator 36 from cathode separator. If the anode electrons produced in the reaction were able to participate in the cathode reaction of the same cell, a short circuit would result. Therefore, the electrons would not travel outside the cell to perform work.

[0076] If an MEA having an electrically insulating membrane extending to the edge of the cell can be used, it may not be necessary to use electrically insulating material 54 as described above.

[0077] The electrically insulating material 54 also has an outer edge portion 62. The outer edge portion 62 may follow the perimeter 42 of the anode separator 36 and be aligned therewith.

[0078] like Figure 5 As shown, information regarding the material, shape, size, and feature location of the electrically insulating material 54 may be stored in the above-mentioned data file or in a separate data file in or in communication with the computer 34 .

[0079] Reactant supply and outlet ports 74, 76 may be located in electrically insulating material 54. Ports 74, 76 in material 54 preferably align and mate with ports 44, 46 in anode separator 36. At least these ports 44, 46, 74, 76 together form reactant supply and outlet manifolds 78, 80.

[0080] The electrically insulating material 54 forms the frame of the membrane electrode assembly or MEA 64. Figure 5 As shown schematically, the MEA 64 may be manually or automatically placed in the frame on the exposed surface 60 of the anode separator 36. One embodiment of the MEA 64 positioned on the anode separator 36 of the electrically insulating material frame 54 is shown in FIG. Figure 6That is, the face 66 of the MEA 64 is in direct contact with the face 60 of the anode separator 36 , and the periphery 42 of the MEA 64 is in direct contact with the electrically insulating material 54 .

[0081] MEA 64 is the core component of the fuel cell, which helps to produce the electrochemical reaction required to separate the electrons. On the anode side of MEA 64, the fuel (hydrogen, methanol, etc.) is catalytically decomposed into protons, electrons and other reaction products. The protons diffuse through the membrane and meet the oxidant (oxygen or air) on the cathode side, which combines with the protons while receiving the electrons separated from the fuel. The catalysts on each side can react, and MEA 64 allows the protons to pass while keeping the gases separated. In this way, the cell potential is maintained and current is drawn from the cell to generate electrical energy.

[0082] A typical MEA 64 consists of a polymer electrolyte membrane and catalyst layers applied to the anode and cathode sides. This is often referred to as a three-layer MEA. If two gas diffusion layers are included in the MEA, it is often referred to as a 5-layer MEA 64'. In some cases, the MEA 64 may be provided with a plastic frame (not shown) having the same size and shape as the separator. The plastic frame prevents electrical short circuits between cells. It is understood that such a frame can eliminate the need for electrical insulating materials.

[0083] Fig. 6A One embodiment of a 5-layer MEA 64' is depicted, with gas diffusion layers 65A, 65B. Rather than being integrated with the MEA 64', the gas diffusion layers 65A, 65B can be attached directly to a separator (e.g., anode separator 36), respectively, such as by bonding. The gas diffusion layers 65A, 65B can be formed, for example, by printing, in the same manner as described above, using the same materials as described above. The other layers of the MEA 64' can then be attached to the gas diffusion layers 65A, 65B.

[0084] Reference Figure 7 , schematically depicting the beginning of another layer in the printing process. Figure 7 6, an initial layer of cathode separator 68 has been laid down. This layer is directly on and in direct contact with electrically insulating material 54 and MEA 64. That is, the initial layer of a central region 70 of cathode separator 68 is directly on and in direct contact with the cathode side of MEA 64, while an outer edge region 72 of cathode separator 68 is directly on and in direct contact with electrically insulating material 54.

[0085] Through the printing process, one or more reactant supply ports and / or outlet ports 82, 84 may be defined in the plate 68. The ports 82, 84 preferably align with and mate with the ports 74, 76, thereby extending the manifolds 78, 80.

[0086] Additionally, one or more MEA side channels 86 may be printed in the plate 68. More specifically, as Figure 7 As shown, a plurality of MEA side channels 86 can extend from one port 82, 84 to another port 82, 84 on one side or face 88 of the plate 68. The MEA side channels 86 can extend or meander at least over a central region 90 of the face 88. The MEA side channels 86 can be closed on three sides and have an open top side. The MEA side channels 86 can be formed or printed directly in the face 88, and can include grooves or continuous depressions in the face 88.

[0087] Although the drawings depict one embodiment of the direction, number, shape and length of the channels 86, the method is not limited to these directions, numbers, shapes and lengths. For example, channels 86 of different widths, depths, sizes and shapes can be printed simultaneously on the face 88. Of course, while this printing is being performed, the plate 68 and / or ports 82, 84 are printed.

[0088] The additive printing process adds one or more layers to the cathode separator 68 such that the MEA side channels 86 are further defined with sidewalls and a bottom.

[0089] Fig. 7A An alternative embodiment is depicted in which a permeation barrier is located in plate 68. The permeation barrier can be located in plate 68 between channel 86 and coolant channel 92 (described below). The permeation barrier can be, for example, a metal foil or metal plate 69. Although metal is suggested for plate 69, other materials with functionally similar properties can be used. Plate 69 can be formed in a monolithic, one-piece, and integrated manner. The permeation barrier blocks or prevents gas (such as hydrogen in channel 86) from permeating into coolant channel 92.

[0090] See now Figure 8 , the process may additionally print one or more coolant channels 92 in one or more layers of the cathode separator 68. The coolant channels 92 may extend over a face 94 of the partially formed plate 68. The channels 92 may extend or meander over at least a central region 96 of the partially formed plate 68.

[0091] As the printing process continues, the channel 92 is further formed and defined. The channel 92 can have any cross-sectional area, including a constant or variable cross-sectional area within a single channel or within adjacent or non-adjacent channels. The channel 92 is in communication with the coolant port 98. In the illustrated embodiment, the channel 92 can have a circular cross-sectional area. Thus, the printing process includes printing a concave lower wall, a circular side wall, and a concave upper wall until the channel 92 is completely enclosed within the plate 68.

[0092] like Fig. 9As shown, other printed layers are added to the cathode separator 68 to form the bipolar plate side 100 of the cathode separator 68 .

[0093] A gas diffusion layer (GDL) (not shown) may be printed onto the bipolar plate side 102 of the cathode separator 68. The gas diffusion layer may be printed using the same or different material as used to print the cathode separator 68.

[0094] In one embodiment, the GDL may include a carbon fiber mat or paper that acts as a gas diffusion layer and has catalyst particles thereon. In one embodiment, the carbon fiber mat or paper with or without catalyst may be printed or deposited by a FFF device. If no catalyst is present in the deposited material, the catalyst may be applied after the second step.

[0095] Fig. 9 One embodiment of a finished cathode separator 68 printed by an additive process is depicted. In this embodiment, the shape of the plate 68 has been further defined, and the supply / outlet ports 82, 84 and the coolant port 98 are also further defined. Further defined means that the ports 82, 84, 98 extend through the plate 68 from one side of the plate 68 to the other side of the plate 68. The depth of the ports 82, 84, 98 is defined by the amount of material added to the plate 68 by the printing process. The cross-section of the ports 82, 84, 98 can be circular, or can be other shapes besides circular. During the printing process, the shape of each port 82, 84, 98 can change, so the shape of each individual port 82, 84, 98 can change, or the shape of multiple ports 82, 84, 98 in the plate 68 can change relative to each other.

[0096] The bipolar plate side (opposite the MEA side) of the cathode separator 68 is defined by ports 82, 84, 98. In addition, one or more bipolar plate side channels 100 may be printed into the cathode separator 68. More specifically, as Fig. 9 As shown, a plurality of bipolar plate side channels 100 may extend from one port 82, 84 to another port 82, 84 on a bipolar plate side 102 of the plate 68. The bipolar plate side channels 100 may extend or meander at least over a central region 104 of the side 102. The bipolar plate side channels 100 may be closed on three sides and have an open top side. The bipolar plate side channels 100 may be formed or printed directly in the side 102, and the bipolar plate side channels 100 may include grooves or continuous depressions.

[0097] Although the figures depict one embodiment of the direction, number, shape and length of the channels 100, the method is not limited to these directions, numbers, shapes and lengths. For example, channels 100 of different widths, depths, sizes and shapes can be printed simultaneously on the side 102. Of course, while this printing is being performed, the plate 68 and / or ports 82, 84 are printed.

[0098] In an embodiment of the process, either of the plates 36, 68 may have one or more channels 48, 86, 92, 100 printed with different widths at different locations or areas of the plates 36, 68. Channels of various sizes and shapes may influence, adjust and / or change the rates of reactions occurring in the fuel cell.

[0099] In addition, in the same or different embodiments, the cross-sectional area of ​​one or more ports 44, 46, 74, 76, 98 can be changed. That is, one or more ports 44, 46, 74, 76, 98 can have different shapes and / or sizes. Changing the cross-sectional area can affect, adjust and / or change the fluid flow rate or pressure through the battery, which can change the rate of the reaction occurring in the battery.

[0100] Fig.11 One such embodiment is shown schematically. Fig.11 One embodiment of the ports forming the manifold is depicted, but other shapes, sizes, quantities, etc. may be used. For example, when the components described above are combined to form a fuel cell, ports 44, 46, 74, 76, 98 will be aligned to form a corresponding fluid manifold. In the case of a plurality of fuel cells combined, the fluid manifold in the stacked fuel cell can be lengthened so that the fluid flow through the manifold is different at different parts of the cell stack and the manifold. By changing the cross-sectional area of ​​ports 44, 46, 74, 76, 98 and the manifold through a printing process, the fluid performance (e.g., speed and / or pressure) of the manifold can be adjusted to the desired performance. That is, at the beginning of the fuel cell stack, a manifold may have a cross-sectional area of ​​X, and at the end of the fuel cell stack, the same manifold has a cross-sectional area of ​​Y, where Y is less than X. In this case, physics teaches that the fluid in the Y cross-sectional area is faster / faster than the fluid in the X cross-sectional area. Therefore, a simple, economical and reliable way to adjust or customize the fluid flow along the fuel cell manifold can be obtained by the above process.

[0101] For example, for cells that may require additional cooling, the manifold may be designed to direct coolant to the cells at a faster rate to remove more heat. It is also understood that the coolant channels for a particular cell may be modified to have different cross-sections to allow for more (or less) cooling. The manifold and cooling channels may also be modified by other features, such as including internal structures to produce desired fluid flow dynamics (e.g., turbulence) characteristics or effects.

[0102] In another embodiment, Fig.10 As shown, manifold conduits 106 external to one or more of the plates 36, 68 or layers may be printed from a non-conductive material. It will be appreciated that the external manifold conduits 106 may have different cooling characteristics than manifolds located within the cells or layers because the conduits 106 are not directly affected by the heat in the layers or tubes. The conduits 106 may be printed at the same time or at a different time than the layers are printed. The conduits 106 may be printed with the layers, or printed separately and connected later. The conduits 106 may replace or supplement the internal ports / manifolds.

[0103] As with the manifold described above, the cross-sectional area of ​​the conduit 106 may vary over its length so that the properties of the fluid flowing therein may be tailored as desired. Fig.10 In the embodiment shown in FIG. 1 , the first external manifold conduit 108 has been printed so as to taper from top to bottom, and the second external manifold conduit 110 has been printed so as to taper from bottom to top.

[0104] In one embodiment, the FFF apparatus 20 may include an energy transmitting device 112 for distributing energy to the deposited or deposited material 22, thereby heating the material 22 or causing the material 22 to heat. The device 112 is schematically shown in Figure 1 Although only in Figure 1 1, but the device 112 may be used in any or all steps / figures herein. The energy transmitting device 112 may be associated with the FFF device 20, or may be located separately from the FFF device 20 or disconnected from the FFF device 20.

[0105] In any case, the deposited material 22 may remain in a molten state for an extended period of time, or re-melt if solidified to ensure bonding of the various sections and / or adjacent sections of the deposited material. In one embodiment, the dispersed energy may be thermal energy, such as infrared radiation, plasma energy, or microwave electromagnetic energy. In one embodiment, the launch device 112 launches a plasma beam onto the deposited material 22 to warm, heat, or maintain the deposited material 22 in a molten state. In another embodiment, the launch device 112 launches microwave radiation that is absorbed by the carbon in the filaments and heats the deposited material 22. In another embodiment, the launch device 112 may continuously emit infrared radiation to maintain the build area at a predetermined temperature, thereby maintaining the deposited material 22 in a semi-fluid state.

[0106] Energy can be emitted when depositing material 22. Alternatively, energy can be emitted after each completed layer has been deposited and before the next layer is deposited on the lower layer. In another embodiment, the layers can be irradiated with another device, such as by placing a partially printed structure in a microwave chamber and then depositing the next layer thereon to ensure that the next layer will be deposited on a still molten or flowable material to improve the bonding between the layers. In another embodiment, after any layer has been manufactured, the entire layer can be irradiated by an energy emitting device or another device to produce interlayer bonding. The reheating, remelting and resolidification process produces a stronger bond along the sections of the deposited material 22, between the sections of the single layer in the xy plane, and between the layers in the z direction. This improved bonding can result in improved structural integrity of the layer, and improved conductivity of the entire layer and between the layers along the z direction.

[0107] For example, before placing the MEA on the anode separator 36, the area 50 on the anode separator 36 that accommodates the MEA or the MEA itself can be heated to allow some carbon fibers of the gas diffusion layer of the MEA to sink or embed into the anode separator 36 at a certain depth, thereby reducing the resistance between the gas diffusion layer and the anode separator 36. The gas diffusion layer should not be embedded too deep to prevent the reactants from diffusing to the catalyst particles through the pores of the gas diffusion layer. In another embodiment, the same process can be used, and the anode or cathode layer has a gas diffusion layer. In other words, one of the anode layer or cathode layer, or an area of ​​the separator that accommodates it, can be heated to allow the embedding of the gas diffusion layer.

[0108] In any of the above steps, a coating (not shown) may be applied to the partially or fully formed channels or ports. The coating may be hydrophilic or hydrophobic in nature to aid in water management or media distribution. A sprayer (not shown) may be associated with the FFA apparatus 20 to spray the material and cure it in place if necessary.

[0109] In another embodiment, during any of the above steps, positioning features (not shown) may be printed on any layer or plate 36, 68. The positioning features may be printed patterns or raised features. The positioning features may be used by the FFF equipment 20 (e.g., computer 34) to understand where subsequent layers, plates, or other features of the battery should be positioned relative to previous layers.

[0110] An automated vision system (not shown) may be used to photograph or otherwise image any layer or layer portion to ensure quality control. The automated system may be connected to the computer 34 to stop the process if the layer is not properly placed or aligned.

[0111] In another embodiment, an activation step may be used. The activation step may be used to cure the conductive material 22. The activation step may be thermal and / or chemical in nature. For example, the activation step may include exposing the material 22 to another substance (e.g., water or moisture) to promote curing. The step may also include mixing the conductive material 22 with another material to promote curing of the conductive material 22. The mixing may occur at some time during or after the deposition of the conductive material 22. Curing may also be achieved by irradiation, such as by plasma or microwave energy or ultraviolet or infrared light directed to the conductive material 22. The activation or curing step may promote bonding or connection of the conductive material 22 to itself or to adjacent structures.

[0112] Fuel cells produced using the above-described FFF apparatus 20 can be connected with other fuel cells to form a fuel cell stack. Individually manufactured fuel cells can be assembled into a fuel cell stack by manually attaching or securing the fuel cells together using attachment hardware known in the art.

[0113] Fuel cells are typically counter-flow or parallel-flow, which describes which way the reactants flow across the cell's surface. For example, in a parallel-flow cell, hydrogen and oxygen enter and leave the same side or end of the cell. Hydrogen may flow through one cell face, while oxygen flows through the opposite cell face. In a counter-flow cell, hydrogen enters the side of the cell where oxygen exits, and vice versa. Hydrogen may flow through one cell face, while oxygen flows through the opposite cell face. With traditional manufacturing, the design is fixed as either parallel or counter-flow - since the reactants enter the manifold at the end of the stack, this cannot be changed.

[0114] The present apparatus and method not only allows printing, but also directs the manifold 106 into the plate so that one cell can be parallel flow while the adjacent cell can be counter flow. Fig.12 An example is shown schematically in . Fig.12A first cell 114 is shown having an inlet 116 on a first end portion 118 of the cell 114. Fluid flow may pass through the cell face 120 to an outlet 124 that is opposite the inlet 116 on a second end portion 126 of the cell 114.

[0115] A second cell 128 in at least one channel 122 is located directly adjacent to the first cell 114. The second cell 128 can have an inlet 130 adjacent to the first cell outlet 124. For example, the inlet 130 can be at an end portion 132 of the second cell 128. The end portion 132 can be directly adjacent to the end portion 126, for example.

[0116] A manifold 134 external to both cells 114, 128 may connect the second cell inlet 130 to the first cell inlet 116. It will be appreciated that the manifold may extend internally through one or both cells 114, 128. Thus, using the additive process described above, a co-current / counter-current arrangement may be easily created in directly adjacent cells.

[0117] Back to Fig.11 , which shows another possible feature. The feature includes at least one fastener retainer 136 located in at least one of the anode separator 36, the electrically insulating material 54, and / or the cathode separator 68.

[0118] exist Fig.11 , two fastener retainers 136 are depicted in the anode separator 36, and two fastener retainers 136 are depicted in the cathode separator 68. Although fastener retainers 136 are depicted in certain locations of the plates 36, 68, other locations are also permitted. Fig.11 Fastener retainers 136 are depicted in corner portions 138 of panels 36, 38. These corner portions 138 may be where there are no channels or other openings in panels 36, 68 to interfere with them. Furthermore, while two fastener retainers 136 are depicted in panels 36, 68, a greater or lesser number is also permitted.

[0119] When printing the plates 36, 68, the fastener retainers 136 are preferably disposed in the plates 36, 68. The fastener retainers 136 may be a separate structure inserted into the plates 36, 68, or they may be manufactured by, during, the same printing process that produces the plates 36, 68, or they may be printed separately and then inserted into the plates 36, 68. In either case, the fastener retainers 136 are preferably non-removably fastened or fixed to the plates 36 or 68.

[0120] In one embodiment, the fastener retainer 136 may be a receptacle or connector for a fastener. Fig.11In the embodiment, the fastener holder 136 can be, for example, a structure having an opening 140 for receiving a fastener 142 therein. If the fastener 142 is threaded, the area around the opening 140 or defining the opening 140 can be threaded so that the fastener 142 can be fastened to the fastener holder 136.

[0121] As just one example, the fastener retainer 136 may be, for example, a hexagonal nut that has been partially overprinted into one of the plates 36, 68 by the printing process described above. Preferably, the printing process does not block the opening 140 in the nut, but rather the printing process has tightened the nut so that it is not easy to remove the nut from the plates 36, 68.

[0122] In another embodiment (not shown), the fastener retainer can be, for example, one half of a snap-fitting. As described above, the snap-fitting half can be provided, for example, by printing, on one of the plates 36, 68. The fastener can be, for example, the other half of a snap-fitting.

[0123] An end cap or cover 144 may be at least partially located on one or more of the panels 36, 68. The end cap may be fastened to the panels 36, 68 by fasteners 142 coupled to the fastener retainers 136. In one embodiment, the fasteners 142 may be coupled to the end caps 144 or extend into the end caps 144 to engage with the fastener retainers 136.

[0124] Fig.11 Also shown is at least one sensor 146. In the illustrated embodiment, at least one sensor 146A is located in the anode separator 36, at least one sensor 146B is located in the electrically insulating layer 54, and at least one sensor 146C is located in the cathode separator 68.

[0125] Although Fig.11 Sensors 146A-C are shown in one location of the panels / layers 36, 54, 68, but the sensors are not limited to these locations. Furthermore, although only one sensor 146A-C is located in each panel / layer 36, 54, additional sensors are permitted.

[0126] like Fig.11 As shown, during the above-described printing process, sensors 146A-C may be embedded in their respective plates / layers 36, 54, 68. By way of example only, it can be seen that sensor 146A may be embedded when initially forming anode separator 36. However, sensor 146B may have been embedded in electrically insulating layer 54 halfway through its completion. Finally, sensor 146C may have been embedded in cathode separator 68 near completion.

[0127] Sensors 146A-C may be the same, different, or a combination of sensor types. By way of example only, sensors 146A-C may be, for example, thermocouples or battery voltage sensors. In any case, sensors may be embedded to monitor conditions including, but not limited to, temperature, battery voltage, humidity, and / or chemical concentration.

[0128] The sensors 146A-C may be wired or wireless, providing the data or conditions they sense to a controller (not shown). In embodiments where the sensors 146A-C may be wired, wires for the sensors 146A-C may extend from the plates 36 or 68, or the electrically insulating material 54. These wires may then be connected to the controller.

[0129] Reference Fig.13 , depicts another embodiment of a print frame 148 . Fig.13 A completed printed frame 148 is depicted, however, based on the above description, it will be appreciated that the frame 148 may be printed in layers or portions in the manner described above.

[0130] The frame 148 may have a polygonal perimeter 150 , although other shapes may be used, such as those required to fit within a particular vehicle area.

[0131] The frame 148 may define at least one manifold region. Fig.13 In the illustrated embodiment of FIG, a first manifold area and a second manifold area 152, 154 are shown. The two manifold areas 152, 154 are on opposite sides of the frame 154 and are separated by a central opening 156. Two manifold areas 152, 154 are shown, but there may be a greater or lesser number of manifold areas. The manifold areas 152, 154 may have the same size and shape, but other designs are also allowed.

[0132] Each manifold region 152, 154 in the figure depicts three fluid openings 158, but a greater or lesser number of fluid openings 158 may be used. The fluid openings 158 have the same size and shape, but openings 158 of different sizes and shapes may be used herein as well. In addition, the fluid openings 158 may vary as they extend through the frame 148. For example, through a printing process, the cross-sectional area of ​​each fluid opening 158 may vary, thereby varying the flow rate through each fluid opening 158.

[0133] The central opening 156 may also be formed by a printing process. The central opening 156 may be polygonal, but other shapes are also permitted. Preferably, the central opening 156 has an insert 160 of a complementary shape.

[0134] Insert 160 may include anode separator 36' and cathode separator 68'. Primers are used with plates 36' and 68' to specify that plates 36', 68' may be the same or different than plates 36, 68. As one example of possible differences, plates 36' and 68' may have different cooling fluid passages.

[0135] The plates 36', 68' can be printed simultaneously with the frame 148, or they can be printed separately and subsequently connected. In any case, the plates 36', 68' are preferably connected to the frame 148. They can be connected via the launch device 112 or a similar structure so that the plates 36', 68' and / or the frame 148 are melted to each other. Additionally or alternatively, the device 20 can print the material to connect the plates 36', 68' and the frame 148. It is expected that the plates 36', 68' are connected together to provide an electrical path therebetween. It is also expected that any intersection between the insert 160 and the frame 148 is sealed to prevent the reactant gas from flowing through the frame 148 and the insert 160 assembly.

[0136] The panels 36', 68' may be supported by a frame 148. Fig.13 In the illustrated embodiment, the panels 36', 68' can rest on a flange 162 surrounding the central opening 156. The frame 148 can define a thickness, with the flange 162 occupying only a small portion of it. The flange 162 can extend completely around the central opening or only a selected area of ​​the central opening 156.

[0137] The plates 36', 68' may have cooling fluid channels 164. The channels 164 may be formed when the plates 36', 68' are printed. In the embodiment shown in FIG. 14, the channels 164 may be defined on an outer surface 166 of each plate 36', 68'. The channels 164 in the figure are depicted as open channels 164 because complementary plates 36', 68' from another frame (not shown) are located above and below the plate channels 164, which close the open channels 164. The channels 164 may also be embedded in the plates 36', 68' and thus closed by the plates 164 when the plates 164 are printed.

[0138] The use of additive manufacturing processes to produce bipolar plates, fuel cells, and fuel cell stacks has multiple advantages over existing technologies. For example, the geometry or design of MEA components, bipolar plates, fuel cells, and / or stacks can be changed without reassembly. This allows fuel cell components, and the fuel cells produced thereby, to have non-standard shapes. As a result, fuel cells can be located in non-traditional spaces within a vehicle, making more efficient use of vehicle space.

[0139] In addition, fuel cell components can be printed relative to each other to form a fuel cell without the need for gaskets and clamping mechanisms to seal the fuel cell or cell stack. This significantly reduces the failure mode of the fuel cell and reduces the cost, weight and complexity of the fuel cell.

[0140] The method or process disclosed herein uses additive manufacturing to produce fuel cell components and / or fuel cells having substantially the same structural integrity, strength, and conductivity in all three dimensions. In addition, the method disclosed herein uses additive manufacturing to produce fuel cells and fuel cell stacks. By printing the components of the fuel cell stack in a uniform manner, gaskets and compression processes and equipment can be reduced or eliminated. In addition, by using additive manufacturing to produce fuel cell components, it reduces the need for excessive component handling during manufacturing and fuel cell stack assembly. In addition, the printed components are significantly lighter and can be customized according to size and shape.

[0141] According to the provisions of the patent statutes, the present invention has been described in a manner that is considered to represent its preferred embodiments. However, it should be understood that the description and the embodiments of the present invention should not be understood in a limiting manner, and the present invention can be implemented in other ways than those specifically shown and described without departing from the true spirit and scope of the present invention defined by the appended claims. In addition, it should be understood that any changes and modifications will be understood by those skilled in the art as being equivalent to one or more elements recorded in the appended claims, and should be covered by the claims to the maximum extent permitted by law.

Claims

1. A method for manufacturing an electrochemical cell component, the method comprising: a. An additive manufacturing apparatus for producing a 3D object is provided, the additive manufacturing apparatus comprising: a support platform having a building area for producing a three-dimensional object on the support platform; and a movable deposition device for depositing a flowable conductive material on the building area; b. heating the conductive material to a temperature higher than the first temperature by a heating device, thereby providing a flowable conductive material to the deposition device, the flowable material solidifying at a temperature lower than the second temperature; c. moving the movable deposition device to sequentially deposit the flowable conductive material on the building area of ​​the support platform to produce an anode separator having at least one channel for medium transmission; d. placing the membrane electrode assembly on the deposited anode separator in direct contact with at least one channel of the anode separator; e. so that the non-conductive material is located on the anode separator that does not extend from the membrane electrode assembly, and the non-conductive material forms a frame for the membrane electrode assembly; and f. depositing a layer of flowable material on the membrane electrode assembly and the non-conductive material to produce a cathode separator having at least one channel on a side facing the membrane electrode assembly and at least one channel produced by the deposited material on a side opposite to the membrane electrode assembly formed by the deposited material, wherein both channels are used to transport the medium, Therein, the conductive material is carbon-coated thermoplastic filaments.

2. The method of claim 1, wherein: The cross-sectional area of ​​the channel changes as the deposition progresses.

3. The method of claim 1, further comprising: An apparatus is used to print a plurality of channels in a part and one or more manifolds communicating with the channels.

4. The method of claim 1, wherein: The conductive material is a thermosetting material.

5. The method of claim 1, wherein: The channels are printed as zigzag channels that run along the length of a part face, traversing the part face from one side to the opposite side of the face.

6. The method of claim 5, wherein: The component is printed to include a first opening at one end of the tortuous channel and in fluid communication with the tortuous channel, and a second opening at the other end of the tortuous channel and in fluid communication with the tortuous channel.

7. The method of claim 1, wherein: Components are printed to include anode separators, cathode separators, and / or bipolar plates.

8. The method of claim 7, wherein: The bipolar plate is printed to include two active surfaces on opposite sides of the plate, wherein one active surface faces the anode electrode cell and the opposite side faces the cathode electrode cell.

9. The method of claim 5, wherein: Printing the component to include an anode separator having an anode separator tortuous channel printed on one side of the anode separator and further comprising: Add electrical insulation around the anode separator, Place the membrane electrode assembly on the anode separator. Printing cathode separator with initial flowable deposition material on membrane electrode assembly and electrical insulation material, The cathode separator is printed with a first cathode plate tortuous channel on a first side and a second cathode plate tortuous channel on a second side.

10. The method of claim 9, further comprising: Energy is applied to one or more of the anode separator, cathode separator, electrical insulation, or membrane electrode assembly.

11. The method of claim 10, wherein: The energy causes the anode separator to become flowable, thereby allowing the membrane electrode assembly to be embedded in the anode separator.

12. The method of claim 3, wherein: One or more manifolds printed in the anode separator and cathode separator are printed with variable cross-sections to vary the flow rate of the fluid in the manifold.

13. The method of claim 5, wherein: At least one gas diffusion layer is printed on at least one of the anode separator or the cathode separator, and the membrane electrode assembly is positioned in direct contact with the last at least one gas diffusion layer.

14. A method for manufacturing a fuel cell stack, the method comprising: a. Providing an additive manufacturing device for producing a 3D object, the additive manufacturing device comprising: a support platform for supporting the manufacture of a three-dimensional object thereon; b. heating the conductive material to a temperature higher than the first temperature, thereby providing a flowable conductive material to the deposition mechanism, the flowable material solidifying at a temperature lower than the second temperature; c. depositing a flowable material layer by layer on a support platform according to a data file to produce an anode separator supported on the support platform, wherein the anode separator is deposited to have at least one channel to allow a medium to pass therethrough; d. placing the membrane electrode assembly on the deposited anode separator in direct contact with at least one channel of the anode separator; e. so that the non-conductive material is located on the anode separator that does not extend from the membrane electrode assembly, and the non-conductive material forms a frame for the membrane electrode assembly; f. depositing a layer of flowable material on the membrane electrode assembly and the non-conductive material to produce a cathode separator having at least one channel on a side facing the membrane electrode assembly and at least one channel produced by the deposited material on a side opposite to the membrane electrode assembly formed by the deposited material, wherein both channels are used to transport the medium; and g. applying energy to one or more individual layers during deposition, Therein, the conductive material is carbon-coated thermoplastic filaments.

15. The method of claim 14, wherein: The energy is heat which is added to the at least non-conductive material to soften it, thereby causing the membrane electrode assembly to be at least partially embedded therein.

16. The method of claim 14, wherein: Plasma or microwave energy is applied to each individual layer during deposition.

17. The method of claim 14, wherein: At least one channel is deposited to include a plurality of tortuous channels running along the length of the anode separator face from one side of the face to an opposite side of the face.

18. The method of claim 14, wherein: The anode separator is deposited to include a first opening at one end of the plurality of tortuous channels and in fluid communication with the plurality of tortuous channels, and a second opening at the other end of the tortuous channels and in fluid communication with the tortuous channels.

19. The method of claim 14, wherein: One or more manifolds printed in the anode separator and the second separator are printed with variable cross-sections to vary the flow rate of the fluid in the manifold.

20. The method of claim 14, wherein: The fastener retainer is embedded in the anode separator or the cathode separator.

21. The method of claim 14, wherein: The sensor is embedded in the anode separator or cathode separator.

22. The method of claim 14, further comprising: A permeation barrier is positioned in the cathode separator between at least one channel on the side facing the membrane electrode assembly and at least one channel on the side opposite the membrane electrode assembly.

23. A method of making an electrochemical cell, comprising: Printing a component of an electrochemical cell using an additive manufacturing device, wherein the electrochemical cell comprises: an anode separator having at least one channel for medium transmission, the anode separator being printed with a conductive material; a membrane electrode assembly on the anode separator, the membrane electrode assembly being in direct contact with at least one channel of the anode separator; a non-conductive material on the anode separator where the membrane electrode assembly does not extend, wherein the non-conductive material forms a frame for forming the membrane electrode assembly; and A cathode separator having at least one channel on a side facing the membrane electrode assembly and at least one channel on a side opposite to the membrane electrode assembly, wherein both channels are used to transport the medium, and the cathode separator is printed using a conductive material, Therein, the conductive material is carbon-coated thermoplastic filaments.

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