Stackable electrosynthetic or electrical energy cells

Abstract

An electrical or electrosynthetic cell is disclosed, the architecture of which allows them to be easily stacked into a cell stack. These cells include polymer cell frames, functional materials (e.g., inter-electrode membranes, electrodes, metal bipolar plates, etc.) incorporated therein. For example, an electrical or electrosynthetic cell includes a polymeric cell frame, a first electrode and a second electrode, and an inter-electrode membrane positioned between the first electrode and the second electrode. The squeeze member is positioned adjacent to the first electrode. The squeeze member may be a metal bipolar plate squeeze member and / or a metal porous transport layer squeeze member. In one example, a polymer cell frame is sealed to a metal bipolar plate by a polymer-to-metal bond. In another example, at least one polymeric structural positioning member positions the metal bipolar plate against the polymeric cell frame. A cell stack comprising a plurality of cells is disclosed.

Description

Technical Field

[0001] The present invention broadly relates to electrochemical cells, for example for use as electrosynthesis cells or power cells. Example embodiments relate to cells whose architecture allows the cells to be easily stacked into industrial cell stacks that effectively form a single electrosynthesis or power device or apparatus. Background Art

[0002] Energy cells are electrochemical cells that generate electricity over a sustained period of time for use outside the cell. Energy cells differ from other primary cells in that they require a constant external supply of reactants. The products of the electrochemical reaction must also be constantly removed from such cells. Unlike batteries, energy cells do not store chemical or electrical energy within the energy cell.

[0003] Examples of power cells include, but are not limited to, polymer electrolyte membrane (PEM) hydrogen-oxygen fuel cells, hydrogen-oxygen alkaline fuel cells, ammonia fuel cells, and the like.

[0004] An electrosynthetic cell may similarly be thought of as an electrochemical cell that produces one or more chemical materials for use outside the cell over a sustained period of time. The chemical materials may be in the form of a gas, liquid, or solid. Like an electrical energy cell, an electrosynthetic cell also requires a constant supply of reactants and a constant removal of products. An electrosynthetic cell may further require a constant input of electrical energy.

[0005] Examples of electrosynthetic cells include, but are not limited to, water electrolysis cells, chlor-alkali cells, and cells for making hydrogen peroxide, ammonia, and the like.

[0006] Another characteristic of electrosynthesis or power cells is the large amounts of reactants and products typically involved in their operation. Such cells need to be constantly fed with large amounts of reactants, while at the same time large amounts of products must be constantly removed.

[0007] Since a large amount of electrical energy is involved in operating electrical energy and electrosynthesis cells, a key challenge in their development is to make them as energy-efficient as possible during operation. This can be achieved in part by minimizing their electrical impedance. Impedance is the obstacle that a cell circuit presents to the current when a voltage is applied. A well-known method of minimizing impedance is to adopt a cell architecture in which the anode electrode and the cathode electrode of the cell are placed facing each other, as close to each other as possible, without touching (which will produce a short circuit). Then, ideally, the gap between the two electrodes should also be occupied by an electrolyte with the highest possible conductivity. In general, as a category, liquid electrolytes have the highest conductivity. The liquid electrolyte can be incorporated into a porous inter-electrode spacer that prevents the electrodes from touching each other. Accordingly, many electrical energy cells or electrosynthesis cells use liquid electrolytes in the cell or component half-cell itself, which can be highly conductive.

[0008] Another problem with this type of electrical energy or electrosynthesis cells is that in industrial applications they are often ideally 'stacked' with a number of other cells in electrical series to thereby create a 'cell stack'. This is most commonly achieved in a so-called 'filter press' arrangement. In such an arrangement, individual cells having a substantially flat profile are stacked between two end plates.

[0009] The challenges of manufacturing and maintaining filter press type cell stacks are well known. Firstly, it is crucial that the design and architecture of the cells allow them to be easily and reliably combined into filter press type cell stacks. This means that when the cells are squeezed together between the end plates to form a filter press type cell stack, they should be sealed to each other to thereby ensure that there is no leakage of liquid and / or gas from the cell stack or there is no unwanted mixing of liquid and / or gas within the stack. This often requires a very specific and / or high overall squeezing level and a very uniform squeezing distribution over the lateral length of the cells in the stack. In addition, the squeezing may need to be spread very evenly on each face of each individual cell so that there is no location of over- or under-squeezing on the front or back of any of the cells in the stack. Each cell may further need to be positioned very precisely relative to the other cells before and during the application of the squeezing. Achieving these requirements is often difficult, especially in a large-scale production environment where such precision must be achieved in a minimum of time.

[0010] Additionally, after forming the cell stack, it may typically be necessary to precisely maintain often very high and / or very specific compression to ensure that no leakage of liquid and / or gas or unwanted mixing of liquid and / or gas occurs during electrochemical operation. However, during operation, the cell stack may cycle between low and high temperatures and between low and high pressures, causing heat and / or pressure-induced expansion and contraction of the cells in the stack. The resulting dimensional changes may modify the lateral and surface compression experienced by each cell, thereby inducing liquid and / or gas to leak from the cell stack or unwanted mixing of liquid and / or gas within the stack. For this reason, the thermal or pressure-induced expansion rate of each of the cell components needs to be considered and matched as carefully as possible. Where this is not possible or feasible, suitable gaskets must be applied between adjacent components to avoid leakage of liquid and / or gas from the cell stack or unwanted mixing of liquid and / or gas within the stack. However, gaskets may move or deteriorate during continuous heat and / or pressure cycles, causing them to fail. Finding ways to minimize or at least reduce the number of gaskets required and the operating stresses applied to those gaskets within the stack represents an important area of ​​innovation.

[0011] For example, known electrochemical stacks use metal plates (referred to as bipolar plates) that are located between the cells in the stack and are held in place as a whole only by the extrusion applied to the stack. Bipolar plates are conductive plates in an electric energy or electrosynthetic cell stack that connect the anode of one cell to the cathode in an adjacent cell. Its main function is to accumulate and evenly distribute current from one cell to the next. Bipolar plates can have complex patterns for fluid flow that are etched, machined, stamped, sunk, or otherwise formed on their faces. These patterns (often referred to as flow fields) can include pits (i.e., low points on a metal structure) and bosses (i.e., high points on a metal structure), or ribs and spaces, or steps and gaps. For example, a metal bipolar plate with a serpentine flow field has one or more channels arranged in a serpentine shape that sink into their faces. This type of metal flow field can often be most conveniently produced by stamping the flow field into a metal plate at high speed and high capacity using an industrial precision stamping or forming process. However, the physical dimensions of the structures thus produced in the metal plates may vary due to 'springback' of the metal in the plates. The resulting dimensional variations may cause serious problems in stacks comprising such bipolar plates due to leaks, incorrect flow dynamics, etc. (resulting from dimensional variations). Therefore, a major challenge in industrializing the production of cell stacks is to produce components in high-speed, high-volume processes that produce structures with minimal variation in their physical dimensions (i.e., exhibiting high 'tolerances'). Alternatively, new methods are needed to successfully and reliably form cell stacks using components having structures that exhibit significant variation in their physical dimensions (i.e., exhibiting low 'tolerances').

[0012] Another metal component often used in electrosynthesis or power cells is called a porous transport layer. A porous transport layer is a conductive metal structure that is permeable to liquid and / or gaseous fluids and is typically located between an electrode and its bipolar plate. The porous transport layer provides an electrical connection between the electrode and the bipolar plate while allowing liquid or gas to move to or from the electrode.

[0013] Accordingly, there is a need to solve or mitigate one or more of these problems. For example, there is a need to develop cells or components that can be simply and reliably formed into cell stacks that do not leak and mix liquid or gaseous reactants and products both during the stack assembly process itself and thereafter during subsequent operations. In another example, there is a need to develop methods for assembling cell components with low tolerances that produce reliable and successful cell stacks that do not leak and mix liquid or gaseous reactants and products both during the formation of the cell stack and thereafter during subsequent operations. This needs to be achieved while providing high energy efficiency in the operation of the cells and cell stacks.

[0014] Reference in this specification to any previous publication (or information derived therefrom) or any known matter is not and should not be taken as an acknowledgement or approval or any form of suggestion that the previous publication (or information derived therefrom) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. Summary of the invention

[0015] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify all key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0016] In various example aspects, embodiments relate to electrical energy or electrosynthetic cell architectures that provide simplified and reliable assembly into or within cell stacks that do not allow leakage or mixing of liquid or gaseous reactants and products both after assembly and during subsequent operation and provide high energy efficiency.

[0017] Example embodiments relate to electric energy or electric synthesis cell architectures that include polymer cell frames, functional materials (e.g., electrode spacers, electrodes, porous transport layers, bipolar plates, etc.) incorporated within or around them. Preferably, some or all of these individual functional materials can be attached to the cell frame. For example, the polymer electrode spacer can be attached to the polymer cell frame via one or more polymer-to-polymer joins. The polymer-to-polymer join can seal the junction between the polymer electrode spacer and the polymer cell frame to, for example, allow gas to leak from one side of the electrode spacer to the other across the thickness of the electrode spacer.

[0018] Preferably, the polymer electrode separator film is thin, to thereby maximize the energy efficiency of the cell.Preferably, the polymer electrode separator film is less than 0.35 mm thick, less than 0.2 mm thick, less than 0.1 mm thick, less than 0.05 mm thick, or less than 0.025 mm thick.

[0019] In another example, one or more of the metallic functional materials can be attached to the polymer frame via one or more polymer-to-metal joints. For example, the metal bipolar plate can be attached to the cell frame via one or more polymer-to-metal joints. The polymer-to-metal joint can seal the joint between the metal bipolar plate and the polymer cell frame to, for example, prevent liquid or gas from leaking to or from the outside of the cell.

[0020] In various aspects, assembled 'inwardly extruded' electrical or electrosynthetic cells are provided, the architecture of which allows them to be easily stacked into cell stacks. These cells include a polymer cell frame, functional materials (e.g., electrode spacer membranes, electrodes, metal bipolar plates, etc.) incorporated therein. For example, the electrical or electrosynthetic cell includes a polymer cell frame, a first electrode and a second electrode, and an electrode spacer membrane positioned between the first electrode and the second electrode. An extrusion component is positioned adjacent to the first electrode, the extrusion component applying a clamping force on the first electrode, thereby squeezing the first electrode against the electrode spacer membrane. The extrusion component can be a metal bipolar plate extrusion component and / or a metal porous transport layer extrusion component. In one example, the polymer cell frame is sealed to the metal bipolar plate by a polymer-to-metal joint, which fully or partially imparts the required stiffness in the assembled cell to produce the above-mentioned clamping force. In another example, at least one polymer 'structural locating member' (bonded to the polymer cell frame via a polymer-to-polymer joint) locates the metal bipolar plate against the polymer cell frame and fully or partially imparts the required stiffness in the assembled cell to generate the above-mentioned clamping force.

[0021] A polymer 'structural retaining feature' is a polymer structure in an electrocomposite or electrical energy cell which, when attached to a polymer cell frame by one or more polymer to polymer joints, mechanically holds a physically disconnected metallic structure in place within or around the cell and / or cell frame.

[0022] A 'squeezing member' is a springed or sprung structure which, when properly positioned in an assembled cell, exerts a clamping force on at least one of the electrodes, thereby squeezing at least one of the electrodes against the electrode spacer membrane. In doing so, after assembly, the cell is 'inwardly squeezed'. Such 'inwardly squeezed' reduces or avoids the need to generate the necessary clamping force during the formation of the cell stack. In conventional electric energy or electrosynthetic filter press cell stacks, the necessary clamping force is generated in each cell during the squeezing and assembly of the cell stack (which involves assembling and squeezing a large number of cells simultaneously). However, when cells that have been preassembled into 'inwardly squeezed' are combined into a cell stack, they may not need to be accurately positioned and precisely squeezed as would normally be required. That is, preassembling individual cells in an 'inwardly squeezed' form can simplify and speed up the process of cell stack formation, which may be useful in high-volume, automated manufacturing of cell stacks. Such pre-assembled and 'inwardly pressed' cells can also be individually tested and subjected to quality control and validation procedures before they are combined into a cell stack to thereby ensure that they will function correctly in the stack. This option is not available in conventional filter press cell stacks, in which the individual cells are only assembled into functional units during the formation of the cell stack. If one cell so assembled proves to function incorrectly, the entire stack must be disassembled to remove it. Preferably, the above-mentioned spring-like or spring-like action is produced in at least one of the metal bipolar plates or the metal porous transport layer.

[0023] A 'bipolar plate extrusion component' is a bipolar plate that also has an extrusion function. That is, the bipolar plate extrusion component is a spring-like or spring-like structure that, when positioned in an assembled cell, applies a clamping force on its associated electrode, thereby pressing the associated electrode against the electrode spacer membrane. It will be understood that such a spring-like action is preferably designed into the bipolar plate extrusion component so that the bipolar plate extrusion component imparts a specific, predetermined clamping force to the electrode within a relatively narrow clamping force range. The bipolar plate extrusion component does not impart the clamping force merely sporadically or in an uncontrolled or non-repeatable manner. Preferably, the clamping force within the assembled cell is generated entirely or in part by the stiffness of: (1) the polymer-to-metal joint between the bipolar plate extrusion component and the polymer cell frame, or (2) the polymer-to-polymer joint between the 'polymer structural positioning' element and the polymer cell frame.

[0024] A 'porous transport layer extrusion component' is a porous transport layer that also has an extrusion function. That is, the porous transport layer extrusion component is a spring-like or spring-like structure that, when properly positioned in an assembled battery cell, exerts a clamping force on its associated electrode, thereby pressing the associated electrode against the electrode spacer membrane. It will be understood that such a spring-like action is preferably designed into the porous transport layer extrusion component so that the porous transport layer extrusion component imparts a specific, predetermined clamping force to the electrode within a relatively narrow clamping force range. The porous transport layer extrusion component does not impart the clamping force merely sporadically or in an uncontrolled or non-repeatable manner. Preferably, the clamping force within the battery cell is generated entirely or in part by the stiffness of: (1) the polymer-to-metal joint between the bipolar plate extrusion component and the polymer battery cell frame, or (2) the polymer-to-polymer joint between the 'polymer structural positioning' element and the polymer battery cell frame.

[0025] Further, different extrusion members are provided, for example, 'metal bipolar plate extrusion members', 'metal porous transport layer extrusion members', and / or 'metal electrode extrusion members'. Such structures are metal structures that act as spring-like or spring-like structures, which, when properly positioned in an assembled cell, exert a clamping force on the associated electrode, thereby pressing the electrode against the electrode spacing membrane.

[0026] Preferably, the clamping force applied inwardly by the extrusion member on the electrode in the assembled cell to press the electrode against the electrode separator is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, or greater than 20 bar.

[0027] Preferably, the clamping force applied inwardly by the metal bipolar plate extrusion component on the first electrode or the second electrode in the battery cell during assembly to press the first electrode or the second electrode against the electrode separator is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, or greater than 20 bar.

[0028] Preferably, the extrusion applied inwardly in the assembled battery cell is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, or greater than 20 bar.

[0029] Preferably, but not exclusively, the cell architecture also incorporates at least one 'compliant' component that is displaced to evenly accommodate and distribute the compressive force applied by the at least one spring-like or springy component. Optionally, the compliant component comprises at least one of a metal bipolar plate, a metal porous transport layer, or a metal electrode. That is, different compliant components may be provided, for example, a 'metal bipolar plate compliant component', a 'metal porous transport layer compliant component', and / or a 'metal electrode compliant component'.

[0030] In one aspect, an electric energy or electric synthesis cell is provided, comprising a polymer cell frame, a first electrode, and a second electrode. An electrode spacer is positioned between the first electrode and the second electrode. A metal bipolar plate extrusion member is positioned adjacent to the first electrode, the bipolar plate extrusion member exerting a clamping force on the first electrode, thereby pressing the first electrode against the electrode spacer. Preferably, the polymer cell frame is sealed to the metal bipolar plate extrusion member.

[0031] In one example, the seal between the polymer cell frame and the metal bipolar plate extrusion component is created by a polymer-to-metal joint. In another example, at least one polymer structural locating component connected to the cell frame by one or more polymer-to-polymer joints positions the metal bipolar plate extrusion component against the polymer cell frame. In this example, the seal between the polymer cell frame and the metal bipolar plate extrusion component can be created by one or more polymer-to-polymer joints between the at least one polymer structural locating component and the polymer cell frame, and the at least one polymer structural locating component mechanically holds the metal bipolar plate extrusion component against the polymer cell frame.

[0032] In another aspect, an electric energy or electric synthesis cell is provided, which includes a polymer cell frame, a first electrode and a second electrode. The electrode spacer membrane is positioned between the first electrode and the second electrode. The metal porous transport layer extrusion component is positioned adjacent to the first electrode on the side opposite to the electrode spacer membrane. The metal bipolar plate is positioned adjacent to the metal porous transport layer extrusion component on the side opposite to the first electrode. Preferably, the metal bipolar plate is attached to the polymer cell frame by one or more polymer-to-metal joints, or at least one polymer structural positioning component connected to the cell frame by one or more polymer-to-polymer joints positions the metal bipolar plate against the polymer cell frame.

[0033] Preferably, but not exclusively, some or all of the metallic functional materials used for each half-cell within the entire cell may be further attached to each other via one or more metal-to-metal joints (e.g., via one or more metal-to-metal welds). For example, the metal electrodes and metal bipolar plates comprising the metal components of a single half-cell may be attached to each other via one or more metal-to-metal joints (e.g., via one or more metal-to-metal welds). In an alternative example, the metal electrodes, metal porous transport layers, and metal bipolar plates comprising the metal components of a single half-cell may be attached to each other via one or more metal-to-metal joints (e.g., via one or more metal-to-metal welds). As used herein, the term 'metal-to-metal weld' refers to any form of metallurgical metal-to-metal joint that may be considered to involve welding (including but not limited to fusion welding and pressure welding).

[0034] Metal-to-metal joints (such as, for example, metal-to-metal welds) can provide reduced or unchanged resistance between metallic functional materials, thereby providing improved energy efficiency by the battery cell during operation. Preferred embodiments can employ such metal-to-metal joint structures because the extrusion involved in battery cell assembly may be too low to damage or destroy the metal-to-metal joints (e.g., metal-to-metal welds). In addition, when the assembled cells are then combined into a cell stack, low extrusion may again be required. In contrast, as noted in the Background section, in conventional battery cell stack formation, much higher extrusions are typically required; such high extrusions may easily damage or destroy any metal-to-metal joints (e.g., metal-to-metal welds) present.

[0035] Preferably, but not exclusively, one or more of the metal functional materials thus attached to each other may be further attached to the polymer cell frame via one or more metal-to-polymer joints. For example, the bipolar plates in a metal-to-metal joint assembly of the above type may be attached to the polymer cell frame via one or more metal-to-polymer joints. The metal-to-polymer joint may seal the joint between the metal bipolar plate and the polymer cell frame to, for example, prevent liquid or gas from leaking to or from the outside of the cell.

[0036] In another exemplary aspect, a polymer 'structural positioning component' is provided. When attached to a polymer frame via one or more polymer-to-polymer joints, such polymer 'structural positioning components' can mechanically hold one or more of the metal functional materials in a suitable position within or around the cell frame after assembling the cell. In doing so, the metal functional material can be appropriately positioned within or around the cell frame without being physically attached to the cell frame. For example, the 'structural positioning component' can be attached to the polymer cell frame via one or more polymer-to-polymer joints to thereby mechanically hold the above-mentioned metal-to-metal connection assembly of the metal electrode and the metal bipolar plate and optionally the metal porous transport layer in a suitable position within or around the cell frame after assembling the cell. In doing so, the assembly of the metal functional material can be not physically attached to the polymer cell frame after assembling the cell. Nevertheless, the metal bipolar plates in the assembly of the metal functional material can be positioned tightly against or very close to the polymer cell frame. They can be positioned so tightly that the joint is sealed to, for example, allow liquid or gas to leak to or from the outside of the cell. Alternatively, a properly shaped gasket may be positioned between the metal bipolar plate and the polymer cell frame to more securely seal their joint. Due to the close structural match of the metal bipolar plate and the polymer cell frame, the operational stress applied to the gasket during operation of the cell may be minimized.

[0037] In a first exemplary aspect, an electrosynthetic or electric energy cell is provided which utilizes at least one metal bipolar plate having a 'waffle' structure or a grid or grid arrangement of pits and bosses, or ribs and spaces, or steps and gaps on its face. This provides a 'metal waffle bipolar plate'. The 'waffle' structure is similar to the structure present on a waffle iron. Preferably, but not exclusively, the metal bipolar plate is a sheet of metal whose face has been etched, machined, stamped, formed, sunken or otherwise shaped into a waffle structure (i.e., a grid structure or grid). Preferably, but not exclusively, the waffle bipolar plate is springy, so as to thereby include an 'extruded bipolar plate'. That is, preferably, but not exclusively, the waffle structure facilitates the at least one metal bipolar plate to become an extruded component. Preferably, but not exclusively, the waffle bipolar plate is produced by precision industrial stamping, forming or similar processes.

[0038] In another example aspect, the metal electrode is directly attached to at least some or all of the bosses of the waffle structure by metal-to-metal joints (e.g., metal-to-metal welds) to some or all of the ribs or steps of the mesh structure or grid on the face of the metal bipolar plate. Preferably, where the waffle piece is an extruded bipolar plate, the above metal-to-metal joints (e.g., metal-to-metal welds) utilize the extrusion properties of the bipolar plate to exert a clamping force on the attached electrode to compress the electrode against the electrode spacer membrane.

[0039] Preferably, the above metal-to-metal joints stabilize the structure of the bipolar plate, thereby stopping, slowing or avoiding deformation (e.g., 'springback'). Optionally, the metal-to-metal joints minimize changes in the physical dimensions of the bipolar plate and its flow field, thereby allowing the waffle bipolar plate to be produced using precision industrial stamping, forming and other manufacturing processes.

[0040] In a further example, the metal porous transport layer is attached to some or all of the bosses of the waffle structure of the metal bipolar plate by a metal-to-metal joint (e.g., a metal-to-metal weld), wherein the other side of the metal porous transport layer is attached to the electrode by a different metal-to-metal joint (e.g., a metal-to-metal weld). In a further example, the extruded metal porous transport layer (i.e., a metal porous transport layer extrusion component) is attached to some or all of the bosses of the waffle structure of the metal bipolar plate by a metal-to-metal joint (e.g., a metal-to-metal weld), wherein the other side of the metal porous transport layer is attached to the electrode by a different metal-to-metal joint (e.g., a metal-to-metal weld). Preferably, in the case where the porous transport layer is an extrusion component, the above metal-to-metal joint (e.g., a metal-to-metal weld) utilizes the extrusion properties of the porous transport layer extrusion component to apply a clamping force on the attached electrode to press the electrode against the electrode spacer membrane.

[0041] Preferably, the above metal-to-metal joints stabilize the structure of the bipolar plate, thereby stopping, slowing or avoiding deformation (eg, 'springback'). Optionally, the metal-to-metal joints minimize changes in the physical dimensions of the bipolar plate and its flow field, thereby allowing the use of precision industrial stamping, forming and other manufacturing processes.

[0042] Preferably, the metal-to-metal bonds between the waffle metal bipolar plates, metal electrodes, and (where applicable) the metal porous transport layer provide high electrical conductivity between these components and uniform distribution of current and voltage at the attached electrodes.

[0043] Preferably, the metal-to-metal bonds between the metal waffle bipolar plates, electrodes, and (where applicable) the porous transport layer provide high thermal conductivity between these components and uniform distribution of the heat generated by the cell.

[0044] In a first preferred example, the peripheral region of the metal waffle bipolar plate (with attached electrodes / porous transport layers) is attached to the polymer cell frame via one or more polymer-to-metal joints. Preferably, but not exclusively, the assembled waffle structure (with attached electrodes / porous transport layers) is spring-like (or spring-like) so as to thereby exert an inward clamping force on the electrode within the cell, thereby pressing the electrode against the electrode spacer membrane. Optionally, the assembled waffle structure (with attached electrodes / porous transport layers) is compliant so as to thereby shift to accommodate the squeezing force applied by another functional component in the cell. Optionally, one or more polymer-to-metal joints between the waffle structure (with attached electrodes / porous transport layers) and the polymer cell frame partially or completely seal the cell body of the electrosynthetic or electric energy cell.

[0045] In a second preferred example, the peripheral region of the metal waffle bipolar plate (with the attached electrode / porous transport layer) can be tightly mechanically held against a region of the polymer cell frame by at least one polymer 'structural locating member', which is attached to the cell frame via one or more polymer-to-polymer joints. Optionally, the tight contact seals the joint between the waffle bipolar plate and the cell frame. Optionally, a suitable gasket can be placed between the bipolar plate and the cell frame to thereby provide an improved seal.

[0046] Optionally, the waffle structure on the metal waffle bipolar plate in one cell is structurally complementary to the waffle structure on another metal waffle bipolar plate of an adjacent cell in the cell stack, thereby allowing the two waffle structures to interlace and fit together when they are pressed against each other. Preferably, such structural fit assists in aligning the cells in the cell stack and reduces the need for accurate and precise pressing during and after assembly of the cell stack. Preferably, such structural fit provides a higher electrical contact surface area between the cells in the cell stack.

[0047] In another exemplary aspect, preferably, all or most of the possible seals that can be produced within the cell (i.e., 'in-cell' seals) are formed during cell assembly. This reduces the number of reliable seals that must be formed during cell stack assembly to only or mostly those seals required between cells (i.e., 'inter-cell' seals). That is, during cell assembly, the 'cell body' of the electric energy or electrosynthetic cell is preferably sealed inwardly by its components. The 'cell body' is defined herein as the portion of the cell that must be sealed between cells during the formation of the cell stack (i.e., the 'inter-cell' seal), which does not include external liquid and gas piping system orifices and openings (i.e., 'headers' or 'manifold' orifices or openings). Preferably, the cell body is sealed by a polymer-to-polymer joint or a polymer-to-metal joint produced during cell assembly, whereby only the 'inter-cell' liquid and / or gas connections (outside the 'cell body') are left to be produced during the assembly of the cell stack. In doing so, the process of forming the cell stack can be simplified and accelerated. It can also reduce the need for accurate and precise pressing during cell stack assembly.

[0048] In a first preferred example, the cell body is sealed by a metal-to-polymer bond present between the one or more metal bipolar plates and the polymer cell frame.

[0049] In a second preferred example, the cell body is sealed by physical contact between the one or more metal bipolar plates and the polymer cell frame, wherein the metal bipolar plates are tightly held against the cell frame by polymer-to-polymer joints between the one or more polymer structural locating members and the polymer cell frame. Optionally, a suitable gasket may be present between the bipolar plates and the cell frame to provide an enhanced seal.

[0050] While direct polymer-to-metal joints of the type described in the first preferred example above may be pulled apart by differential expansion of the metal and polymer components during thermal or pressure cycling, seals that avoid direct polymer-to-metal joints of the type described in the second preferred example above may resist such degradation. That is, metal-to-polymer seals (in which the metal and polymer components are physically disconnected) may provide improved durability during repeated temperature and pressure cycling, particularly where the thermal and / or pressure-induced expansion of the metal and polymer cell components differ significantly.

[0051] Preferably, the above type of assembled electrical energy or electrical synthesis cell architectures can provide simplified and reliable formation (assembly) of cell stacks, which appropriately (pre) position the metal components and polymer components of the cell via polymer-to-polymer joints, polymer-to-metal joints and / or metal-to-metal joints. Such appropriate positioning can avoid or alleviate the need to accurately position cells and cell components during the formation of the cell stack, thereby speeding up the process and improving the reliability of the cell stack assembly. Preferably, the cell architecture described above also provides such cells, that is, these cells can be assembled into or within the cell stack using only moderate or low extrusion that does not need to be precisely applied (face or sideways). Preferably, the resulting cell stack can then be operated while maintaining only moderate or low extrusion, thereby avoiding the need for specific or high extrusion during and / or thereafter during the assembly of the cell stack. Moderate or low squeezing may preferably be produced and maintained by torsion, mechanical, hydraulic (i.e., liquid) or other means that can accommodate dimensional changes in the length of the cell stack (such as may occur during repeated temperature or pressure cycles). In combining appropriate (pre)positioning with reduced squeezing requirements, the above cell architecture preferably provides for simplified and reliable, high-speed, high-capacity industrial assembly of electrical energy or electrosynthetic cells into or within cell stacks that do not leak or mix liquid or gaseous reactants and products both after assembly and during subsequent operation.

[0052] In a first preferred example embodiment, an electric energy or electric synthesis cell architecture is provided, comprising at least one polymer cell frame to which are attached:

[0053] - at least one polymer electrode spacer membrane attached to the at least one polymer cell frame by or via one or more polymer-to-polymer bonds; and

[0054] - At least one metallic functional component attached to the at least one polymer cell frame by or via one or more polymer-to-metal joints.

[0055] Most preferably, the at least one metal functional component is a metal bipolar plate. Most preferably, the metal bipolar plate forms part of a metal-to-metal coupling assembly, which comprises at least one metal bipolar plate and at least one metal electrode coupled to each other (e.g., by one or more metal-to-metal welds). Optionally, the metal-to-metal coupling assembly may include at least one metal porous transport layer, which is located between the at least one electrode and the at least one bipolar plate and coupled to one or both of them (e.g., by one or more metal-to-metal welds). A metal-to-metal coupling portion (such as, for example, a metal-to-metal weld) can provide a reduced or constant resistance between the metal functional materials, thereby improving the energy efficiency of the battery cell during operation. Most preferably, one or more polymer-to-metal coupling portions between the polymer battery cell frame and the metal bipolar plate hold the metal-to-metal coupling assembly in a suitable position within or around the battery cell frame. Most preferably, one or more polymer-to-metal coupling portions between the polymer battery cell frame and the metal bipolar plate seal the polymer battery cell frame to the metal bipolar plate. In one example, the metal bipolar plate is an extruded component (is a metal bipolar plate extruded component).

[0056] Optionally, the at least one metallic functional component comprises a metal electrode or a metallic porous transport layer. Optionally, the metal electrode or the metallic porous transport layer forms part of a metal-to-metal coupling assembly comprising at least one metal bipolar plate. Optionally, one or more polymer-to-metal couplings between the polymer cell frame and the metal electrode or between the polymer cell frame and the metallic porous transport layer hold the metal-to-metal coupling assembly in a suitable position within or around the cell frame. Optionally, one or more polymer-to-metal couplings between the polymer cell frame and the metal electrode or between the polymer cell frame and the metallic porous transport layer seal the metal-to-metal coupling assembly to the cell frame. In one example, the metallic porous transport layer is an extruded component (a metallic porous transport layer extruded component).

[0057] In a second preferred example embodiment, an electric energy or electric synthesis cell architecture is provided, comprising at least one polymer cell frame to which are attached:

[0058] - at least one polymer electrode spacer membrane attached to the at least one polymer cell frame by or via one or more polymer-to-polymer bonds; and

[0059] - At least one polymeric 'structural locating component' attached to the at least one polymeric cell frame by one or more polymer to polymer joints, wherein the at least one polymeric structural locating component mechanically holds at least one metallic functional component in place within or about the cell frame.

[0060] Most preferably, the at least one metallic functional component comprises a metal bipolar plate. Most preferably, the metal bipolar plate forms part of a metal-to-metal joint assembly comprising at least one metal bipolar plate and at least one metal electrode joined to each other (e.g., by one or more metal-to-metal welds). Optionally, the metal-to-metal joint assembly may include at least one metallic porous transport layer located between the at least one electrode and the at least one metal bipolar plate and joined to one or both of them (e.g., by one or more metal-to-metal welds). A metal-to-metal joint (such as, for example, a metal-to-metal weld) may provide a reduced or constant resistance between metallic functional materials, thereby improving the energy efficiency of the cell during operation. Most preferably, a polymer-to-polymer joint between a polymer cell frame and the at least one polymer structural positioning component mechanically holds the metal-to-metal joint assembly in a suitable position within or around the cell frame. Most preferably, the metal bipolar plate in the at least one metal-to-metal joint assembly is held tightly against the polymer cell frame, thereby sealing their joints. Optionally, suitable gaskets may be present between the bipolar plates and the cell frame to thereby provide an enhanced seal.

[0061] Optionally, the at least one metallic functional component comprises a metallic electrode or a metallic porous transport layer. Optionally, the metallic electrode or the metallic porous transport layer forms part of a metal-to-metal coupling assembly comprising at least one metallic bipolar plate in a suitable position within or around the cell frame. Optionally, the at least one polymeric structural positioning component also mechanically retains the at least one metal-to-metal coupling assembly in a suitable position within or around the cell frame.

[0062] Turning now to the header / manifold apertures and openings in an electrocomposition or power cell, these apertures and openings are only sealed when a large number of cells are combined into a single cell stack; that is, 'inter-cell' seals that must be made outside the 'cell body' during stack assembly. In a further aspect, such header / manifold apertures and openings are sealed to equivalent header / manifold apertures and openings of the next cell in the stack by one or more polymer-to-polymer joints. That is, 'inter-cell' polymer-to-polymer seals can be used during cell stack formation to completely seal a cell whose 'cell body' has already been sealed during cell (pre)assembly. In other words, during cell stack formation, the cell can be completely sealed by creating polymer-to-polymer joints between liquid and / or gas connections entering and leaving the remaining cells in the cell stack during cell stack formation.

[0063] Such 'inter-cell' polymer-to-polymer bonds can further reduce the challenges of creating seals by accurate and precise extrusion during cell stack formation. They can also provide more reliable seals that are less dependent on high extrusion being maintained across the cell stack. In contrast, conventional cell stacks rely almost entirely on high extrusion to create and maintain such seals.

[0064] Any polymer-to-polymer joining technique can be used to produce the desired junction, including any of the polymer-to-polymer joining techniques described or listed in this specification.

[0065] In a particularly preferred example, such polymer-to-polymer joints are produced by patterning and placing resistive metal wires or circuits around the polymer header / manifold orifices to be sealed on each cell. After the cells are stacked for cell assembly and squeezed to the desired extent, current is passed through each of the existing circuits, thereby causing each circuit to heat up and cause the polymer material of the adjacent cells around the circuit to melt and fuse. The resulting cell stacking architecture includes cells stacked and joined together via polymer-to-polymer joints that incorporate resistive wires and / or circuits around the header / manifold orifices.

[0066] In another preferred example, a gasket (e.g., a shaped rubber sheet or ring) is placed around a first portion of the polymer area to be sealed, followed by a polymer-to-polymer seal of the type described above in a second portion of the polymer area to be sealed. The gasket can provide additional, long-term leakage protection, which may be particularly useful where structurally complex polymer-to-polymer connections are required. The resulting cell stacking architecture includes cells stacked and connected together via polymer-to-polymer connections that combine resistive wires and / or circuits with gaskets near the polymer-to-polymer connections around the header / manifold orifices.

[0067] In other examples, the desired polymer-to-polymer bond may be too complex or demanding for a reliable seal, in which case one or more gaskets may be used and relied upon. The resulting cell stack architecture includes stacked cells with gaskets around header / manifold apertures, wherein compression of the stack maintains the gasket seal.

[0068] Preferably, the sealing architectures described above provide simplified and reliable assembly of components and cells into or within cell stacks that do not allow leakage or mixing of liquid or gaseous reactants and products both after assembly and during subsequent operation. Preferably, they also provide high-speed, high-volume industrial assembly of electrosynthesis or power cell stacks.

[0069] In example aspects, the overall extrusion pressure applied to the cell stack during assembly and thereafter (e.g., during electrochemical operation) is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, greater than 20 bar, greater than 30 bar, greater than 40 bar, greater than 50 bar, or greater than 100 bar.

[0070] In various other exemplary aspects, embodiments relate to reliable and successful assembly of electrical energy or electrosynthesis cells and cell stacks when using components with low tolerances. The resulting cells and cell stacks preferably do not allow leakage or mixing of liquid or gaseous reactants and products both after assembly and during subsequent operation.

[0071] Preferably, a metal-to-polymer joint or polymer-to-polymer joint of the type described above incorporates one or more 'tolerance compensating features' that adjust for low tolerances and high variability in the dimensions of cell components (including polymer cell frames, electrode spacer membranes, electrodes, porous transport layers or bipolar plates). Tolerance compensating features include structures designed to accommodate variability in the components being joined. They include channels, grooves, slots, tongues, and other structural features that are slightly oversized or slightly undersized to thereby accommodate variations in the amount of material released during joining. Some tolerance compensating features may be incorporated in the form of forced joining components (e.g., tongue-and-groove joints, locating pins and wells, etc.).

[0072] In various other example aspects, embodiments relate to polymer-to-polymer joints, polymer-to-metal joints, and metal-to-metal joints that can be used in the above cell and cell stacking architectures and technologies. In some examples, such joints incorporate one or more 'tolerance compensation features'. 'Tolerance compensation features' accommodate low tolerances and high variability in the dimensions of cell components (including polymer cell frames, electrode spacer membranes, electrodes, extruded components, porous transport layers, or bipolar plates). Preferably, but not exclusively, the following joints that can incorporate tolerance compensation features can be used:

[0073] (1) 'Sealing wire welding' connection

[0074] (2) 'Polymer-to-metal' junction

[0075] In various other example aspects, embodiments relate to polymer-to-polymer bonds and polymer-to-metal bonds that may be used in the above cell and cell stacking architectures and techniques.

[0076] Preferably, but not exclusively, the following polymer-to-metal bonds may be used in the above cell and cell stack architectures and technologies:

[0077] (1) 'Continuous edge heat welding' joint,

[0078] (2) 'textured metal to polymer' joint,

[0079] (3) 'Roll-formed' joint.

[0080] Other preferred example embodiments include, but are not limited to, polymer-to-metal joints and polymer-to-polymer joints involving:

[0081] (1) Chemical bonding, with or without the use of chemical adhesion-promoting materials, includes the application of:

[0082] i. Various types of adhesives and glues, including but not limited to

[0083] 1. Adhesives according to chemical composition, including: epoxy resin adhesives, polyurethane adhesives, polyimide adhesives, cyanoacrylate adhesives, polyvinyl acetate adhesives,

[0084] 2. Adhesives in physical form, including: adhesive paste, adhesive glue, adhesive film, adhesive cement, adhesive resin, adhesive bonding agent, elastomeric adhesive, wet adhesive, 3. Adhesives in classification, including: contact adhesive, reactive adhesive, one-component reactive adhesive, two-component or multi-component reactive adhesive, hot melt adhesive, pressure sensitive adhesive, thermosetting adhesive,

[0085] 4. Adhesives according to load-bearing capacity, including: structural adhesives, non-structural adhesives, and semi-structural adhesives;

[0086] (2) polymer dissolution and rematerialization, including but not limited to

[0087] i.Solvent welding;

[0088] (3) Melting or softening of polymers with or without the use of wetting agents that promote polymer flow, including but not limited to

[0089] i. Thermal welding,

[0090] ii. Hot plate or press plate welding,

[0091] iii. Ultrasonic or vibration welding,

[0092] iv. Laser or laser beam welding,

[0093] v. Hot air welding,

[0094] vi. Spin welding,

[0095] vii. Friction welding,

[0096] viii. Frequency or high frequency or radio frequency welding,

[0097] ix. Infrared or non-contact welding,

[0098] x. High-speed tip welding,

[0099] xi. Extrusion welding,

[0100] xii. Contact welding,

[0101] xiii. Induction welding, and

[0102] xiv. Injection welding.

[0103] In various other exemplary aspects, embodiments relate to metal-to-metal joints that can be used in the above cell and cell stacking architectures and technologies. Preferred exemplary embodiments include, but are not limited to, metal-to-metal joints involving:

[0104] (1) Mechanical connections, including but not limited to connections formed by:

[0105] i. Riveting,

[0106] ii. Filling gaps,

[0107] iii. Bolting,

[0108] iv. Shrink fit,

[0109] v.Fold;

[0110] (2) Chemical linkages, including but not limited to linkages formed by:

[0111] i. Bonding, including bonding metals using glue (including conductive glue);

[0112] (3) Metallurgical joints, including but not limited to joints formed by:

[0113] i. Fusion welding, including:

[0114] 1. Electric energy: arc welding, electron beam welding,

[0115] 2. Chemical energy: gas welding,

[0116] 3. Light energy: laser welding;

[0117] ii. Pressure welding, including:

[0118] 1. Electricity: resistance welding, including resistance spot welding, projection welding, seam welding, resistance butt welding, flash welding,

[0119] 2. Chemical energy: explosion welding,

[0120] 3. Mechanical energy: cold pressure welding, friction welding, friction stir welding, ultrasonic welding, diffusion welding;

[0121] iii. Brazing / soldering, including:

[0122] 1. Electricity: induction heating copper welding, soft copper welding, brazing,

[0123] 2. Chemical energy: torch copper welding, flame copper welding,

[0124] 3. Light energy: beam copper welding, laser copper welding,

[0125] 4. 'Soldering',

[0126] 5. 'Braze'.

[0127] Preferably, but not exclusively, the liquid electrolyte used in the example embodiment comprises a hydroxide salt and has a pH value of at least 10. Optionally, the liquid electrolyte used in the example embodiment has a pH value of less than 10.

[0128] Preferably, the battery cells and battery cell stacks having the above characteristics are electric energy or electrosynthetic battery cells or battery cell stacks, such as: (i) hydrogen and oxygen fuel cells, including polymer electrolyte membrane (PEM) fuel cells or alkaline fuel cells, (ii) direct alcohol fuel cells, including direct methanol or direct ethanol fuel cells, (iii) phosphoric acid fuel cells, or (iv) ammonia fuel cells.

[0129] Preferably, the battery cells and battery cell stacks having the above characteristics are electrosynthetic battery cells or battery cell stacks, such as: (i) a water electrolyzer, (ii) a chlor-alkali electrolyzer, (iii) a nitrogen reduction battery cell for ammonia production, or (iv) a CO2 electrolyzer, including a combined carbon capture and CO2 electrolyzer.

[0130] Preferably, the battery cells and battery cell stacks having the above features are capillary-fed electric energy or electric synthesis battery cells or battery cell stacks of the type described in International Patent Publication Nos. WO 2022056603, WO 2022056604, WO 2022056605 and WO 2022056606, which are hereby incorporated by reference. BRIEF DESCRIPTION OF THE DRAWINGS

[0131] Illustrative embodiments will now be described by way of non-limiting example only and with reference to the accompanying drawings. Various example embodiments will be apparent from the following description of at least one preferred but non-limiting embodiment, given by way of example only, described in conjunction with the accompanying drawings.

[0132] Figure 1 The assembly of a preferred example embodiment battery cell is schematically depicted.

[0133] Figure 2 The assembly of another preferred example embodiment battery cell is schematically depicted.

[0134] Figure 3 The assembly of a further preferred example embodiment battery cell is schematically depicted.

[0135] Figure 4 Depicted is the attachment of an example electrode to an example waffle bipolar plate via a metal-to-metal bond.

[0136] Figure 5 Depicted is the assembly of an example battery cell stack.

[0137] Figure 6 Depicts how a heating wire can be used to seal two cells together in a cell stack.

[0138] Figure 7 The assembly of a second example embodiment cell and cell stack is schematically depicted in cross-section, with the metal components physically disconnected from the polymer components.

[0139] Figure 8 The creation of a preferred polymer to metal joint incorporating tolerance compensation features (referred to as a 'sealed wire bond' joint) is depicted schematically in cross section.

[0140] Fig. 9 A preferred polymer-to-metal joint incorporating tolerance compensation features (referred to as a 'ridged polymer-to-metal' joint) is depicted schematically in cross-section.

[0141] Fig.10 The creation of a preferred polymer to metal bond (referred to as a 'continuous edge thermal stack') is depicted schematically in cross section.

[0142] Fig.11 The creation of a preferred polymer to metal joint involving the use of laser welding is schematically depicted in cross section.

[0143] Fig.12 The creation of a preferred polymer to metal joint (referred to as a 'roll formed' joint) is depicted schematically in cross section. DETAILED DESCRIPTION

[0144] The following modes, features or aspects are described (given by way of example only) to provide a more precise understanding of the subject matter of one or more preferred embodiments.

[0145] definition

[0146] 'Reactants' are chemical materials consumed during the electrochemical reaction.

[0147] 'Products' are chemical materials produced during the electrochemical reactions.

[0148] An 'electrolyte' is a liquid containing dissolved ions that have the ability to conduct electricity.

[0149] 'Room temperature' is defined as 21°C.

[0150] In the context of a manufactured part, the term 'tolerance' refers to the amount of permissible variation in the dimensions of that part. A 'high' tolerance is associated with high precision - i.e. it indicates small dimensional variations in the manufactured part. A 'low' tolerance is associated with low precision - i.e. it indicates large dimensional variations in the manufactured part.

[0151] In the context of this specification, the term 'join / joined / joins' refers to a secure physical attachment of two structures, such as welding, fusing, bonding, adhering, blending, fusing or merging. For example, a 'polymer-to-polymer' joint refers to a secure physical attachment between two polymer structures. A 'polymer-to-metal' joint refers to a secure physical attachment between a polymer structure and a metal structure.

[0152] A 'liquid-gas' cell is defined as an electrochemical cell having at least one liquid phase reactant or product and at least one gas phase reactant or product.

[0153] An 'electric power cell' is an electrochemical cell that generates electricity continuously or continually for an unlimited period of time during operation for use external to the cell. During operation, an electric power cell may require a constant external supply of reactants. Products of the electrochemical reaction may also be continually removed from such a cell during operation. An electric power cell may be a liquid-gas cell. An example of an electric power cell is a hydrogen-oxygen fuel cell. This example is also a liquid-gas cell.

[0154] An 'electrosynthesis cell' is an electrochemical cell that manufactures one or more chemical materials for use external to the cell continuously or continually over an unlimited period of time during operation. The chemical materials may be in the form of a gas, liquid or solid. Like an electric energy cell, an electrosynthesis cell may also require a constant supply of reactants and a constant removal of products during operation. An electrosynthesis cell may further require a constant input of electrical energy during operation. An electrosynthesis cell may be a liquid-gas cell. An example of an electrosynthesis cell is a water electrolysis cell. This example is also a liquid-gas cell.

[0155] Power and electrosynthesis cells differ from other types of electrochemical cells (e.g., batteries, sensors, etc.) in that they neither incorporate all / some of the reactants they need to operate within the cell body, nor do they incorporate all / some of the products they generate during operation within the cell body. Instead, these can be constantly brought in or removed from outside the cell during operation. For example, power cells differ from primary cells in that primary cells store their reactants and products within the cell body. Unlike batteries, power cells do not store chemical or electrical energy within them. Similarly, while some electrochemical sensors may consume reactants and generate products in limited amounts during sensing operations, all / some of these are stored within the cell body itself.

[0156] 'Electrode spacer' is defined as a structure within an electrical power and electrosynthesis cell that is permeable to ions but largely impermeable to gases, and which is placed between the electrodes in an electrosynthesis or electrical power cell to prevent gas from crossing from one of the component half-cells into the other half-cell. Examples of 'electrode spacer' include ion permeable membranes (e.g., Nafion 117 and Nafion 115 manufactured by Du Pont Nemours), diaphragms (e.g., Zirfon PERL manufactured by Agfa), fabrics (e.g., various asbestos fabrics used in the past), or similar structures. The term 'electrode spacer' includes inter-electrode porous capillary membranes as defined as set forth in International Patent Publication Nos. WO 2022056603, WO 2022056604, WO 2022056605, and WO2022056606, which are hereby incorporated by reference.

[0157] An 'electrode' is a conductive structure, typically metallic, at which electrons are converted to ions or vice versa within an electrosynthetic or electrical energy cell. During operation of the cell, an electrode may typically be an anode or a cathode.

[0158] A 'porous transport layer' is a porous layer containing voids through which gases or liquids pass during operation of the electrosynthesis or power cell. The porous transport layer may be conductive and / or metallic and / or positioned close to or adjacent to the electrode. The porous transport layer may also be located between the electrode and the bipolar plate. That is, the porous transport layer may be a conductive, often metallic structure that is permeable to liquid and / or gaseous fluids and is located between the electrode and its bipolar plate. The porous transport layer may provide an electrical connection between the electrode and the bipolar plate while allowing liquid or gas to move to or from the electrode.

[0159] 'Bipolar plates' are electrically conductive plates, usually metal, that are located on the outside of an electrocombination or power cell or between electrocombination or power cells in a cell stack. The term 'bipolar' refers to the fact that within a cell stack, a voltage applied to a bipolar plate can be used on one side for an anode reaction and on the other side for a cathode reaction. The main function of a bipolar plate is to accumulate and evenly distribute electrical current from one cell to the next.

[0160] A 'flow field' is a pattern of dimples and bosses, or ribs and spaces, or steps and voids etched, machined, stamped, sunken or otherwise formed on the face of a bipolar plate. A common flow field is a serpentine flow field having one or more channels sunk into their face in a serpentine arrangement.

[0161] A 'waffle' flow field is a pattern of dimples and terraces, or ribs and spaces, or steps and voids (reminiscent of the pattern in a waffle iron).

[0162] A 'waffle bipolar plate' is a bipolar plate having a 'waffle' flow field present on its face. That is, its flow field is similar to that of a waffle iron. It will be understood that the term 'waffle bipolar plate' may be used herein to describe any bipolar plate that may simultaneously act as a porous transport layer. That is, the term 'waffle bipolar plate' is used herein to also describe any bipolar plate whose face contains voids through which gases may pass during operation of an electrosynthesis or electric energy cell. In other words: the term 'waffle bipolar plate' may be used herein to describe any bipolar plate that provides a porosity of the type also found in a porous transport layer.

[0163] A 'cell stack' or 'stack' is a collection of electrochemical cells that are stacked sideways one after the other so that they are connected in electrical series. Cell stacks may be designed to accumulate the reactants and products involved in their constituent cells into a single external product and / or reactant stream that is easier to manage than multiple smaller streams.

[0164] The cell stack may take the form of a 'filter press' arrangement, which is defined as a cell stack in which the cells are pressed together between end plates during assembly and / or operation thereof.

[0165] An 'end plate' is defined as a rigid, substantially non-compressible, substantially flat structure which is used at the ends of a 'filter press' cell stack and between which the cells in the cell stack are compressed.

[0166] An assembled cell is defined as 'inwardly pressed' if a clamping force is imparted to at least one electrode within the assembled cell thereby pressing the electrode against an electrode spacer membrane. In a preferred embodiment, the individual cells are preferably assembled before the cells are combined into a cell stack. Preferably, such assembled cells are 'inwardly pressed', meaning that a clamping force has been imparted to at least one electrode within the assembled cell thereby pressing the electrode against an electrode spacer membrane. Combining such (pre)assembled cells into a cell stack may be achieved considerably easier and faster than assembling the cells during the cell stack formation process itself (as may be conventionally done for electrosynthesis or power filter press type cell stacks). Furthermore, due to the fact that the cells in the stack are already 'inwardly pressed', the need for accurate and precise pressing of the cell stack during and thereafter its formation may be reduced.

[0167] A 'manifold aperture' or 'manifold opening' is an external aperture or opening in an individual cell that is used to convey liquid or gaseous fluids into or out of the cell. When combined with equivalent manifold apertures in other cells in the stack, the manifold aperture or opening forms a corresponding 'manifold' in the cell stack.

[0168] A 'header' is a channel, tube, chamber or slot formed by a combination of header holes or openings in the individual cells in a cell stack, which is used to transport liquid or gaseous fluids through the entire thickness of the cell stack. A header is formed when a set of equivalent header holes or openings in multiple cells are aligned and sealed when the cells are pressed together to form a cell stack.

[0169] A 'manifold' is one or more pipes, tubes, chambers or channels with multiple openings that are used to transport fluids. Within a cell stack, a header may also be a manifold.

[0170] The term 'cell body' is defined as that portion of the cell external to the external openings used to convey liquid or gaseous fluids into or out of the cell; i.e., it is the portion of the cell excluding header / manifold apertures or openings. That is, it is the portion of the cell that can be sealed by an 'intra-cell' seal (i.e., a seal involving and can be produced within only a single cell), and does not include the portion of the cell that can be sealed only by an 'inter-cell' seal (i.e., a seal necessarily involving two or more cells).

[0171] A cell is 'stackable' if it is designed to be deployed in a cell stack. For example, in the case of a filter press type cell stack, it may contain manifold orifices or openings for liquid or gas piping systems that dock with equivalent orifices or openings in other cells in the stack to form a header or manifold. In the non-limiting example of a filter press type cell stack, the cells are substantially flat and are pressed against each other between end plates during assembly and / or operation thereof.

[0172] 'Structural retaining features' are defined as polymer structures in electrocomposite or electrical energy cells which, when attached to a polymer cell frame, mechanically hold physically disconnected metallic structures in place within or around the cell and / or cell frame.

[0173] A 'compressive component' or 'compressive element' in a cell is defined as a spring-like or spring-like structure which, when properly positioned in the cell, exerts a clamping force on at least one of the electrodes, thereby pressing the electrode against the electrode separator. Preferably, the spring-like or spring-like action is produced in at least one of the metal bipolar plate or the metal porous transport layer. Alternatively, the spring-like or spring-like action may be produced in at least one of the metal electrodes.

[0174] A 'bipolar plate extrusion component' is a bipolar plate that also has an extrusion function. That is, the bipolar plate is a spring-like or spring-like structure which, when properly positioned in an assembled cell, exerts a clamping force on its associated electrode, thereby pressing the electrode against the electrode spacer membrane. It will be understood that such spring-like action is preferably designed into the bipolar plate extrusion component so that the bipolar plate extrusion component imparts a specific, predetermined clamping force to the electrode within a relatively narrow clamping force range. The bipolar plate extrusion component does not impart the clamping force merely sporadically or in an uncontrolled or non-repeatable manner, for example due to 'rebound'. Preferably, the clamping force within the cell is generated entirely or in part by the stiffness of: (1) the polymer-to-metal joint between the bipolar plate extrusion component and the polymer cell frame, or (2) the polymer-to-polymer joint between the 'polymer structural positioning' element and the polymer cell frame.

[0175] A 'porous transport layer extrusion component' or 'spring-like porous transport layer' is a porous transport layer that also has an extrusion function. That is, the porous transport layer is a spring-like or spring-like structure which, when properly positioned in an assembled cell, exerts a clamping force on its associated electrode, thereby pressing the electrode against the electrode spacer membrane. It will be understood that such a spring-like action is preferably designed into the porous transport layer extrusion component so that the porous transport layer extrusion component imparts a specific, predetermined clamping force to the electrode within a relatively narrow clamping force range. The porous transport layer extrusion component does not impart the clamping force merely sporadically or in an uncontrolled or non-repeatable manner. Preferably, the clamping force within the cell is generated entirely or in part by the stiffness of: (1) the polymer-to-metal joint between the bipolar plate extrusion component and the polymer cell frame, or (2) the polymer-to-polymer joint between the 'polymer structural positioning' element and the polymer cell frame.

[0176] Different extrusion members may be provided, for example, 'metal bipolar plate extrusion members', 'metal porous transport layer extrusion members', and / or 'metal electrode extrusion members'. Such structures are metal structures that act as spring-like or spring-like structures, which, when properly positioned in an assembled cell, exert a clamping force on the associated electrode, thereby pressing the electrode against the electrode separation membrane.

[0177] A 'compliant component' or 'compliant element' in a battery cell is defined as a compressible structure which, when properly positioned in the battery cell, shifts to adapt to and evenly distribute the compressive force. Preferably, the compliant action is generated in at least one of the metal bipolar plate or the metal porous transport layer. Optionally, the compliant action can be generated in at least one metal electrode. A 'bipolar plate compliant component' is a bipolar plate that also has a compliant function. A 'porous transport layer compliant component' is a porous transport layer that also has a compliant function. That is, different compliant components can be provided, for example, a 'metal bipolar plate compliant component', a 'metal porous transport layer compliant component', and / or a 'metal electrode compliant component'.

[0178] The term 'metal to metal weld' as used herein is defined as any form of metallurgical metal to metal joint that may be considered to involve welding including but not limited to fusion welding and pressure welding.

[0179] A 'gasket' is defined as a shaped rubber sheet or ring or other resilient material that seals the joint between two surfaces that are not physically joined together.

[0180] A 'tolerance compensating feature' is defined as a structure designed to accommodate variability in the components being joined. Tolerance compensating features include but are not limited to channels, grooves, slots, tongues, and other structural features that are slightly oversized or slightly undersized to thereby accommodate variations in the amount of material that flows during joining.

[0181] 'Positive engagement components' are complementary structures that facilitate engagement between two surfaces, such as tongue and groove joints, dowel pins and holes, etc. Some positive engagement components may include one or more tolerance compensating features.

[0182] Preferred Embodiments

[0183] The inventors have developed new electrosynthetic or electric energy cell architectures that simplify the process of reliably assembling cells into cell stacks and maintaining these cell stacks during subsequent operations. The cells include polymer cell frames, functional materials (e.g., electrode spacers, electrodes, porous transport layers, and bipolar plates) incorporated within or around them. These individual functional materials can be attached to the cell frame via polymer-to-polymer junctions or polymer-to-metal junctions. In one example, one or more polymer functional materials can be attached to the polymer cell frame via one or more polymer-to-polymer junctions. For example, the polymer electrode spacer can be attached to the polymer cell frame via one or more polymer-to-polymer junctions. The polymer-to-polymer junction can seal the junction between the polymer electrode spacer and the polymer cell frame, such as to allow gas to leak from one side of the electrode spacer to the other side across the thickness of the electrode spacer. In another example, one or more metal functional materials can be attached to the polymer cell frame via one or more metal-to-polymer junctions. For example, a metal bipolar plate can be attached to the cell frame via one or more polymer-to-metal junctions. The polymer-to-metal joint may seal the joint between the metal bipolar plate and the polymer cell frame, for example, to prevent leakage of liquids or gases to or from the exterior of the cell.

[0184] Some or all of the metal functional materials used for each half-cell within the entire cell can be further attached to each other via one or more metal-to-metal joints (e.g., metal-to-metal welds). For example, the metal electrodes and metal bipolar plates comprising the metal components of a single half-cell can be attached to each other via one or more metal-to-metal joints (e.g., metal-to-metal welds). In an alternative example, the metal electrodes, metal porous transport layers, and metal bipolar plates comprising the metal components of a single half-cell can be attached to each other via one or more metal-to-metal joints (e.g., metal-to-metal welds). Such metal-to-metal joints (e.g., metal-to-metal welds) can thereby produce a single metal component to be processed during the assembly of the cell, thereby simplifying the cell assembly. In addition, such a metal-to-metal joining process can be implemented separately and independently of the cell assembly, thereby simplifying the cell assembly again.

[0185] One or more of the metal functional materials thus attached to each other may be attached to the polymer cell frame via one or more metal-to-polymer joints. For example, a bipolar plate in one of the above-mentioned metal-to-metal joint assemblies may be attached to the polymer cell frame via one or more metal-to-polymer joints. The metal-to-polymer joint may seal the joint between the metal bipolar plate and the polymer cell frame to, for example, prevent liquid or gas from leaking to or from the outside of the cell.

[0186] In an alternative embodiment, a polymer 'structural positioning component' can be attached to the polymer cell frame via one or more polymer-to-polymer joints to thereby structurally constrain some or all of the metal functional components to a suitable position within or around the cell frame. A structural positioning component is a polymer structure that, when attached to a polymer cell frame, mechanically holds one or more physically disconnected metal components in a suitable position within or around the cell frame. In such cases, the metal functional components may not be physically attached to the polymer cell frame. Nevertheless, some of the metal functional components (such as, for example, bipolar plates) may be positioned tightly against or very close to the polymer cell frame. They may be positioned so tightly that the joint is sealed to, for example, allow liquid or gas to leak to or from the outside of the cell. Alternatively, a properly shaped gasket may be positioned between the metal bipolar plate and the polymer cell frame to more securely seal their joints. Due to the close structural matching of the metal bipolar plate and the polymer cell frame, the operating stress applied to the gasket during operation of the cell can be minimized.

[0187] This type of cell architecture may also be partially self-sealing. For example, by virtue of the sealing characteristics described above, the 'cell body' of such an electrical energy or electrical composite cell architecture may be sealed inwardly through its components, thereby reducing the need to create a reliable seal by accurately and precisely squeezing it during assembly of the cell stack and thereafter. The 'cell body' is that portion of the cell that does not include external liquid and gas piping system orifices and openings; that is, it is that portion of the cell that is outside the 'header' or 'manifold' orifice or opening. In other words, the 'cell body' is the portion of the cell that can be sealed by an 'intra-cell' seal (i.e., a seal involving and that can be created by cell components within a single cell), and does not include portions of the cell that can be sealed only by an 'inter-cell' seal (i.e., a seal that necessarily bridges two or more cells). Preferably, the cell body is effectively sealed by the presence of cell components and the presence of polymer-to-polymer joints or polymer-to-metal joints, so that only 'inter-cell' liquid and / or gas connections are left to be made during the assembly of the cell stack. That is, the cell body can be sealed by the metal-to-polymer joints present between the one or more metal bipolar plates and the polymer cell frame. Alternatively, the cell body can be sealed by physical contact between the one or more metal bipolar plates and the polymer cell frame, wherein the metal bipolar plates are tightly held against the cell frame by the polymer-to-polymer joints between the one or more polymer structural locating components and the polymer cell frame. Optionally, a suitable gasket may be present between the bipolar plate and the cell frame to provide an enhanced seal. Although the former type of direct polymer-to-metal joint can be pulled apart by forces generated by the different expansion of the metal components and the polymer components during heat or pressure cycles, the seal that avoids the latter type of direct polymer-to-metal joint can resist such degradation. That is, a metal-to-polymer seal, in which the metal component and the polymer component are physically disconnected, can provide improved durability during repeated temperature and pressure cycles, particularly where the thermal and / or pressure-induced expansion of the metal component and the polymer cell component differ significantly.

[0188] The above type of electrical energy or electrocombination cell architecture may also be 'inwardly pressed' to thereby reduce the need to accurately and precisely press the cell stack during and after assembly thereof. That is, the architecture of the assembled cell may exert a clamping force on at least one of the electrodes, thereby pressing the electrode against the electrode spacing membrane.

[0189] This can be achieved by incorporating at least one compressive component (e.g., a spring-like component or element, or a spring-like component or element) into the cell architecture, which exerts a clamping force on at least one of the electrodes (e.g., the first electrode or the second electrode), thereby pressing the electrode against the electrode spacer membrane. The at least one compressive component (e.g., a spring-like component or a spring-like component) can include a metal bipolar plate or a metal porous transport layer. Alternatively, but less advantageously, the at least one compressive component can include a metal electrode.

[0190] Preferably, the clamping force applied inwardly by the extrusion member on the electrode in the assembled cell to squeeze the electrode against the electrode separator is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, or greater than 20 bar.

[0191] Preferably, the extrusion applied inwardly in the assembled battery cell may be greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, or greater than 20 bar.

[0192] In order to mediate and evenly distribute the inward compressive force, the battery cell can further incorporate at least one compliant component. Such a compliant component can be evenly displaced to accommodate the compressive force applied by the at least one compressive component. The compliant component can be a metal bipolar plate, a metal porous transport layer, or a metal electrode.

[0193] The above types of electrical energy or electric synthesis cell architectures can provide simplified and reliable assembly of cell stacks, which can appropriately position metal components and polymer components in (pre) assembled cells via polymer-to-polymer joints, polymer-to-metal joints and / or metal-to-metal joints. Such suitable positioning in the assembled cells can avoid or alleviate the need to accurately position the cell components in the cell stack during the formation of the cell stack. The cell architecture described above can also provide assembled cells so that only moderate or low extrusion that does not need to be accurately applied (face or sideways) is used to assemble into or within the cell stack. In addition, the resulting cell stack can be subsequently operated while maintaining only moderate or low extrusion, thereby avoiding the need for specific or high extrusion after the cell stack is formed. Moderate or low extrusion can be produced and maintained by torsion, mechanical, hydraulic (i.e., liquid) or other means that can adapt to dimensional changes in the length of the cell stack (such as may occur during repeated temperature or pressure cycles). Accordingly, when proper positioning in assembled cells is combined with reduced extrusion requirements, the above cell architecture can provide simplified and reliable, high-speed, high-capacity industrial formation of electrical energy or electrosynthetic cell stacks (particularly filter press cell stacks) that will not cause leakage or mixing of liquid or gaseous reactants and products either after assembly or during subsequent operation.

[0194] Example Preferred Embodiments: First Preferred Example Embodiment Cell Architecture

[0195] In a first preferred non-limiting example embodiment, an electric energy or electric synthesis cell architecture is provided, comprising at least one polymer cell frame to which are attached:

[0196] - at least one polymer electrode spacer membrane attached to the at least one polymer cell frame by or via one or more polymer-to-polymer bonds; and

[0197] - At least one metallic functional component attached to the at least one polymer cell frame by or via one or more polymer-to-metal joints.

[0198] The at least one metal functional component can be a metal bipolar plate. The metal bipolar plate can form part of a metal-to-metal joint assembly (e.g., a metal-to-metal welded assembly), which, for example, includes at least one metal bipolar plate and at least one metal electrode (e.g., cathode or anode) and optionally at least one metal porous transport layer. One or more polymer-to-metal joints between the polymer cell frame and the metal bipolar plate can hold the metal-to-metal joint assembly in a suitable position within or around the cell frame. The presence of the one or more polymer-to-metal joints can seal the polymer cell frame to the metal bipolar plate.

[0199] Alternatively, the at least one metallic functional component may include a metallic electrode or a metallic porous transport layer. The at least one metallic electrode or the at least one metallic porous transport layer may also form part of a metal-to-metal joint assembly (e.g., a metal-to-metal welded assembly) comprising at least one metallic bipolar plate. Optionally, one or more polymer-to-metal joints between the polymer cell frame and the metallic electrode or between the polymer cell frame and the metallic porous transport layer may hold the metal-to-metal joint assembly in a suitable position within or around the cell frame.

[0200] Figure 1 The components and assembly of a first preferred example embodiment electrical energy or electrical synthesis cell 10 are schematically depicted. Figure 1 Starting at the upper left of , along row A, the battery cell includes a polymer battery frame 11 and an electrode spacer membrane 12, which has a relatively large open window (i.e., a window cutout) at its center. In one example, the base material of the electrode spacer membrane is a polymer material, i.e., the electrode spacer membrane is a polymer electrode spacer membrane. Preferably, but not exclusively, the base material of the electrode spacer membrane includes a polymer material that is the same as or substantially similar to the base material of the battery frame 11. The window cutout is preferably a space without material. However, in some examples, there may be material, such as ribs or supports made of, for example, a polymer material, and they may span portions of the cut-out window area to achieve the structural integrity of the polymer battery frame or to support other components.

[0201] Figure 1 Row B in FIG. 1 shows that the electrode spacer film 12 is bonded to the cell frame 11 by a polymer-to-polymer bond around the perimeter of the window cutout in the cell frame 12, thereby forming an assembly 112. The electrode spacer film 12 is bonded to the polymer cell frame 11 and positioned in the window cutout. Figure 1Other components in the exploded view shown in row B in include a first electrode 13 and a second electrode 14 (i.e., electrodes 13, 14 or two electrodes 13, 14), which may be porous and may include a metal base or be entirely metallic. Depending on the specific example, the first electrode 13 may be an anode or a cathode, and the second electrode 14 may be an anode or a cathode. The electrodes 13 and 14 are pre-cut to fit in the windows of the cell frame 11, i.e., the electrodes 13 and 14 are positioned in the polymer cell frame. On the outside of the electrodes 13 and 14 and adjacent to them are respectively a first extrusion component 15 and a second extrusion component 16 (i.e., extrusion components 15, 16), which in this particular non-limiting example are conductive metallic porous transport layers that also perform extrusion (e.g., spring-like) functions. The extrusion component 15 is positioned adjacent to, or immediately adjacent to, or adjacent to the first electrode 13 on the side opposite to the electrode spacer membrane 12. The extrusion member 16 is positioned adjacent to, or immediately adjacent to, or abutting the second electrode 14 on the side opposite to the electrode spacer membrane 12. The extrusion members 15, 16 (also referred to as metal porous transport layer extrusion members 15, 16 in this example) are also cut to fit in the cut-out windows of the cell frame 11. Figure 1 On the outside of the exploded view at the middle row B are the first metal bipolar plate 17 and the second metal bipolar plate 18 (i.e., metal bipolar plates 17, 18). The metal bipolar plates 17, 18 have been pre-cut to be larger than the cut-out windows of the polymer cell frame 11 and thus overlap with the outside of the polymer cell frame 11, including at the top, bottom and side edges of the polymer cell frame 11.

[0202] Figure 1 Row C in FIG. 1 depicts the components in assembly and the next stage. Electrodes 13 and 14 are placed in the window cutouts of cell frame 11 and positioned tightly against opposite sides of electrode spacer 12 that has been attached to cell frame 11. The assembly of cell frame 11, electrode spacer 12, and electrodes 13 and 14 is labeled assembly 1112.

[0203] like Figure 1It can be seen in row C that the compressive components 15, 16 (e.g., spring-like porous transport layers 15 and 16) are to be inserted into the cut-out windows of the cell frame 11. Thereafter, the metal bipolar plates 17 and 18 are securely attached to the uncovered, exposed polymer surfaces at their top, bottom, and around the sides on the front and back sides of the cell frame 11, respectively, by polymer-to-metal joints to thereby seal the 'cell body' of the cell 10. When the metal bipolar plates 17 and 18 are attached to the polymer cell frame 11 by polymer-to-metal joints, the compressive components 15, 16 (e.g., spring-like porous transport layers 15 and 16) located between the metal bipolar plates 17 and 18 and the electrodes 13 and 14 exert a clamping force inwardly on the electrodes 13 and 14, respectively, thereby pressing the electrodes 13 and 14 tightly against opposite sides of the electrode separator 12.

[0204] therefore, Figure 1 A non-limiting example of an electric energy or electrosynthesis cell 10 is shown, which includes a polymer cell frame 11, and a first electrode 13 and a second electrode 14. An electrode spacer membrane 12 is positioned between the first electrode 13 and the second electrode 14. A (first) extrusion member 15 (being a metal porous transport layer extrusion member 15) is positioned adjacent to the first electrode 13 on the side opposite to the electrode spacer membrane 12. A (first) metal bipolar plate 17 is positioned adjacent to the (first) extrusion member 15 on the side opposite to the first electrode 13. In the example shown (which may not always be necessary in various other examples), a second extrusion member 16 (being a second metal porous transport layer extrusion member 16) is positioned adjacent to, immediately adjacent to or adjacent to the second electrode 14 on the side opposite to the electrode spacer membrane 12, and a second metal bipolar plate 18 is positioned adjacent to the second extrusion member 16 on the side opposite to the second electrode 14. Optionally, at least one polymer structural positioning member ( Figure 1 (not shown) the metal bipolar plate 17 is positioned against the polymer cell frame 11.

[0205] In an alternative example, the electrode spacer forms part of the polymer cell frame, or is integrally formed as part of the polymer cell frame and is a polymer electrode spacer, but is still positioned between the first electrode and the second electrode.

[0206] Figure 1The example in depicts the case where both the extrudable components 15 and 16 (e.g., metal porous transport layer extrudable components 15 and 16) have an extrudable function. However, it will be understood that alternative preferred examples involve one of the extrudable components 15 and 16 having an extrudable function (e.g., one of the porous transport layers 15 and 16), such as the first extrudable component 15 (i.e., being a metal porous transport layer extrudable component), and another extrudable component (e.g., the second porous transport layer 16) having a compliant function (i.e., being a metal porous transport layer compliant component).

[0207] Figure 1 The image at the lower right depicts a fully assembled cell 10 .

[0208] As in Figure 1 As can be seen, the following important points are related to cell 10:

[0209] (1) The polymer-to-metal joints between the metal bipolar plates 17 and 18 and the uncovered, exposed polymer surfaces on opposite sides of the cell frame 11 cause the compressible components 15 and 16 (e.g., spring-like porous transport layers 15 and 16) to be pressed against the electrodes 13 and 14, respectively. That is, the architecture of the cell 10 causes the cell 10 to be pressed inwardly. This pressing is typically easier, faster, more reliably, uniformly, and precisely achieved in the assembly of individual cells in a more controllable and forgiving manner than when many cells need to be pressed simultaneously during the assembly of a large cell stack. In addition, having been pressed inwardly, the individual cells can be assembled into or within the cell stack without having to precisely apply (face-wise or laterally) a specific or high overall pressing (as is typically required for the assembly of filter press-type cell stacks, in particular). In addition, before forming the cell stack, each individual cell can be tested separately to determine whether its inward pressing and operation are correct. This option is not available when the required cell assembly and compression (clamping force) is generated only during the formation of the cell stack, as is usually required in particular in filter press type cell stacks. Additionally, individual cells in the cell stack that fail or in which the required compression is lost during operation can be easily removed and replaced. This option is also not conventionally available; the entire conventional cell stack must be disassembled and then reassembled - a difficult and time-consuming task.

[0210] (2) The polymer-to-metal joints between the metal bipolar plates 17 and 18 and the uncovered, exposed polymer surfaces on opposite sides of the cell frame 11 result in the 'cell body' of each cell being completely sealed. That is, the 'cell body' of each cell is sealed inwardly through its components. That is, the interior area of ​​the cell is sealed, or in other words, the cell is sealed. This reduces the need to produce a reliable seal by accurate and precise face and lateral extrusion (as is typically required during the assembly of a filter press type cell stack). In addition, before assembling the cell stack, each individual cell can be tested separately to determine whether its cell body is properly sealed. This option is not available when the required seal of the cell body is only produced during the formation of the cell stack. Additionally, cells in which the seal of the cell body fails during operation can be easily removed and replaced in the cell stack. This option is not available in conventional cell stacks; the entire conventional cell stack must be disassembled and then reassembled - a difficult and time-consuming task.

[0211] (3) The polymer-to-metal joints between the metal bipolar plates 17 and 18 and the uncovered, exposed polymer surfaces on opposite sides of the cell frame 11 cause the components of the individual cells to be positioned in their optimal positions around the cell frame and within the cell. That is, the extrudable components 15 and 16 (e.g., the spring-like porous transport layers 15 and 16) and the electrodes 13 and 14 are maintained in extrusion tension in their correct positions within the cell. This reduces the need to accurately position the cell components during the formation of the cell stack. In addition, before forming the cell stack, each individual cell can be tested separately to determine whether its components are correctly positioned. This option is not available when the desired positioning of the cell components is only produced during the formation of the cell stack. Additionally, cells in which components move during operation and become improperly positioned can be easily removed and replaced in the cell stack. This option is not available in conventional cell stacks; the entire conventional cell stack must be disassembled and then reassembled - a difficult and time-consuming task.

[0212] Figure 2 Another preferred example embodiment of an electrical energy or electrical synthesis cell 100 is schematically depicted. As can be seen, the components involved in rows A and B are similar to those in FIG. Figure 1 However, in this example embodiment, a metal-to-metal joint (e.g., a metal-to-metal weld) has been used to attach the second metal bipolar plate 18 to the second extrusion component 16 (e.g., a second metal porous transport layer extrusion component 16) and the second metal electrode 14, thereby forming a second metal-to-metal joint assembly 114.

[0213] Similarly, a metal-to-metal joint (e.g., a metal-to-metal weld) has been used to attach the first metal bipolar plate 17 to the first extrusion component 15 (e.g., a first metal porous transport layer extrusion component 15) and the first metal electrode 13 to form a first metal-to-metal joint assembly 113.

[0214] Figure 2 Row D in the figure depicts a polymer component 112 (which includes a polymer cell frame 11 and a polymer electrode spacer membrane 12 attached and sealed to each other via a polymer-to-polymer joint), which is flanked by a second metal-to-metal joint component 114 (including a metal-to-metal joint (e.g., metal-to-metal welding) functional component of one of the half cells), and a first metal-to-metal joint component 113 (including a metal-to-metal joint (e.g., metal-to-metal welding) component of the other half cell).

[0215] The battery cell 100 is formed when a first metal bipolar plate 17 (part of a first metal-to-metal bonding assembly 113) and a second metal bipolar plate 18 (part of a second metal-to-metal bonding assembly 114) are securely attached to uncovered, exposed polymer surfaces at the top, bottom, and around the sides of the battery cell frame 11, respectively, on both sides of the battery cell frame 11 (i.e., on the front and back sides) via polymer-to-metal bonding portions.

[0216] The polymer-to-metal bond between the metal bipolar plates 17 and 18 and the polymer cell frame 11 seals the 'cell body' of the cell 100 .

[0217] The polymer-to-metal joint between the metal bipolar plates 17 and 18 and the polymer cell frame 11 also causes the compressive components 15 and 16 (e.g., spring-like porous transport layers 15 and 16) (which are part of the metal-to-metal joint assemblies 113 and 114, respectively) to exert a clamping force inward on the electrodes 13 and 14, respectively, thereby pressing the electrodes 13 and 14 tightly against opposite sides of the electrode separator 12. The electrodes 13 and 14 are part of the metal-to-metal joint (e.g., metal-to-metal weld) assemblies 113 and 114, respectively.

[0218] Figure 2 The example in depicts the case where both the extrudable components 15 and 16 (e.g., the porous transport layer extrudable components 15 and 16) have an extrudable function. However, it will be understood that alternative preferred examples involve one of the extrudable components 15 and 16 having an extrudable function (e.g., one of the porous transport layers 15 and 16), such as the first extrudable component 15 (i.e., being a metal porous transport layer extrudable component), and another extrudable component (e.g., the porous transport layer 16) having a compliant function (i.e., being a metal porous transport layer compliant component).

[0219] Figure 2 The image at the lower right depicts the thus assembled battery cell 100. Figure 2 As can be seen in the above text, around Figure 1 All important points (1) to (3) described in the discussion of Figure 2 It is related to the battery cell 100.

[0220] Figure 3 A most preferred example embodiment of an electrical energy or electrical synthesis cell 1000 is schematically depicted. As can be seen, the components involved in row A are similar to those in row B. Figure 1 and Figure 2 . However, in this example embodiment, there are no components 15 and 16 (e.g., there are no porous transport layer extrusion components 15 and 16). Instead, bipolar plates 17 and 18 are extrusion components. These bipolar plates can also act as porous transport layers; that is, these bipolar plates have porous structures on their surfaces facing their electrodes 13 and 14, respectively, that allow gas or liquid to access their electrodes 13 and 14, respectively. The properties and qualities of such porous structures are discussed in the following sections.

[0221] That is, Figure 3 As shown in row E of , the metal functional components of one half cell include a second extruded metal bipolar plate 18 (i.e., a second metal bipolar plate extruded component 18) and a second metal electrode 14, while the metal functional components of the other half cell include a first extruded metal bipolar plate 17 (i.e., a first metal bipolar plate extruded component 17) and a first metal electrode 13.

[0222] exist Figure 3 In the example shown in FIG. 1 , an electric energy or electric synthesis cell 1000 is shown, which includes a polymer cell frame 11, a first electrode 13, and a second electrode 14. An electrode separator 12 is sealed to the cell frame 11 and positioned between the first electrode 13 and the second electrode 14. A metal bipolar plate extrusion member 17 is positioned adjacent to, in close proximity to, or adjacent to the first electrode 13.

[0223] Preferably, the polymer cell frame 11 is sealed to the metal bipolar plate extrusion member 17. In one example, the seal between the polymer cell frame 11 and the metal bipolar plate extrusion member 17 is produced by a polymer-to-metal joint. In another example (discussed in detail in the second preferred example embodiment cell architecture section below), at least one polymer structural positioning member ( Figure 3The metal bipolar plate extrusion member 17 is positioned against the polymer cell frame 11 (not shown). In this example, the seal between the polymer cell frame 11 and the metal bipolar plate extrusion member 17 can be produced by one or more polymer-to-polymer joints between the at least one polymer structural positioning member and the polymer cell frame 11, and the at least one polymer structural positioning member mechanically holds the metal bipolar plate extrusion member 17 against the polymer cell frame 11.

[0224] The second metal bipolar plate extrusion member 18 is positioned adjacent, proximate or abutting the second electrode 14. Preferably, the polymer cell frame 11 is sealed to the second metal bipolar plate extrusion member 18. In one example, the seal between the polymer cell frame 11 and the second metal bipolar plate extrusion member 18 is created by a polymer-to-metal joint. In another example (discussed in detail in the second preferred example embodiment cell architecture section below), at least one additional polymer structural positioning member ( Figure 3 The second metal bipolar plate extrusion member 18 is positioned against the polymer cell frame 11 (not shown). In this example, the seal between the polymer cell frame 11 and the second metal bipolar plate extrusion member 18 can be produced by one or more additional polymer-to-polymer joints between the at least one polymer structural positioning member and the polymer cell frame 11, and the at least one polymer structural positioning member mechanically holds the second metal bipolar plate extrusion member 18 against the polymer cell frame 11.

[0225] The first electrode 13 and the second electrode 14 are positioned in the polymer cell frame 11. For example, as shown, the polymer cell frame 11 includes a window cutout, and the first electrode 13 and the second electrode 14 are positioned in the window cutout of the polymer cell frame 11. The electrode spacer 12 is also positioned in the polymer cell frame 11, between the first electrode 13 and the second electrode 14. Preferably, the electrode spacer 12 is a polymer electrode spacer, and the polymer cell frame 11 is coupled to the polymer electrode spacer via a polymer-to-polymer coupling portion. Preferably, the first electrode 13 is a first metal electrode, and the second electrode 14 is a second metal electrode.

[0226] In addition, a metal-to-metal joint (e.g., a metal-to-metal weld) may be used to attach the second metal bipolar plate extrusion member 18 to the second metal electrode 14, thereby forming a second metal-to-metal joint assembly 118. Similarly, a metal-to-metal joint (e.g., a metal-to-metal weld) may be used to attach the first metal bipolar plate extrusion member 17 to the first metal electrode 13, thereby forming a first metal-to-metal joint assembly 117.

[0227] Figure 4 (a) depicts an example embodiment metal bipolar plate extrusion component 17 or 18 (i.e., a metal waffle bipolar plate) that may be suitable for such direct attachment to a metal electrode, as well as attaching a metal electrode 13 or 14 thereto via a metal-to-metal joint (e.g., a metal-to-metal weld).

[0228] The metal bipolar plate extrusion 17 or 18 has a flow field on a portion of its face having a 'waffle' structure 181 (or a grid or grid arrangement of dimples and bosses, or ribs and spaces, or steps and voids). The 'waffle' structure is somewhat similar to the structure found on a waffle iron. Figure 4 The metal bipolar plate extrusion member 17 or 18 depicted in (a) is a metal sheet whose face has been etched, machined, stamped, formed, sunken or otherwise shaped into a waffle structure 181 (i.e., a mesh structure or grid). The metal bipolar plate extrusion member 17 or 18 also has a flat peripheral area 182 surrounding the waffle structure 181 that has no flow field embossed thereon. The waffle portion of the metal bipolar plate 17 or 18 may have a slightly domed shape, which demonstrates the fact that it is spring-like or springy.

[0229] exist Figure 4 In step A of (a), a metal electrode 13 or 14 (being a metal mesh electrode) is placed on the waffle structure 181. Thereafter, in step B, the metal mesh electrode is directly attached to at least some or all of the bosses of the waffle structure 181 by a metal-to-metal joint (e.g., a metal-to-metal weld that attaches the metal electrode 13 or 14 (i.e., the metal mesh electrode) to some or all of the ribs or steps of the mesh structure or grid on the face of the metal bipolar plate extrusion component 17 or 18). The resulting metal-to-metal joint assembly 117 or 118 includes a metal electrode 13 or 14, respectively, which is attached to some or all of the bosses of the waffle structure 181 by a metal-to-metal joint, wherein a flat peripheral area 182 of the metal bipolar plate extrusion component surrounding the waffle structure 181 is not touched.

[0230] Figure 4 (b) depicts a close-up view of how such a metal-to-metal joint can be achieved. A metal electrode 13 or 14 (in this case a metal mesh electrode) can be placed on the waffle structure 181. A metal-to-metal joint, such as a metal-to-metal weld, can then be created at some or all of the points 183 where the strands of the mesh 13 or 14 cover the bosses of the waffle structure 181.

[0231] This type of metal-to-metal joint (e.g., metal-to-metal weld) can stabilize the structure of the bipolar plate, thereby stopping, slowing, or avoiding deformation (e.g., 'springback'). In doing so, the metal-to-metal joint can minimize changes in the physical dimensions of the bipolar plate and its flow field, thereby allowing the use of precision industrial stamping, forming, and other high-speed, high-volume manufacturing processes.

[0232] The metal-to-metal joints between the metal bipolar plate extrusion component (i.e., the metal waffle bipolar plate 181) and the metal electrode 13 or 14 can further provide high electrical conductivity between these components and uniform distribution of current and voltage at the attached electrode. The number of metal-to-metal joints can be selected to be an optimal number considering the desired electrical conductivity between these components and the desired area distribution of current and voltage at the attached electrode.

[0233] The metal-to-metal joint between the metal bipolar plate extrusion (i.e., metal waffle bipolar plate 181) and the metal electrode 13 or 14 can also provide high thermal conductivity between these components and uniform distribution of heat generated by the battery cell. For example, heat generated at the electrode can be efficiently conducted to the metal bipolar plate extrusion 17 or 18, which can be cooled to thereby maintain the temperature of the battery cell.

[0234] Return to Figure 3 , Figure 3 Row F in the figure depicts a polymer component 112 (which includes a polymer cell frame 11 and a polymer electrode spacer membrane 12 attached and sealed to each other via a polymer-to-polymer joint), which is flanked by a metal component 118 (including a metal-to-metal bonded metal bipolar plate extrusion component 18 and a second electrode 14; i.e., a metal functional component of one of the half-cells), and a metal component 117 (including a metal-to-metal bonded metal bipolar plate extrusion component 17 and a first electrode 13; i.e., a metal functional component of the other half-cell).

[0235] The battery cell 1000 is formed when the metal bipolar plate extrusion component 17 (part of the metal-to-metal bonding assembly 117) and the metal bipolar plate extrusion component 18 (part of the metal-to-metal bonding assembly 118) are attached to the uncovered, exposed polymer surfaces on the front and back sides of the polymer battery cell frame 11 through polymer-to-metal bonding portions at their top, bottom and around the sides.

[0236] This may involve the peripheral area of ​​the metal waffle bipolar plate 17 or 18 (e.g. Figure 4 The planar peripheral region 182 in the embodiment of the present invention is attached to the polymer cell frame 11 via one or more polymer-to-metal joints. Figure 3The image at the lower right depicts the thus assembled cell 1000. The slightly domed shape of the waffle structure 181 can thereby be flattened, which means that its spring-like (or spring-like) properties have been exploited to exert an inward clamping force on the attached electrode 13 or 14 within the cell 1000, thereby pressing the electrode against the electrode spacer membrane 12. That is, once assembled by forming a polymer-to-metal joint between 117 or 118 and the cell frame 11, the spring-like waffle structure within 117 or 118 provides a compressive component that tightly clamps the attached electrode 13 or 14 against the electrode spacer membrane 12, respectively.

[0237] The polymer-to-metal bond between the metal bipolar plate extrusions 17 and 18 and the polymer cell frame 11 may further seal the 'cell body' of the electrocomposite or power cell 1000 . Figure 3 The example in illustratively depicts the case where both metal bipolar plate extrusion members 17 and 18 have an extrusion function. However, it will be understood that an alternative preferred example involves one of the metal bipolar plate extrusion members 17 or 18 having an extrusion function, and the other metal bipolar plate extrusion member having a compliance function. For example, a metal bipolar plate extrusion member and a metal bipolar plate compliance member may be provided.

[0238] It will be understood that in this example embodiment, the purpose of such a waffle bipolar plate is to include and combine the functionality of a porous transport layer within the bipolar plate. Thus, the waffle structure contains voids between the bosses of the waffle; these voids provide the same type of porosity found in the porous transport layer. Accordingly, any bipolar plate flow field that provides such voided porosity may potentially be used without the need for a separate porous transport component. That is, the waffle structure depicted provides only one example of a bipolar plate that can also act as a porous transport layer. Any such voided porous bipolar plate may fall within the scope of the term 'waffle bipolar plate' or 'metal waffle bipolar plate'.

[0239] It will be further understood that although only Figure 3 and Figure 4 and the associated text explicitly discuss the use of metal waffle bipolar plates, but the use of Figure 1 and Figure 2 The example embodiments described herein and their associated text may also utilize one or more metal waffle-type bipolar plates.

[0240] As in Figure 3 As can be seen in the above, Figure 1 All important points (1) to (3) described in the associated text are also related to Figure 3 The exemplary cells 10, 100 and 1000 are characterized by the complete absence of gaskets in their cell architecture.

[0241] Additionally: Metal-to-metal joints (such as, for example, metal-to-metal welds) can provide reduced or constant resistance between metallic functional materials, thereby providing improved energy efficiency from the electrical energy or electrical resultant cell during operation. Preferred embodiments may employ such metal-to-metal joint structures because the extrusion involved in cell assembly may be too low to damage or destroy the metal-to-metal joints (e.g., metal-to-metal welds). Furthermore, when the assembled cells are then combined into a cell stack, low extrusion may again be required. In contrast, as noted in the Background section, in conventional cell stack formation, much higher extrusions are typically required; such high extrusions may easily damage or destroy any metal-to-metal joints (e.g., metal-to-metal welds) present.

[0242] Preferably, the polymer electrode separator film in the above example embodiments is thin, to thereby maximize the energy efficiency of the battery cell. Preferably, the polymer electrode separator film is less than 0.35 mm thick, less than 0.2 mm thick, less than 0.1 mm thick, less than 0.05 mm thick, or less than 0.025 mm thick.

[0243] Preferred Example Embodiment Battery Cell Stack Assembly

[0244] Figure 5 Schematically depicts how example battery cells 10, 100, or 1000 may be stacked in a battery cell stack 20. An aperture / opening (e.g., Figure 5 The holes / openings (e.g., 21-23) in the top and bottom of each cell 10, 100, 1000 (e.g., 24-25) are referred to as headers or manifold holes. The headers / manifold holes / openings in each cell within the stack are aligned after the stack is assembled to thereby effectively form a conduit through the length of the cell stack 20.

[0245] Typically, in a conventional filter press type cell stack, the headers (e.g., the headers formed by the orifices / openings 21, 22, 23, 24, 25) will be sealed to each other by tightly squeezing the cells in the stack between two end plates during stack assembly and maintaining such squeezing thereafter. Particularly high squeezing will typically be required to ensure that liquids and / or gases in the headers cannot leak from the formed ducts or mix by flowing into the spaces between the cells. The metal bipolar plates between the cells in such a filter press type cell stack will similarly be sealed to their cell frames by squeezing rather than by polymer-to-metal joints, as described above. The required squeezing of the components in each cell (including the clamping of the electrodes against the electrode spacer membrane) will also typically be provided by squeezing applied to the cell stack during formation of the cell stack and thereafter.

[0246] However, in a preferred example embodiment, it is not necessary to seal the bipolar plates by extrusion of the cell stack, since the bipolar plates are already attached to their cell frames by polymer-to-metal joints during assembly of the cells. It may also be unnecessary to provide the required clamping forces to press the electrodes against the electrode spacer membranes in each cell, since such clamping forces already exist due to the (pre)assembly of the cells. The need to accurately and precisely (facially and laterally) compress the cell stack during and after formation of the cell stack can thereby be reduced.

[0247] Accordingly, preferably, the preferred embodiment cell stack is formed (and completely sealed) by gently squeezing the cells together and then sealing the header / manifold aperture or opening in each cell to the equivalent header / manifold aperture or opening in the next cell in the stack until all header / manifold apertures or openings in the stack are sealed. All header / manifold apertures or openings in the stack may also be sealed simultaneously, i.e., they may all be sealed at once.

[0248] The header / manifold apertures or openings of an electrocomposition or power cell may be sealed to an equivalent header / manifold aperture or opening of the next cell in the stack via one or more polymer-to-polymer joints during cell stack assembly. That is, during cell stack assembly, an assembled cell (whose 'cell body' is already sealed due to its cell architecture) may be completely sealed by creating liquid and / or gas connections into and out of the rest of the cell stack by polymer-to-polymer joints. Such polymer-to-polymer joints may further reduce the need to create seals by accurate and precise extrusion during and after assembly of the cell stack.

[0249] Any polymer-to-polymer joining technique can be used to produce the desired junction, including any of the polymer-to-polymer joining techniques described or listed in this specification.

[0250] In a particularly preferred example, such polymer-to-polymer joints can be produced by patterning and placing resistive metal wires or circuits around the polymer header / manifold orifices to be sealed on each cell. After the cells are stacked for cell assembly and squeezed to the desired extent, current can be passed through each of the existing circuits, causing each circuit to heat up and cause the polymer material of the adjacent cells around the circuit to melt and fuse. The resulting cell stacking architecture can include cells stacked and joined together via polymer-to-polymer joints that incorporate resistive wires and / or circuits around the header / manifold orifices.

[0251] In another preferred example, a gasket (e.g., a shaped rubber sheet or ring) may be placed around a first portion of the polymer region to be sealed, followed by a polymer-to-polymer seal of the type described above in a second portion of the polymer region to be sealed. The gasket may provide additional, long-term protection against leakage, which may be particularly useful where structurally complex polymer-to-polymer connections are required. The resulting cell stack architecture may include cells stacked and connected together via polymer-to-polymer connections that combine resistive wires and / or circuits around the header / manifold orifices with gaskets near the polymer-to-polymer connections.

[0252] In other examples, the required polymer-to-polymer welds may be too complex or demanding for a reliable seal, in which case one or more gaskets may be used. The resulting cell stack architecture may include stacked cells with gaskets around header / manifold apertures, wherein compression of the stack maintains the gasket seal.

[0253] Preferably, the sealing architectures described above can provide simplified and reliable assembly of components and cells into or within cell stacks that do not allow leakage or mixing of liquid or gaseous reactants and products both after assembly and during subsequent operation. They can also provide high-speed, high-volume industrial assembly of electrosynthesis or power cell stacks.

[0254] In an example, the cell stack is a filter press type cell stack. In another example, the liquid inlet manifold of the cell in the cell stack is pressurized to a higher pressure than the liquid in each cell, and the liquid outlet manifold of the cell in the cell stack is pressurized to a lower pressure than the liquid in each cell. In a preferred example, the overall extrusion pressure applied to the cell stack during assembly and thereafter (e.g., during electrochemical operation) is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, greater than 20 bar, greater than 30 bar, greater than 40 bar, greater than 50 bar, or greater than 100 bar.

[0255] Compression may be maintained by torsional, mechanical, hydraulic (ie, liquid), or other means that can accommodate dimensional changes in the length of the cell stack, such as may occur during repeated temperature or pressure cycles.

[0256] Figure 6Schematically illustrated is the sealing of the header / manifold apertures by patterning and placing a resistive metal wire or circuit around the polymer header / manifold aperture to be sealed on each cell.

[0257] Figure 6 A cell 301 having a plurality of header apertures 303-308 is depicted. A second cell 302 having equivalent header apertures is placed against cell 301 with its header apertures aligned with the header apertures 303-308 in cell 301. To seal the header apertures 303-308 on cell 301 to their equivalent header apertures on cell 302, wire 309 (preferably thin wire) may be bent in a pattern matching the headers before being placed around the headers 303-308 on the surface 310 of cell 301. The cell frames 301 and 302 are then pressed together and current is passed along wire 309 by connecting a suitable power source across its ends 3091 and 3092. Wire 309 heats due to the current flowing through it, thereby melting the polymer adjacent thereto in cells 301 and 302 and causing the polymer cell frames of cells 301 and 302 to fuse together around wire 309, thereby sealing the headers 303-308 in cell 301 to their equivalent headers in cell 302. This process may be repeated with many cell frames, thereby creating a sealed cell frame stack. In an example, the liquid inlet headers of the cells within the cell stack may be pressurized to a higher pressure than the liquid in each cell, and the liquid outlet headers of the cells within the cell stack may be pressurized to a lower pressure than the liquid in each cell.

[0258] In this way, it may be possible to assemble an electrical energy or electrosynthetic cell stack with moderate to small compression during assembly and subsequent operation. It may also be possible to reduce or even completely eliminate the need to maintain the cell stack under precise lateral and surface compression after assembly during the operational life of the stack.

[0259] This type of patterned wire can also be placed around the perimeter of a cell frame, allowing multiple cell frames to be welded together in the same manner. Patterned wire can further be placed around other headers and / or other features to seal them in the same manner.

[0260] It will be appreciated that there are numerous alternatives to wire 309. For example, instead of a wire, a polymer film coated with a conductive metal layer and cut into the shape shown for 309 could be used. Such a polymer cutout could be as shown in FIG. Figure 6309. When the polymer cell frames of cells 301 and 302 are pressed together, including a thin, cut polymer film (coated with a thin layer of conductive metal and shaped as shown for 309) between these polymer cell frames can create a better seal than a wire (when electrically heated to create a seal).

[0261] 'Inter-cell' polymer-to-polymer bonds of the type described above can further reduce the challenges of creating seals by accurate and precise extrusion during cell stack formation. They can also provide more reliable seals that are less dependent on high extrusion being maintained constantly across the cell stack. In contrast, conventional cell stacks rely almost entirely on high extrusion (maintained constantly) to create and maintain such 'inter-cell' seals.

[0262] Example Preferred Embodiment: Second Preferred Example Embodiment Cell Architecture: Use of 'Structural Positioning Components'

[0263] In other example embodiments, during thermal or pressure cycling of the type that may occur during operation, the dimensions of the polymer components (e.g., cell frame 11 and electrode spacer membrane 12) may change more than the dimensions of the metal components (e.g., bipolar plates 17 and 18, porous transport layers 15 and 16, and electrodes 13 and 14). This may be due to different coefficients of thermal expansion or pressure-induced expansion of the polymer components relative to the metal components.

[0264] In such cases, it may not be possible to achieve a reliable seal by physically attaching a metal component (e.g., bipolar plate 17 or 18) to a polymer component (e.g., cell frame 11) via one or more polymer-to-metal joints. Instead, it may be necessary to structurally constrain the physically disconnected metal component / components to be close to or tightly against the polymer component to thereby seal their joint. Alternatively, a suitably shaped gasket may be positioned between the metal component and the polymer component to more securely seal their joint. The creation of a close structural match between the metal component and the polymer component can ensure that operational stresses applied to the gasket during operation of the cell can be minimized.

[0265] In a second non-limiting preferred exemplary embodiment, an electric energy or electric synthesis cell architecture is provided, comprising at least one polymer cell frame to which are attached:

[0266] - at least one polymer electrode spacer membrane attached to the at least one polymer cell frame by or via one or more polymer-to-polymer bonds; and

[0267] - At least one polymeric 'structural locating component' attached to the at least one polymeric cell frame by or via one or more polymer to polymer joints, wherein the at least one polymeric structural locating component mechanically holds at least one metallic functional component in position within or around the cell frame.

[0268] Preferably, the polymer electrode separator film in the above example embodiments is thin, to thereby maximize the energy efficiency of the battery cell. Preferably, the polymer electrode separator film is less than 0.35 mm thick, less than 0.2 mm thick, less than 0.1 mm thick, less than 0.05 mm thick, or less than 0.025 mm thick.

[0269] The at least one metal functional component may include a metal bipolar plate, such as a metal bipolar plate extrusion component. The metal bipolar plate may form part of a metal-to-metal coupling assembly, which comprises at least one metal bipolar plate and at least one metal electrode, and optionally at least one metal porous transport layer. The at least one polymer structural positioning component may mechanically hold the metal-to-metal coupling assembly in a suitable position within or around the battery cell frame. The metal bipolar plate in the at least one metal-to-metal coupling assembly may be tightly held against the polymer battery cell frame, thereby sealing their joints. Alternatively, a suitable gasket may be present between the bipolar plate and the battery cell frame to thereby provide an enhanced seal.

[0270] Alternatively, the at least one metallic functional component may include a metallic electrode or a metallic porous transport layer. The metallic electrode or metallic porous transport layer may form part of a metal-to-metal coupling assembly comprising at least one metallic bipolar plate in a suitable position within or around the cell frame. The at least one polymer structural positioning component may mechanically retain the at least one metal-to-metal coupling assembly in a suitable position within or around the cell frame.

[0271] Figure 7 An example of a single half-cell of a preferred embodiment is schematically depicted.

[0272] Figure 7 The upper left of is depicted a metal waffle bipolar plate 41 (i.e., a metal bipolar plate extrusion component) that includes a waffle structured region 412 and a surrounding peripheral region 413 that is flat and has no flow field thereon. Structure 411 is a schematic depiction of a cross section of the waffle bipolar plate 41 showing dimples (e.g., dimple 4111) and bosses (e.g., boss 4112). The waffle bipolar plate may, for example, have been manufactured by an industrial precision stamping or forming process.

[0273] exist Figure 7In step A of , a metal electrode 42 (preferably a flat metal mesh electrode) is attached to at least some or all of the bosses of 411 by one or more metal-to-metal joints (e.g., metal-to-metal welds). This may involve, for example, welding the metal electrode 42 to the bipolar plate 411 at some or all of the bosses (e.g., 4112). The resulting electrode-bipolar plate assembly 43 (depicted as a cross section) is then a single metal part held together by metal-to-metal joints (e.g., metal-to-metal welds). The peripheral region 413 of the bipolar plate 41 (a flat peripheral region without a flow field thereon) is separated from the waffle portion to which the metal electrode 42 is attached and is marked as segment 4121 in the electrode-bipolar plate assembly 43.

[0274] Figure 7 Schematically depicted in the upper right of the figure is a polymeric 'structural locating member' 44 in the form of a polymeric cover disk having a flattened donut shape (schematically shown in cross section as section 441). The central opening of the polymeric 'structural locating member' 44 is sized to partially enclose the bipolar plate 41 and attach to the metal electrode 42 (i.e., electrode-bipolar plate assembly 43). Figure 4 Section 45 shows in schematic cross-section how the electrode-bipolar plate assembly 43 fits into and is covered by the polymer 'structural locating feature' section 441 after step B in FIG.

[0275] Figure 7 The lower left of FIG. 1 shows a cell frame 11 in combination with an attached electrode spacer membrane 12, which is as shown for Figure 1 , Figure 2 and Figure 3 The resulting assembly 112 is depicted as section 461 in the schematic cross-section.

[0276] Figure 7 Step C in FIG. 4 depicts a cross section of a polymer 'structural locating member' section 441 within which the electrode-bipolar plate assembly 43 (i.e., assembly 45) is attached to the cell frame 11 (i.e., in assembly 112) via a polymer-to-polymer bond. The polymer-to-polymer bond in the resulting assembly 471 is shown at location 4511.

[0277] As can be seen in the schematic cross-section of assembly 471, the peripheral region 413 (a flat peripheral region without a flow field thereon) of the metal bipolar plate 41 (i.e., segment 4121) can thereby be mechanically held close to or tightly against the inner surface 4112 of the polymer 'structural locating component' 44. In doing so, the joint between the metal bipolar plate 4121 and the segment 4112 of the polymer 'structural locating component' 44 can be sealed. Nevertheless, the electrode-bipolar plate assembly 43 can be physically disconnected from the polymer structure in assembly 471. The slightly arched shape of the extruded waffle bipolar plate 41 can now be flattened, indicating that its spring-like (or springy) properties have been utilized in assembly 471 to apply a clamping force that squeezes the attached electrode 42 against the electrode spacer membrane 12.

[0278] The polymer-to-polymer joint at position 4511 in assembly 471 can be produced by polymer components having very similar expansion coefficients. Accordingly, the polymer-to-polymer joint at position 4511 in assembly 471 is less likely to be pulled apart during heat or pressure cycles. In addition, the metal component 43, which may have very different expansion coefficients, is not physically connected to the polymer component. Therefore, there is no polymer-to-metal joint that may be pulled apart during heat or pressure cycles due to the mismatch of the polymer and metal expansion coefficients. Therefore, this arrangement can accommodate the mismatch of the expansion coefficients of the polymer component and the metal component during heat and pressure cycles. That is, the expansion of the metal component 431 does not need to match the expansion of the polymer structure because the metal component is physically disconnected from the polymer component.

[0279] As in Figure 7 As shown in the assembly 481 after the arrow D in, a gasket 4711 (whose shape matches the outer perimeter of the bipolar plate 41) can be additionally introduced into the joint of the metal bipolar plate 41 (i.e., segment 4121) and the polymer'structural positioning component' 44 (i.e., segment 4112). That is, the gasket 4711 is positioned at the joint between the metal bipolar plate and the polymer battery cell frame. Such a gasket 4711 can provide an enhanced seal. Due to the close structural match of the metal bipolar plate (i.e., segment 4121) and the polymer'structural positioning component' 44 (i.e., segment 4112), the operating stress applied to the gasket during operation of the battery cell can be minimized.

[0280] Alternatively, as in Figure 7As depicted in assembly 491 following arrow E in FIG. 4, gasket 4712 can be inserted in the joint between metal bipolar plate 41 (i.e., segment 4121) and polymer cell frame 11. Such gasket 4712 can also provide enhanced sealing. Due to the close structural matching of the metal bipolar plate (i.e., segment 4121) and the polymer cell frame 11, the operating stress applied to the gasket during operation of the cell can be minimized.

[0281] In this preferred embodiment, the location selected for the gasket can depend on various factors, including structural changes of the adjacent polymeric and metallic components during thermal or pressure cycling. Such example embodiment cells are characterized by the use of at least a single gasket 4711 in at least one of their half-cells during their assembly and operation.

[0282] By these means, it is possible to manufacture sealed cells which, for quality control purposes, can be assembled into Figure 5 The cell stack 20 shown in FIG. 2 is tested before it is tested. In such a cell stack 20 , the bipolar plates 41 in adjacent cells need to be in electrical contact with each other. Figure 7 The cross-sectional assembly 491 in Figure 491 shows that such contact can be easily made using the example embodiment battery cells. As can be seen, the dimples 4111 in the bipolar plates 41 of adjacent battery cells can directly contact each other during even slight compression of the battery cell stack. Additionally, such compression can provide improved sealing at the joint of the metal bipolar plate 41 (i.e., segment 4121) and either the polymer 'structural locating member' 44 (i.e., segment 4112) and / or the polymer battery cell frame 11.

[0283] Bringing the polymer 'structural locating features' 44 (i.e., segment 4112) in adjacent cells into contact can potentially be accomplished by attaching to each other either all the way along the perimeter of the 'structural locating features' or at selected locations around the perimeter, for example, polymer-to-polymer joints. Such polymer-to-polymer welds will effectively lock the compression applied to the cell stack and maintain all cells in the stack in their compressed sealed state indefinitely. That is, this type of polymer-to-polymer joint can avoid the need to externally maintain the cell stack under compression at all times after the cell stack has been assembled, including during electrochemical operation. In addition, this type of polymer-to-polymer joint can be reliably fixed and will not experience pulling apart due to mismatched thermal expansion coefficients.

[0284] Another alternative would be to join some or all of the dimples (i.e., dimples 4111) of the waffle bipolar plates in adjacent cells in assembly 491 to one another by metal-to-metal joints (e.g., which may be produced by laser welding). Such metal-to-metal joints will also be securely fastened and will not experience pulling apart due to mismatched coefficients of thermal expansion. Furthermore, such joints will ensure good electrical contact between cells and along the cell stack. However, the lateral compression applied to the cell stack will have to be maintained indefinitely and during operation (unless the outer peripheral sections 4112 of the polymer cover disc sections 441 on adjacent cells are also attached to one another).

[0285] Optionally, the waffle structure on the bipolar plate 411 in one cell can be structurally complementary to the waffle structure on the bipolar plate 411 of an adjacent cell, allowing the two waffle structures to interlace and fit together when they are pressed together during stack assembly. Such structural fit can help ensure optimal alignment of cells in a cell stack. It can also provide a higher electrical contact surface area between cells in a cell stack.

[0286] exist Figure 1 To the extent that the seal produced by the polymer-to-metal joint described in the and associated texts is comparable to the polymer-to-metal seal of the preferred example embodiment cell above, Figure 1 All important points (1) to (3) described in the associated text are also relevant to the above preferred example embodiment battery cell.

[0287] Tolerance Compensation Features

[0288] In various other example aspects, embodiments relate to polymer-to-polymer joints, polymer-to-metal joints, and metal-to-metal joints that can be used in the above battery cell and battery cell stacking architectures and technologies. Preferably, such joints incorporate one or more 'tolerance compensating features'. 'Tolerance compensating features' are features that accommodate low tolerances and high variability in the dimensions of battery cell components (including in polymer battery cell frames that can, for example, be injection molded). Tolerance compensating features include structures designed to accommodate variability in the components being joined. They include channels, grooves, slots, tongues, and other structural features that are slightly oversized or slightly undersized or slightly mismatched with another feature to thereby accommodate changes in the amount of material released during the connection. Some tolerance compensating features can be incorporated into forced joining components (e.g., tongue-and-groove joints, locating pins and holes, etc.).

[0289] Preferably, but not exclusively, the following couplings incorporating tolerance compensation features and described below may be used:

[0290] (1) 'Sealing wire welding' connection

[0291] (2) 'Polymer-to-metal' junction

[0292] Figure 6 Schematically illustrates sealing the header / manifold apertures during cell stack assembly by patterning and placing resistive metal wires or circuits around the polymer header / manifold apertures to be sealed on each cell. Figure 8 A tolerance compensating feature that may be incorporated into such a sealing process is schematically illustrated. The tolerance compensating feature forms part of a positively joined component, ie a tongue and groove joint or fitting. The tolerance compensating feature is referred to as a 'sealing wire weld'.

[0293] As in Figure 8 As can be seen in the schematic cross section shown in (a), the resistive wire 500 is included in a groove 550 in one side 520 of the polymer-to-polymer joint. The groove 550 is slightly oversized relative to the tongue protruding from the other side 510 of the polymer-to-polymer joint. This leaves a larger volume (due to the thickness of the groove 550) than would normally be required to accommodate the tongue from the other side 510. Figure 5 That is, the gap 540 between the bottom of the tongue from the other side 510 and the bottom of the groove in the side 520 is larger than the gap 530 between the one side 520 and the other side 510 of the polymer-to-polymer joint.

[0294] When assembling the battery stack, Figure 8 As depicted in (b), the polymer-to-polymer joints between different cells are lined up as shown in stack 5000. When the wire in the leftmost joint is then heated by passing current through it, its tongue melts and partially fills its groove, leaving a reduced but non-zero free volume 560. When joined, tongue-and-groove joints typically leave zero free volume.

[0295] Thus, a slightly oversized slot can compensate for variations in the physical dimensions of the parts as long as the slot is sized so that there is always some free volume 560 left after melting. That is, variations in the physical dimensions of the parts (i.e., low tolerances) can be compensated for by variations in free volume 560 as polymer-to-polymer bonding proceeds from left to right down the stack.

[0296] Fig. 9Another tolerance compensation feature is depicted in cross section in FIG. A polymer component 570 (e.g., a polymer cell frame) is attached to a metal component 571 (e.g., a bipolar plate) via two protruding ridges 572 and 573 of bosses. These ridges have gaps 574 between and around them. During heating of the assembly, the polymer component 570 may expand to a greater extent than the metal component 571. In that case, the ridges 572 and 573 will deform and bend to accommodate the expansion mismatch without destroying their attachment to the metal component 571. They do this because there are gaps 574 between and around the ridges 572 and 573. Two such ridges can be used to provide redundancy, however, any number of ridges can be used, including a single ridge, three ridges, or more ridges. Such a joint is referred to herein as a 'ridge polymer to metal' joint.

[0297] It will be appreciated that the above list of joints incorporating tolerance compensation features is not comprehensive. All forms of polymer to polymer joints, polymer to metal joints, and metal to metal joints including 'tolerance compensation features' may be used in preferred embodiments.

[0298] Preferred Embodiments Polymer-to-Metal Joints and Polymer-to-Polymer Joints

[0299] In various other example aspects, embodiments relate to polymer-to-polymer bonds and polymer-to-metal bonds that can be used in the above cell and cell stack architectures and techniques to seal cells and / or seal one component to another, for example, to seal a polymer cell frame to a metal bipolar plate extrusion.

[0300] Many such polymer to metal joints are created by fluidizing and flowing the polymer component, for example by melting it in a selected area / volume and then flowing it into or around the metal component.One preferred polymer to metal joint is a mechanically bonded joint. Fig.10 An example of creating such a joint is schematically depicted in cross section. In this technique, the edge of a metal part is enlarged and then embedded into a polymer surface using heat. A metal bipolar plate 582 (shown in cross section) has its edge 583 folded over, as depicted. Edge 583 will be attached to a polymer cell frame 580 via a polymer-to-metal joint. A notch 581 is created in the surface of the cell frame 580. The folded edge 583 of the metal bipolar plate 582 is then heated and pressed into the notch 581, as shown by Fig.10 The hot folded edge 583 melts the polymer around the notch, wherein the applied force causes the folded edge 583 to embed itself into the body of the polymer 580. Eventually, the folded edge 583 is completely embedded in the polymer 580, as shown in FIG. Fig.10The heated stamping tool includes features to mold polymer melt into the joint interface and into the cavity formed in the bipolar plate edge bead to improve the mechanical integrity and sealing performance of the bond. This technology is called 'continuous edge heat welding' and the joint is called a 'continuous edge heat welding' joint.

[0301] Continuing from the above: Another preferred polymer-to-metal joint involves joining to an apparently uniform metal surface of the polymer, such as an apparently flat metal surface. For such joints, a generally preferred method of making the polymer-to-metal joint robust involves preparing the metal surface prior to attaching it to the polymer surface. In this regard, preferred pretreatments include, but are not limited to:

[0302] (1) Cleaning and / or pickling metal surfaces with liquids to remove contaminating materials, such as corrosion residues, oils, and organic matter; and / or

[0303] (2) Texturing the metal surface by, for example, creating microstructures (e.g., pits, holes, grooves, porous protrusions, etc.) on the surface. Preferably, this type of structure has an 'undercut' or 'inlay' or similar internal void, wherein the innermost part of the structure is wider or broader or larger than the outermost 'mouth' part of the structure on the external metal surface within the body of the metal. When a polymer-to-metal joint is formed with such a surface, for example by melting the polymer, the polymer can flow into such voids and solidify there. Because the polymer structure inside the structure is then larger than the one / more mouths of the structure, the polymer is then mechanically held by the metal surface, thereby promoting robust adhesion. Texturing of the metal surface in this manner may preferably, but not exclusively, be caused by applying one or more of the following to the surface:

[0304] i. Laser radiation;

[0305] ii.Liquid primer;

[0306] iii. Thermal spraying, metal spraying ('cold spraying') or similar techniques;

[0307] iv. plasma spraying, plasma treatment or similar techniques; or

[0308] v. Certain corona arc technologies.

[0309] Such joints may be broadly referred to as 'textured metal to polymer' joints. It will be appreciated that there are various techniques to produce such joints and the above list is not exhaustive. Any and all such techniques may be used.

[0310] Fig.11 A cross section of a preferred example of this type of polymer-to-metal joint is schematically shown in cross section. The metal part 600 and the polymer part 610 will be attached via a polymer-to-metal joint. In the first step of the process, the surface of the metal part 600 to be attached (i.e., the bottom surface) is prepared. This may involve texturing the surface by, for example, laser texturing as not described above. Alternatively, or in addition, it may involve applying one of the other techniques listed above or another process not listed above to thereby improve its ability to bond to the applied polymer. Many other types of treatments may be employed. A thin polymer layer 620 of the same polymer in the polymer part 610 is then deposited on the treated surface under carefully controlled conditions that provide a strong and firm bond of the thin polymer layer 620 to the treated metal surface of the metal part 600. Then, the polymer part 610 is pressed against the thin polymer layer 620 (which is firmly attached to the metal part 600), and the surface of the metal part 600 is subjected to laser irradiation 640, which causes the metal part 600 to heat up, such as Fig.11 645 in FIG. The heating causes the polymers at interface 630 to melt and fuse to each other, thereby producing the desired polymer-to-metal bond.

[0311] Finally, polymer to metal joints may also be used, where the polymer part and the metal part mechanically interlock on a macro scale. Such joints may be produced, for example, by notching the polymer surface to be joined, and then bending the edge of the metal part to fit into and be held by the notch. Stiffness or tension within the metal part may be exploited, optionally involving spring-like / springy components. Examples in this regard include, but are not limited to, purely mechanical polymer to metal 'roll-formed' joints.

[0312] Fig.12 (a) A 'roll-formed' joint is depicted in cross-section. The polymer part 700 has a notch 730 in its inner surface. The polymer part 700 may be, for example, a polymer cell frame. Optionally, a gasket 720 may be placed on the surface of the polymer part 700, near the notch. The metal part 710 is then placed tightly against the gasket 720 and / or the surface of the polymer part 700. The metal part 710 may be, for example, a bipolar plate. Optionally, the gasket 720 may be spring-type or spring-like (for example, it may be an elastomeric gasket). The metal part 710 is pressed onto the surface of the gasket 720 and / or the polymer part 700, causing its edge to be located over the notch 730. This may be accomplished using a 'clamping plate' 740 (e.g. Figure 4 (b) is then completed using a 'roll forming' tool 750 (as shown in the upper right corner of FIG. Figure 4 (b) (depicted in the upper right of FIG. 7A ) to bend the edge of the metal part 710 into the recess, as depicted at area 731. In doing so, the metal part can be sealed and locked to the polymer part 700 (e.g., a metal bipolar plate can be sealed and locked to a polymer cell frame). In this case, the integrity of the polymer-to-metal seal is maintained by the stiffness between the two internal roll-formed joints of the metal part 710 at the recess 730.

[0313] Fig.12 (b) A 'roll-formed' joint is depicted in cross-section. The polymer part 700 has a notch 730 in its outer surface. The polymer part 700 may be, for example, a polymer cell frame. Optionally, a gasket 720 may be placed on the surface of the polymer part 700, adjacent the notch. The metal part 710 is then placed tightly against the gasket 720 and / or the surface of the polymer part 700. The metal part 710 may be, for example, a bipolar plate. Optionally, the gasket 720 may be spring-type or spring-like (for example, it may be an elastomeric gasket). The metal part 710 is pressed onto the surface of the gasket 720 and / or the polymer part 700, causing its edge to be located over the notch 730. This may be accomplished using a 'clamping plate' 740 (e.g. Figure 4 (b) is then completed using a 'roll forming' tool 750 (as shown in the upper right corner of FIG. Figure 4 (b) is depicted in the upper right corner of FIG. 7B ) to bend the edge of the metal part 710 into the notch, as depicted at area 731. In doing so, the metal part can be sealed and locked to the polymer part 700 (e.g., a metal bipolar plate can be sealed and locked to a polymer cell frame). In this case, the integrity of the polymer-to-metal seal is maintained by the tension placed on the metal part 710 by the two external roll-formed joints.

[0314] Preferably, but not exclusively, the following polymer-to-metal bonds may be used in the above cell and cell stack architectures and technologies:

[0315] (1) 'Continuous edge heat welding' joint,

[0316] (2) 'textured metal to polymer' joint,

[0317] (3) 'Roll-formed' joint.

[0318] Other preferred example embodiments include, but are not limited to, polymer-to-metal joints and polymer-to-polymer joints involving the use of:

[0319] (1) Chemical bonding, with or without the use of chemical adhesion-promoting materials, includes the application of:

[0320] i. Various types of adhesives and glues, including but not limited to

[0321] 1. Adhesives according to chemical composition, including: epoxy resin adhesives, polyurethane adhesives, polyimide adhesives, cyanoacrylate adhesives, polyvinyl acetate adhesives,

[0322] 2. Adhesives in physical form, including: adhesive paste, adhesive glue, adhesive film, adhesive cement, adhesive resin, adhesive bonding agent, elastomeric adhesive, wet adhesive, 3. Adhesives in classification, including: contact adhesive, reactive adhesive, one-component reactive adhesive, two-component or multi-component reactive adhesive, hot melt adhesive, pressure sensitive adhesive, thermosetting adhesive,

[0323] 4. Adhesives according to load-bearing capacity, including: structural adhesives, non-structural adhesives, and semi-structural adhesives;

[0324] (2) polymer dissolution and rematerialization, including but not limited to

[0325] i.Solvent welding;

[0326] (3) Melting or softening of polymers with or without the use of wetting agents that promote polymer flow, including but not limited to

[0327] i. Thermal welding,

[0328] ii. Hot plate or press plate welding,

[0329] iii. Ultrasonic or vibration welding,

[0330] iv. Laser or laser beam welding,

[0331] v. Hot air welding,

[0332] vi. Spin welding,

[0333] vii. Friction welding,

[0334] viii. Frequency or high frequency or radio frequency welding,

[0335] ix. Infrared or non-contact welding,

[0336] x. High-speed tip welding,

[0337] xi. Extrusion welding,

[0338] xii. Contact welding,

[0339] xiii. Induction welding, and

[0340] xiv. Injection welding.

[0341] It will be appreciated that the above list of joints is not comprehensive. All forms of polymer-to-polymer joints and polymer-to-metal joints may be used in preferred embodiments.

[0342] Preferred Embodiment Metal-to-Metal Joint

[0343] In various other example aspects, embodiments relate to metal-to-metal joints that can be used in the above cell and cell stacking architectures and techniques. Metal-to-metal welds are a particularly preferred form of metal-to-metal joints. As used herein, the term 'metal-to-metal weld' is any form of metallurgical metal-to-metal joint that can be considered to involve welding, including but not limited to fusion welding and pressure welding.

[0344] Preferred example embodiments include, but are not limited to, metal-to-metal joints involving:

[0345] (1) Mechanical connections, including but not limited to connections formed by:

[0346] i. Riveting,

[0347] ii. Filling gaps,

[0348] iii. Bolting,

[0349] iv. Shrink fit,

[0350] v.Fold;

[0351] (2) Chemical linkages, including but not limited to linkages formed by:

[0352] i. Bonding, including bonding metals using glue (including conductive glue);

[0353] (3) Metallurgical joints, including but not limited to joints formed by:

[0354] i. Fusion welding, including:

[0355] 1. Electric energy: arc welding, electron beam welding,

[0356] 2. Chemical energy: gas welding,

[0357] 3. Light energy: laser welding;

[0358] ii. Pressure welding, including:

[0359] 1. Electricity: resistance welding, including resistance spot welding, projection welding, seam welding, resistance butt welding, flash welding,

[0360] 2. Chemical energy: explosion welding,

[0361] 3. Mechanical energy: cold pressure welding, friction welding, friction stir welding, ultrasonic welding, diffusion welding;

[0362] iii. Brazing / soldering, including:

[0363] 1. Electricity: induction heating copper welding, soft copper welding, brazing,

[0364] 2. Chemical energy: torch copper welding, flame copper welding,

[0365] 3. Light energy: beam copper welding, laser copper welding,

[0366] 4. 'Soldering',

[0367] 5. 'Braze'.

[0368] It will be appreciated that the above list of joints is not comprehensive. All forms of metal to metal joints may be used in preferred embodiments.

[0369] Electrical energy and electrosynthesis cells and reactions

[0370] In a further specific example, it is provided that:

[0371] (i) Any of the foregoing example cells in an alkaline water electrolyzer or an alkaline fuel cell, wherein the electrolyte is a hydroxide having a pH greater than 10.

[0372] (ii) Any of the aforementioned example cells, having an electrode separator having a thickness of less than 0.2 mm.

[0373] (iii) Any of the foregoing example cells having a clamping force on the electrode that presses the electrode against the electrode separator in excess of 2 bar.

[0374] (iv) Any of the foregoing example cells in an alkaline water electrolyzer or an alkaline fuel cell, wherein the electrolyte is a hydroxide with a pH greater than 10, and the cell has an electrode separator less than 0.2 mm thick.

[0375] (v) Any of the foregoing example cells in an alkaline water electrolyser or alkaline fuel cell, wherein the electrolyte is a hydroxide having a pH greater than 10, and the cell has a clamping force on the electrode that presses the electrode against the electrode separator in excess of 2 bar.

[0376] (vi) Any of the foregoing example cells in an alkaline water electrolyser or an alkaline fuel cell, wherein the electrolyte is a hydroxide having a pH greater than 10, the cell having a clamping force on the electrode that presses the electrode against the electrode separator in excess of 2 bar, and the cell having an electrode separator less than 0.2 mm thick.

[0377] Preferably, but not exclusively, the liquid electrolyte used in the above exemplary embodiments includes a hydroxide salt and has a pH value of at least 10. Optionally, the liquid electrolyte used in the exemplary embodiments has a pH value of less than 10.

[0378] Preferably, the battery cells and battery cell stacks having the above characteristics are electric energy or electrosynthetic battery cells or battery cell stacks, such as: (i) hydrogen and oxygen fuel cells, including polymer electrolyte membrane (PEM) fuel cells or alkaline fuel cells, (ii) direct alcohol fuel cells, including direct methanol or direct ethanol fuel cells, (iii) phosphoric acid fuel cells, or (iv) ammonia fuel cells.

[0379] Preferably, the battery cells and battery cell stacks having the above characteristics are electrosynthetic battery cells or battery cell stacks, such as: (i) a water electrolyzer, (ii) a chlor-alkali electrolyzer, (iii) a nitrogen reduction battery cell for ammonia production, or (iv) a CO2 electrolyzer, including a combined carbon capture and CO2 electrolyzer.

[0380] Preferably, the battery cells and battery cell stacks having the above features are capillary-fed electric energy or electric synthesis battery cells or battery cell stacks of the type described in International Patent Publication Nos. WO 2022056603, WO 2022056604, WO 2022056605 and WO 2022056606, which are hereby incorporated by reference.

[0381] Combination of features

[0382] According to various non-limiting example embodiments, the following bullet points disclose combinations of features that provide various example cells, multi-cell stacks, systems, and / or example methods of operation.

[0383] 1. An electric energy or electric synthesis battery cell, comprising:

[0384] Polymer cell frame;

[0385] a first electrode and a second electrode;

[0386] an electrode spacing membrane positioned between the first electrode and the second electrode; and

[0387] Metal bipolar plate components,

[0388] The polymer cell frame is sealed to the metal bipolar plate extrusion component.

[0389] 2. The electric energy or electric synthesis cell as described in point 1, wherein the bipolar plate component is an extruded component.

[0390] 3. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the bipolar plate is positioned adjacent to the first electrode.

[0391] 4. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein the seal between the polymer cell frame and the metal bipolar plate components is produced by a polymer-to-metal joint.

[0392] 5. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein at least one polymeric structural positioning component positions the metal bipolar plate component against the polymeric cell frame.

[0393] 6. An electric energy or electric composite cell as described in any of the preceding points, wherein the seal between the polymer cell frame and the metal bipolar plate component is produced by one or more polymer-to-polymer joints between the at least one polymer structural positioning component and the polymer cell frame, and the at least one polymer structural positioning component mechanically holds the metal bipolar plate component against the polymer cell frame.

[0394] 7. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the first electrode and the second electrode are positioned in a polymer cell frame.

[0395] 8. The electric energy or electric synthesis cell as described in any of the preceding points, wherein the polymer cell frame comprises a window cut-out, wherein the first electrode and the second electrode are positioned in the window cut-out.

[0396] 9. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein the electrode separator is a polymer electrode separator.

[0397] 10. An electrical energy or electrosynthetic cell as in any of the preceding points, wherein the polymer cell frame is bonded to the polymer electrode separator membrane via polymer-to-polymer bonding.

[0398] 11. The electric energy or electric synthesis cell as described in any of the preceding points, wherein the first electrode is a first metal electrode.

[0399] 12. The electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the metal bipolar plate component is joined to the first metal electrode to form a metal-to-metal joined assembly.

[0400] 13. The electric energy or electric synthesis cell as described in any of the preceding points, further comprising a metallic porous transport layer positioned between the metallic bipolar plate component and the first metallic electrode.

[0401] 14. The electric power or electric synthesis cell as described in any of the preceding points, wherein the metal-to-metal bonding assembly further comprises a metal porous transport layer bonded to the metal bipolar plate component and the first metal electrode.

[0402] 15. The electric energy or electric synthesis cell as described in any of the preceding points, further comprising a second metal bipolar plate component.

[0403] 16. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein the second metallic bipolar plate is an extruded component.

[0404] 17. An electrical energy or electrical synthesis cell as claimed in any of the preceding points, wherein the second bipolar plate is positioned adjacent to the second electrode on the side opposite to the electrode separator.

[0405] 18. An electrical energy or electrocombination cell as claimed in any of the preceding points, wherein the polymer cell frame is sealed to the second metallic bipolar plate component.

[0406] 19. An electrical energy or electrosynthetic cell as in any of the preceding points, wherein the seal between the polymer cell frame and the second metallic bipolar plate component is produced by a polymer-to-metal joint.

[0407] 20. An electrical energy or electrosynthesis cell as claimed in any of the preceding points, wherein at least one further polymeric structural positioning component positions the second metallic bipolar plate component against the polymeric cell frame.

[0408] 21. An electric energy or electric composite cell as described in any of the preceding points, wherein the seal between the polymer cell frame and the second metal bipolar plate component is produced by one or more additional polymer-to-polymer joints between the at least one additional polymer structural positioning component and the polymer cell frame, and the at least one additional polymer structural positioning component mechanically holds the second metal bipolar plate component against the polymer cell frame.

[0409] 22. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein:

[0410] The second electrode is a second metal electrode; and

[0411] The second metallic bipolar plate member is joined to the second metallic electrode to form a second metal-to-metal joined assembly.

[0412] 23. The electric energy or electric synthesis cell as described in any of the preceding points, further comprising a second metallic porous transport layer positioned between the second metallic bipolar plate component and the second metallic electrode.

[0413] 24. The electric energy or electric synthesis cell as described in any of the preceding points, wherein the second metal-to-metal bonding assembly further comprises a second metal porous transport layer bonded to the second metal bipolar plate component and the second metal electrode.

[0414] 25. An electrical energy or electrocomposite cell as described in any of the preceding points, wherein the polymer to metal joint is selected from the group consisting of: a continuous edge heat welded joint, a textured metal to polymer joint, a roll formed joint, chemical bonding, polymer dissolution and rematerialization, and polymer melting or softening.

[0415] 26. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the cell is sealed.

[0416] 27. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the cell is extruded inwardly.

[0417] 28. An electrical energy or electrocombination cell as in any of the preceding points, wherein an electrode spacer membrane is positioned in the window cutout and is bonded to the polymer cell frame.

[0418] 29. An electric energy or electric synthesis battery cell, comprising:

[0419] Polymer cell frame;

[0420] a first electrode and a second electrode;

[0421] An electrode spacing membrane positioned between the first electrode and the second electrode;

[0422] a metallic porous transport layer extrusion member positioned adjacent to the first electrode on a side opposite the electrode spacer membrane; and

[0423] a metallic bipolar plate positioned adjacent to the metallic porous transport layer extrusion member on a side opposite the first electrode,

[0424] Therein, at least one polymeric structural positioning feature positions the metal bipolar plate against the polymeric cell frame.

[0425] 30. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein the at least one polymeric structural positioning component partially encloses the metallic bipolar plate and the first electrode.

[0426] 31. An electrical energy or electrosynthetic cell as in any of the preceding points, wherein the polymer cell frame is sealed to the metallic porous transport layer component.

[0427] 32. An electrical energy or electrosynthetic cell as claimed in any of the preceding points, wherein the joint between the metallic bipolar plate and the at least one polymeric structural positioning component is sealed.

[0428] 33. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein a gasket is positioned at the junction between the metal bipolar plate and the polymer cell frame.

[0429] 34. An electric energy or electric synthesis cell as described in any of the preceding points, wherein the metal bipolar plate is an extruded component.

[0430] 35. An electric energy or electric synthesis cell as described in any of the preceding points, wherein the metal bipolar plate extrusion component is provided as a waffle structure.

[0431] 36. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the first electrode is welded to at least some of the bosses of the waffle structure.

[0432] 37. An electrical energy or electrosynthetic cell as in any of the preceding points, wherein once assembled, the metallic bipolar plate extrusion members are spring-loaded.

[0433] 38. An electric energy or electric synthesis cell as described in any of the preceding points, wherein the metal bipolar plate compressive member applies a clamping force that presses its electrodes against the electrode spacing membrane.

[0434] 39. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein the metallic porous transport layer extrusion member exerts a clamping force pressing its electrodes against the electrode spacing membrane.

[0435] 40. An electric energy or electric synthesis cell as described in any of the two aforementioned key points, wherein the clamping force applied inwardly by the metal bipolar plate extrusion component on the first electrode in the cell to press the first electrode against the electrode separator when assembled is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, or greater than 20 bar.

[0436] 41. An electrical energy or electrical synthesis cell as described in any of the preceding points, further comprising a tolerance compensation feature.

[0437] 42. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the tolerance compensation feature is a channel, a groove, a slot or a tongue.

[0438] 43. An electrical energy or electrical synthesis cell as described in any of the preceding points, wherein the tolerance compensating features are positive engagement components, tongue and groove joints, or locating pins and holes.

[0439] 44. An electrical energy or electrosynthetic cell as described in any of the preceding points, wherein the electrode separator is less than 0.35 mm thick, less than 0.2 mm thick, less than 0.1 mm thick, less than 0.05 mm thick, or less than 0.025 mm thick.

[0440] 45. A battery cell stack comprising a plurality of electrical energy or electrical synthesis cells as described in any one of the preceding points.

[0441] 46. ​​The cell stack according to point 45, wherein the polymer cell frame of one cell in the cell stack is coupled to the polymer cell frame of an adjacent cell in the cell stack.

[0442] 47. The cell stack according to point 45 or 46, wherein the polymer cell frame of one cell in the cell stack is welded to the polymer cell frame of an adjacent cell in the cell stack.

[0443] 48. A cell stack as described in any of points 45 to 47, wherein the waffle structure of the metal bipolar plate extrusion component in one cell in the cell stack is staggered with the waffle structure of the metal bipolar plate extrusion component of an adjacent cell in the cell stack.

[0444] 49. The cell stack as described in any one of points 45 to 48, wherein the waffle structure of the metal bipolar plate extrusion component in one cell in the cell stack is welded to the waffle structure of the metal bipolar plate extrusion component of an adjacent cell in the cell stack.

[0445] 50. The cell stack as described in any one of points 45 to 49, which is a filter press type cell stack.

[0446] 51. A cell stack as described in any of points 45 to 50, wherein the liquid inlet manifold of the cells within the cell stack is pressurized to a higher pressure than the liquid in each cell, and the liquid outlet manifold of the cells within the cell stack is pressurized to a lower pressure than the liquid in each cell.

[0447] 52. A battery cell stack as described in any of points 45 to 51, wherein the extrusion pressure applied to the battery cell stack is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, or greater than 20 bar.

[0448] Throughout this specification and the following claims, unless the context requires otherwise, the word "comprise" and variations such as "comprises" or "comprising" will be understood to imply the inclusion of stated integers or steps or groups of integers or steps but not the exclusion of any other integers or steps or groups of integers or steps.

[0449] Alternative embodiments may also broadly consist in the parts, elements and features referred to or indicated herein, either individually or collectively, in any or all combinations of two or more of such parts, elements or features, and where specific integers having known equivalents in the art to which the invention relates are mentioned herein, such known equivalents are deemed to be incorporated herein as if individually set forth.

[0450] Although the preferred embodiment has been described in detail, it should be understood that many modifications, changes, substitutions, and alterations will be apparent to those skilled in the art without departing from the scope of the invention.

Claims

1. An electric energy or electric synthesis battery cell, comprising: Polymer cell frame; a first electrode and a second electrode; An electrode spacing membrane, the electrode spacing membrane being positioned between the first electrode and the second electrode; as well as a metallic bipolar plate extrusion positioned adjacent to the first electrode, Wherein, the polymer cell frame is sealed to the metal bipolar plate extrusion component.

2. The electric energy or electric synthesis cell according to claim 1, wherein: The seal between the polymer cell frame and the metal bipolar plate extrusion is created by a polymer-to-metal bond.

3. The electric energy or electric synthesis cell according to claim 1, wherein: At least one polymeric structural positioning feature positions the metal bipolar plate extrusion feature against the polymeric cell frame.

4. The electric energy or electric synthesis cell according to claim 3, wherein: The seal between the polymer cell frame and the metal bipolar plate extrusion component is created by one or more polymer-to-polymer joints between the at least one polymer structural positioning component and the polymer cell frame, and the at least one polymer structural positioning component mechanically holds the metal bipolar plate extrusion component against the polymer cell frame.

5. The electric energy or electric synthesis cell according to any one of claims 1 to 4, wherein: The first electrode is a first metal electrode, and the metal bipolar plate extrusion is welded to the first metal electrode to form a metal-to-metal joint assembly.

6. The electric power or electric synthesis cell of claim 5, further comprising a metallic porous transport layer positioned between the metallic bipolar plate extrusion component and the first metallic electrode.

7. The electric energy or electric synthesis cell according to any one of claims 1 to 6, wherein: The metal bipolar plate extrusion is provided as a waffle structure.

8. The electric energy or electric synthesis cell according to claim 7, wherein: The first electrode is welded to at least some of the bosses of the waffle structure.

9. The electric energy or electric synthesis cell according to claim 7 or 8, wherein: Once assembled, the metal bipolar plate extrusion is spring loaded.

10. The electric energy or electric synthesis cell according to any one of claims 1 to 9, wherein: The metal bipolar plate compressive member applies a clamping force on the first electrode to compress the first electrode against the electrode spacing membrane.

11. The electric energy or electric synthesis cell according to any one of claims 1 to 10, wherein: The cell is extruded inwards.

12. The electric energy or electric synthesis cell according to any one of claims 1 to 11, wherein: When assembled, the clamping force applied inwardly by the metal bipolar plate extrusion component on the first electrode in the battery cell to press the first electrode against the electrode separator is greater than 0.01 bar, greater than 0.02 bar, greater than 0.03 bar, greater than 0.04 bar, greater than 0.05 bar, greater than 0.075 bar, greater than 0.1 bar, greater than 0.2 bar, greater than 0.3 bar, greater than 0.5 bar, greater than 0.75 bar, greater than 1 bar, greater than 2 bar, greater than 3 bar, greater than 4 bar, greater than 5 bar, greater than 10 bar, greater than 15 bar, or greater than 20 bar.

13. The electric energy or electric synthesis cell according to any one of claims 1 to 12, wherein: The electrode separation membrane is less than 0.35 mm thick, less than 0.2 mm thick, less than 0.1 mm thick, less than 0.05 mm thick, or less than 0.025 mm thick.

14. The electric energy or electric synthesis cell of any one of claims 1 to 13, further comprising a second metal bipolar plate extrusion member positioned adjacent the second electrode on a side opposite the electrode separator.

15. The electric energy or electric synthesis cell according to claim 14, wherein: The second electrode is a second metal electrode; and The second metal bipolar plate extrusion is welded to the second metal electrode to form a second metal-to-metal bonded assembly.

16. The electric energy or electric synthesis cell according to claim 14, wherein: The polymer cell frame is sealed to the second metal bipolar plate extrusion.

17. The electric energy or electric synthesis cell according to claim 14, wherein: The seal between the polymer cell frame and the second metal bipolar plate extrusion component is created by a polymer-to-metal bond.

18. The electric energy or electric synthesis cell according to claim 17, wherein: At least one additional polymeric structural positioning feature positions the second metallic bipolar plate extrusion feature against the polymeric cell frame.

19. The electric energy or electric synthesis cell according to claim 18, wherein: The seal between the polymer cell frame and the second metal bipolar plate extrusion component is created by one or more additional polymer-to-polymer joints between the at least one additional polymer structural positioning component and the polymer cell frame, and the at least one additional polymer structural positioning component mechanically holds the second metal bipolar plate extrusion component against the polymer cell frame.

20. The electric energy or electric synthesis cell according to claim 2 or 17, wherein: The polymer to metal bond is selected from the group consisting of a continuous edge heat weld bond, a textured metal to polymer bond, a roll formed bond, chemical bonding, polymer dissolution and rematerialization, and polymer melting or softening.

21. The electric energy or electric synthesis cell according to any one of claims 1 to 20, wherein: The first electrode and the second electrode are positioned in the polymer cell frame.

22. The electric energy or electric synthesis cell according to any one of claims 1 to 21, wherein: The polymer cell frame includes a window cutout, wherein the first electrode and the second electrode are positioned in the window cutout.

23. The electric energy or electric synthesis cell according to any one of claims 1 to 22, wherein: The electrode spacer is a polymer electrode spacer.

24. The electric energy or electric synthesis cell according to claim 23, wherein: The polymer cell frame is bonded to the polymer electrode separator via a polymer-to-polymer bond.

25. The electric energy or electric synthesis cell according to any one of claims 1 to 24, wherein: The cell is sealed.

26. The electric energy or electric synthesis cell according to claim 22, wherein: The electrode spacer membrane is positioned in the window cutout and is coupled to the polymer cell frame.

27. An electrical energy or electrical synthesis cell as claimed in any one of claims 1 to 26, further comprising a tolerance compensation feature.

28. The electric energy or electric synthesis cell according to claim 27, wherein: The tolerance compensating feature is a channel, groove, slot or tongue.

29. The electric energy or electric synthesis cell according to claim 27, wherein: The tolerance compensating features are positive engagement components, tongue and groove joints, or dowel pins and holes.

30. A battery cell stack comprising a plurality of the electrical energy or electrical synthesis battery cells according to any one of claims 1 to 29.

31. The battery cell stack according to claim 30, wherein: The polymer cell frame of one cell in the cell stack is coupled to the polymer cell frame of an adjacent cell in the cell stack.

32. The battery cell stack according to claim 30, wherein: The polymer cell frame of one cell in the cell stack is welded to the polymer cell frame of an adjacent cell in the cell stack.

33. The battery cell stack according to any one of claims 30 to 32 and the electric energy or electric synthesis battery cell according to claim 7, wherein: The waffle structure of the metal bipolar plate extrusion component in one cell in the cell stack is interlaced with the waffle structure of the metal bipolar plate extrusion component of an adjacent cell in the cell stack.

34. The battery cell stack according to any one of claims 30 to 32 and the electric energy or electric synthesis battery cell according to claim 7, wherein: The waffle structure of the metal bipolar plate extrusion in one cell in the cell stack is welded to the waffle structure of the metal bipolar plate extrusion in an adjacent cell in the cell stack.

35. The cell stack as claimed in any one of claims 30 to 34, which is a filter press type cell stack.

36. The battery cell stack according to any one of claims 30 to 35, wherein: The liquid inlet headers of the cells within the cell stack are pressurized to a higher pressure than the liquid in each cell, and the liquid outlet headers of the cells within the cell stack are pressurized to a lower pressure than the liquid in each cell.

37. An electric energy or electric synthesis cell, comprising: Polymer cell frame; a first electrode and a second electrode; An electrode spacing membrane positioned between the first electrode and the second electrode; a metallic porous transport layer extrusion member positioned adjacent the first electrode on a side opposite the electrode spacer membrane; as well as a metallic bipolar plate positioned adjacent the metallic porous transport layer extrusion member on a side opposite the first electrode, Wherein, at least one polymer structural positioning component positions the metal bipolar plate against the polymer cell frame.

38. The electric energy or electric synthesis cell as claimed in claim 37, wherein: The at least one polymeric structural positioning component partially encloses the metallic bipolar plate and the first electrode.

39. The electric energy or electric synthesis cell according to claim 37 or 38, wherein: The polymer cell frame is sealed to the metal porous transport layer extrusion component.

40. An electrical energy or electrical synthesis cell as claimed in any one of claims 37 to 39, wherein: The joint between the metallic bipolar plate and the at least one polymeric structural positioning component is sealed.

41. The electric energy or electric synthesis cell as claimed in claim 40, wherein: A gasket is positioned at the joint between the metal bipolar plate and the polymer cell frame.

42. An electrical energy or electrical synthesis cell as claimed in any one of claims 37 to 41, wherein: The metal bipolar plate is an extruded component.

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