Frame assemblies for electrochemical cells and methods of using same

Abstract

The frame assembly includes an electrochemical cell, a frame, and a reinforcement system. The electrochemical cell includes a first catalyst layer, a second catalyst layer spaced apart from the first catalyst layer, and a membrane between the first catalyst layer and the second catalyst layer. The frame includes an upper frame disposed above the membrane and a lower frame disposed below the membrane. The reinforcement system is configured to increase the mechanical stability of the electrochemical cell.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This nonprovisional application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63 / 565,952, filed on March 15, 2024, under 35 U.S.C. §119(e) and any other applicable law or regulation, the entire contents of which are hereby expressly incorporated herein by reference. Technical Field

[0002] The present disclosure relates to a frame assembly for an electrochemical cell and a method of using the frame assembly to provide increased mechanical stability to the electrochemical cell. Background Art

[0003] Fuel cell systems are well known for their ability to efficiently utilize fuel to generate DC electricity, thereby powering mobile applications such as vehicles, trains, buses, and trucks. Electrolyzer systems are known for their efficient use of water and electricity to produce hydrogen and oxygen. Typical fuel cells and electrolyzers consist of a multi-component membrane electrode assembly (MEA) that enables the electrochemical reaction, hence the term "electrochemical cell."

[0004] The membrane electrode assembly (MEA) membrane is susceptible to failure near its outer edges. The outer edges are inactive regions of the membrane that form interfaces with adjacent MEA layers. These inactive regions may not be suitable for forming robust mechanical interfaces to meet battery durability requirements. Therefore, increasing the mechanical stability of the MEA near its outer edges may be beneficial. However, due to their thickness, some electrolyzer membranes and some fuel cell membranes may not be suitable for use in frames.

[0005] Accordingly, the present disclosure relates to a frame assembly for an electrochemical cell and a method of using the frame assembly to increase the mechanical stability of the electrochemical cell. Summary of the Invention

[0006] To satisfy these and other needs, embodiments of the present disclosure are included herein.

[0007] In one aspect described herein, a frame assembly includes an electrochemical cell, a frame, and a reinforcement system. The electrochemical cell includes a first catalyst layer, a second catalyst layer spaced apart from the first catalyst layer along a first axis, and a membrane located between the first catalyst layer and the second catalyst layer. The membrane is formed to include an active area and an inactive area, which are located on each side of the active area of ​​the membrane along a second axis perpendicular to the first axis. The frame includes an upper frame arranged above the inactive area of ​​the membrane relative to the first axis and a lower frame arranged below the inactive area of ​​the membrane relative to the first axis. The reinforcement system is configured to increase the mechanical stability of the electrochemical cell. The reinforcement system includes an outer layer and a core layer. The outer layer is arranged between the upper frame and the lower frame relative to the first axis and is located on each side of the electrochemical cell relative to the second axis. The core layer is arranged on each side of the first catalyst layer and the second catalyst layer relative to the second axis, and the core layer is arranged between the upper frame and the lower frame relative to the first axis.

[0008] In some embodiments, the electrochemical cell may be a fuel cell. In some embodiments, the electrochemical cell may be an electrolyzer cell. In some embodiments, the upper frame may include a first upper plate and a second upper plate spaced apart from the first upper plate relative to the second axis. In some embodiments, the first upper plate and the second upper plate may not overlap the active area of ​​the membrane.

[0009] In some embodiments, the lower frame can include a first lower plate and a second lower plate spaced apart from the first lower plate relative to a second axis. In some embodiments, the first lower plate and the second lower plate can not overlap the active area of ​​the membrane. In some embodiments, the first upper plate can be spaced apart from the first lower plate relative to the first axis to position a portion of the outer layer and a portion of the core layer therebetween. In some embodiments, the second upper plate can be spaced apart from the second lower plate relative to the first axis to position another portion of the outer layer and another portion of the core layer therebetween.

[0010] In some embodiments, the core layer may include (i) a first core sheet disposed adjacent to the first catalyst layer relative to the second axis and disposed between the first upper plate and the inactive region of the membrane relative to the first axis, (ii) a second core sheet disposed adjacent to the first catalyst layer relative to the second axis and disposed between the second upper plate and the inactive region of the membrane relative to the first axis, (iii) a third core sheet disposed adjacent to the second catalyst layer relative to the second axis and disposed between the inactive region of the membrane and the first lower plate relative to the first axis, and (iv) a fourth core sheet disposed adjacent to the second catalyst layer relative to the second axis and disposed between the inactive region of the membrane and the second lower plate relative to the first axis. In some embodiments, the first core sheet, the second core sheet, the third core sheet, and the fourth core sheet may each have a first thickness. In some embodiments, the first thickness may be equal to the second thickness of the first catalyst layer and the second catalyst layer.

[0011] In some embodiments, the first core sheet, the second core sheet, the third core sheet, and the fourth core sheet can each have a first length. In some embodiments, each of the first catalyst layer and the second catalyst layer has a second length. In some embodiments, the first length and the second length can each be less than the third length of the membrane.

[0012] In some embodiments, the sum of the first length of the first core sheet, the second length of the first catalyst layer, and the first length of the second core sheet can be equal to the third length of the membrane. In some embodiments, the frame assembly may further include a filler layer. In some embodiments, the filler layer may include (i) a first filler sheet arranged between the first upper plate and the first core sheet of the core layer relative to the first axis, (ii) a second filler sheet arranged between the second upper plate and the second core sheet of the core layer relative to the first axis, (iii) a third filler sheet arranged between the third core sheet of the core layer and the first lower plate relative to the first axis, and (iv) a fourth filler sheet arranged between the fourth core sheet and the second lower plate of the core layer relative to the first axis.

[0013] In some embodiments, the first thickness of the first filler sheet can be less than the second thickness of the first core sheet. In some embodiments, the first length of the first filler sheet can be less than the second length of the first core sheet.

[0014] According to a second aspect described herein, a frame assembly includes an electrochemical cell, a frame, and a reinforcement system. The electrochemical cell includes a first catalyst layer, a second catalyst layer spaced apart from the first catalyst layer along a first axis, and a membrane located between the first catalyst layer and the second catalyst layer. The membrane is formed to include an active region and an inactive region, the inactive region being located on each side of the active region along a second axis perpendicular to the first axis. The frame includes an upper frame arranged above the membrane relative to the first axis and a lower frame arranged below the membrane relative to the first axis. The reinforcement system is configured to increase the mechanical stability of the electrochemical cell. The reinforcement system includes an outer layer, a core layer, and a filling layer. The outer layer is completely arranged between the upper frame and the lower frame relative to the first axis. The outer layer is located on each side of the electrochemical cell, the core layer, and the filling layer relative to the second axis. The core layer is arranged on each side of the first catalyst layer and the second catalyst layer relative to the second axis, and the core layer is arranged between the upper frame and the lower frame relative to the first axis. The filling layer is completely arranged between the upper frame and the lower frame relative to the first axis.

[0015] In some embodiments, the upper frame may include a first upper plate and a second upper plate spaced apart from the first upper plate relative to a second axis. In some embodiments, the first upper plate and the second upper plate may not overlap with the active area of ​​the membrane. In some embodiments, the lower frame may include a first lower plate and a second lower plate spaced apart from the first lower plate relative to the second axis. In some embodiments, the first lower plate and the second lower plate may not overlap with the active area of ​​the membrane.

[0016] In some embodiments, the core layer may include (i) a first core sheet arranged adjacent to the first catalyst layer relative to the second axis and arranged between the first upper plate and the inactive area of ​​the membrane relative to the first axis, (ii) a second core sheet arranged between the second upper plate and the inactive area of ​​the membrane relative to the first axis and spaced apart from the first core sheet relative to the second axis to position the first catalyst layer therebetween, (iii) a third core sheet arranged adjacent to the second catalyst layer relative to the second axis and arranged between the inactive area of ​​the membrane and the first lower plate relative to the first axis, and (iv) a fourth core sheet arranged between the inactive area of ​​the membrane and the second lower plate relative to the first axis and spaced apart from the third core sheet relative to the second axis to position the second catalyst layer therebetween.

[0017] In some embodiments, the filler layer may include (i) a first filler sheet disposed between the first upper plate and the first core sheet of the core layer relative to a first axis, (ii) a second filler sheet disposed between the second upper plate and the second core sheet of the core layer relative to the first axis, (iii) a third filler sheet disposed between the third core sheet of the core layer and the first lower plate relative to the first axis, and (iv) a fourth filler sheet disposed between the fourth core sheet of the core layer and the second lower plate relative to the first axis. In some embodiments, the first filler sheet may be adhered to each of the first upper plate, the outer layer, and the first core sheet. In some embodiments, the first core sheet may be adhered to each of the first filler sheet, the outer layer, and the inactive area of ​​the membrane.

[0018] In some embodiments, the first filler sheet may have a first thickness and a first length, and the first core sheet may have a second thickness and a second length. In some embodiments, the first thickness may be less than the second thickness, and the first length may be less than the second length. In some embodiments, the outer layer may include (i) a first outer sheet disposed adjacent to the first filler sheet, the first core sheet, and the membrane, (ii) a second outer sheet disposed relative to a first axis between the first outer sheet and the first lower plate, and adjacent to the membrane, the third core sheet, and the third filler sheet, (iii) a third outer sheet disposed adjacent to the second filler sheet, the second core sheet, and the membrane, and (iv) a fourth outer sheet disposed relative to the first axis between the third outer sheet and the second lower plate, and adjacent to the membrane, the fourth core sheet, and the fourth filler sheet. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1A is a schematic diagram of an exemplary fuel cell system including an air delivery system, a hydrogen delivery system, and a fuel cell module including a plurality of fuel cells in a stack;

[0020] Figure 1B is a cross-sectional view of an exemplary fuel cell system including an air delivery system, a plurality of hydrogen delivery systems, and a plurality of fuel cell modules, each module including a plurality of fuel cell stacks;

[0021] Figure 1C yes Figure 1A A perspective view of an exemplary repeating unit of a fuel cell stack of a fuel cell system;

[0022] Figure 1D yes Figure 1C A cross-sectional view of an exemplary repeating unit of a fuel cell stack;

[0023] Figure 2A is a perspective view of an electrolyzer cell stack according to the present disclosure;

[0024] Figure 2B is configured to use Figure 2A Schematic diagram of an electrolysis system of an electrolyzer cell stack;

[0025] Figure 2C yes Figure 2B Schematic diagram of additional parts of the electrolysis system;

[0026] Figure 3A is a diagrammatic illustration of a frame assembly including an electrochemical cell, a frame disposed about the electrochemical cell, and a reinforcement system disposed between the electrochemical cell and the frame;

[0027] Figure 3B yes Figure 3A A diagrammatic representation of a frame assembly having a gas diffusion layer and a bipolar plate assembled on each side of the frame assembly;

[0028] Figure 4 During manufacturing Figure 3A a diagrammatic illustration of an electrochemical cell comprising a first catalyst layer, a second catalyst layer, and a membrane disposed therebetween, and a portion of a reinforcement system comprising a core layer coupled to the membrane;

[0029] Figure 5 During manufacturing Figure 3A a diagrammatic illustration of a frame and a portion of a reinforcement system comprising an outer layer coupled to the frame;

[0030] Figure 6 During manufacturing Figure 3A A schematic diagram of an electrochemical cell, frame, and reinforcement system;

[0031] Figure 7 is with Figure 3A A diagrammatic illustration of another embodiment of a reinforcement system for use with an electrochemical cell and a frame;

[0032] Figure 8 During manufacturing Figure 7 a diagrammatic representation of an electrochemical cell and a portion of a reinforcement system comprising a core layer coupled to a membrane of the electrochemical cell;

[0033] Figure 9 During manufacturing Figure 7 a diagrammatic illustration of a frame and a portion of a reinforcement system comprising an outer layer coupled to the frame and a fill layer coupled to the frame adjacent the outer layer;

[0034] Figure 10 During manufacturing Figure 7A schematic diagram of an electrochemical cell, frame, and reinforcement system;

[0035] Figure 11 is with Figure 3A A diagrammatic illustration of another embodiment of a reinforcement system for use with an electrochemical cell and a frame;

[0036] Figure 12 During manufacturing Figure 11 a diagrammatic representation of an electrochemical cell and a portion of a reinforcement system comprising a core layer coupled to a membrane of the electrochemical cell; and

[0037] Figure 13 During manufacturing Figure 11 A diagrammatic illustration of a frame and a reinforcement system comprising an outer layer coupled to the frame. DETAILED DESCRIPTION

[0038] like Figure 1A As shown, the fuel cell system 10 generally includes one or more fuel cell stacks 12 or fuel cell modules 14 connected to a balance of plant (BOP) 16 including various components to support electrochemical conversion, power generation and / or distribution, thereby helping to meet modern industrial and commercial needs in an environmentally friendly manner. Figure 1B and Figure 1C As shown, the fuel cell system 10 may include a fuel cell stack 12, which includes a plurality of monolithic fuel cells 20. Each fuel cell stack 12 may accommodate a plurality of fuel cells 20 assembled in series and / or in parallel. The fuel cell system 10 may include one or more fuel cell modules 14, such as Figure 1A and Figure 1B In some embodiments, the fuel cell system 10 may include one or more fuel cell stacks 12 .

[0039] Each fuel cell module 14 may include multiple fuel cell stacks 12 and / or multiple fuel cells 20. The fuel cell module 14 may also include a suitable combination of associated structural elements, mechanical systems, hardware, firmware, and / or software that support the function and operation of the fuel cell module 14. Such items include, but are not limited to, piping, sensors, regulators, current collectors, seals, and insulators.

[0040] The fuel cells 20 in the fuel cell stacks 12 can be stacked together to multiply and increase the voltage output of a single fuel cell stack 12. The number of fuel cell stacks 12 in the fuel cell system 10 can vary depending on the amount of power required to operate the fuel cell system 10 and meet the power demands of any loads. The number of fuel cells 20 in the fuel cell stacks 12 can vary depending on the amount of power required to operate the fuel cell system 10 (including the fuel cell stacks 12).

[0041] The number of fuel cells 20 in each fuel cell stack 12 or fuel cell system 10 can be any number. For example, the number of fuel cells 20 in each fuel cell stack 12 can range from about 100 fuel cells to about 1000 fuel cells, including any specific number or range of numbers of fuel cells 20 included therein (e.g., about 200 to about 800). In an embodiment, the fuel cell system 10 can include about 20 to about 1000 fuel cell stacks 12, including any specific number or range of numbers of fuel cell stacks 12 included therein (e.g., about 200 to about 800). The fuel cells 20 in the fuel cell stacks 12 within the fuel cell module 14 can be oriented in any direction to optimize the operating efficiency and function of the fuel cell system 10.

[0042] The fuel cells 20 in the fuel cell stack 12 can be any type of fuel cell 20. The fuel cell 20 can be a polymer electrolyte membrane or proton exchange membrane (PEM) fuel cell, an anion exchange membrane fuel cell (AEMFC), an alkaline fuel cell (AFC), a molten carbonate fuel cell (MCFC), a direct methanol fuel cell (DMFC), a regenerative fuel cell (RFC), a phosphoric acid fuel cell (PAFC), or a solid oxide fuel cell (SOFC). In an exemplary embodiment, the fuel cell 20 can be a polymer electrolyte membrane or proton exchange membrane (PEM) fuel cell or a solid oxide fuel cell (SOFC).

[0043] exist Figure 1C In the illustrated embodiment, the fuel cell stack 12 includes a plurality of proton exchange membrane (PEM) fuel cells 20. Each fuel cell 20 includes a single membrane electrode assembly (MEA) 22 and gas diffusion layers (GDLs) 24, 26 on one or both sides of the membrane electrode assembly (MEA) 22 (see FIG. Figure 1C The fuel cell 20 also includes bipolar plates (BPPs) 28, 30 on the exterior sides of the respective gas diffusion layers (GDLs) 24, 26, such as Figure 1C The above components, particularly the bipolar plate 30 , the gas diffusion layer (GDL) 26 , the membrane electrode assembly (MEA) 22 and the gas diffusion layer (GDL) 24 , all comprise a single repeating unit 50 .

[0044] The bipolar plates (BPPs) 28 and 30 are responsible for transporting reactants, such as fuel 32 (e.g., hydrogen) or oxidant 34 (e.g., oxygen, air), and a coolant 36 (e.g., coolant and / or water) in the fuel cell 20. The bipolar plates (BPPs) 28 and 30 can evenly distribute the reactants 32 and 34 to the active area 40 of each fuel cell 20 through oxidant flow fields 42 and / or fuel flow fields 44 formed on the outer surfaces of the bipolar plates (BPPs) 28 and 30. When viewing the stack 12 from a top-down perspective, the active area 40 is located at the center of the membrane electrode assembly (MEA) 22, the gas diffusion layers (GDLs) 24 and 26, and the bipolar plates (BPPs) 28 and 30. Electrochemical reactions occur in the active area 40 to generate the electricity generated by the fuel cell 20.

[0045] The bipolar plates (BPPs) 28, 30 may each be formed with reactant flow fields 42, 44 formed on opposing outer surfaces of the bipolar plates (BPPs) 28, 30 and with a coolant flow field 52 located within the bipolar plates (BPPs) 28, 30, as shown. Figure 1D For example, the bipolar plates (BPP) 28, 30 may include a fuel flow field 44 for transferring the fuel 32 on one side of the plates 28, 30 for interaction with the gas diffusion layer (GDL) 26. The bipolar plates (BPP) 28, 30 may also include an oxidant flow field 42 for transferring the oxidant 34 on a second, opposite side of the plates 28, 30 for interaction with the gas diffusion layer (GDL) 24.

[0046] like Figure 1D As shown, the bipolar plates (BPP) 28, 30 may also include coolant flow fields 52 formed within the plates (BPP) 28, 30, which are generally centered between the opposing outer surfaces of the plates (BPP) 28, 30. The coolant flow fields 52 facilitate the flow of the coolant 36 through the bipolar plates (BPP) 28, 30 to regulate the temperature of the plate (BPP) 28, 30 materials and the reactants. The bipolar plates (BPP) 28, 30 are compressed against the adjacent gas diffusion layers (GDL) 24, 26 to isolate and / or seal one or more reactants 32, 34 within their respective channels 44, 42, thereby maintaining electrical conductivity, which is necessary for robust operation of the fuel cell 20 (see Figure 1C and Figure 1D ).

[0047] The fuel cell system 10 described herein can be used in stationary and / or immobile power systems, such as industrial applications and power plants. The fuel cell system 10 can also be implemented in conjunction with an air delivery system 18. In addition, the fuel cell system 10 can also be implemented in conjunction with a hydrogen delivery system and / or hydrogen source 19, such as a pressurized tank, including a gaseous pressurized tank, a cryogenic liquid storage tank, a chemical storage member, a physical storage member, a stationary storage member, an electrolysis system, or an electrolyzer. In one embodiment, the fuel cell system 10 is connected and / or attached in series or in parallel to a hydrogen delivery system and / or hydrogen source 19, such as one or more hydrogen delivery systems and / or hydrogen sources 19 in a BOP 16 (see Figure 1A In another embodiment, the fuel cell system 10 is not connected and / or attached to the hydrogen delivery system and / or hydrogen source 19 in series or parallel.

[0048] In some embodiments, the fuel cell system 10 may include an on / off valve 10XV1, a pressure transducer 10PT1, a mechanical regulator 10REG, and a venturi tube 10VEN, which are arranged to be in functional communication with each other and are located downstream of the hydrogen delivery system and / or hydrogen source 19, such as Figure 1A As shown. A pressure transducer 10PT1 can be positioned between the on / off valve 10XV1 and the mechanical regulator 10REG. In some embodiments, a proportional control valve can be used in place of the mechanical regulator 10REG. In some embodiments, a second pressure transducer 10PT2 is positioned downstream of the venturi 10VEN, which is located downstream of the mechanical regulator 10REG.

[0049] In some embodiments, the fuel cell system 10 may further include a recirculation pump 10REC located downstream of the cell stack 12 and functionally connected to the venturi tube 10VEN. The fuel cell system 10 may further include an on / off valve 10XV2 located downstream of the cell stack 12 and a pressure transfer valve 10PSV, such as Figure 1A shown.

[0050] The present fuel cell system 10 may also be included in mobile applications. In an exemplary embodiment, the fuel cell system 10 is in a vehicle and / or powertrain 100. The vehicle 100 including the present fuel cell system 10 may be an automobile, a passenger vehicle, a bus, a truck, a train, a locomotive, an aircraft, a light vehicle, a medium vehicle, or a heavy vehicle. The types of vehicles 100 may also include, but are not limited to, commercial vehicles and engines, trains, trolley buses, trams, airplanes, buses, ships, boats, and other known vehicles, as well as other machinery and / or manufacturing equipment, equipment, facilities, and the like.

[0051] The vehicle and / or powertrain 100 can be used on roads, highways, railways, airways, and / or waterways. The vehicle 100 can be used in applications including, but not limited to, off-highway transportation, vehicles, and / or mining equipment. For example, an exemplary embodiment of the mining equipment vehicle 100 is a mining truck or a mining haul truck.

[0052] like Figure 2A and Figure 2B As shown, the electrolysis system 110 is typically configured to produce hydrogen and oxygen using water and electricity. The electrolysis system 110 typically includes one or more electrolyzer cells 180, which use electricity to produce substantially pure hydrogen 113 and oxygen 115 from deionized water 130 through a chemical process. The power supply for the electrolysis system 110 typically comes from an electrical or power generation system, including renewable energy systems for producing green hydrogen, such as wind power, solar power, hydropower, and geothermal sources. In turn, the pure hydrogen produced by the electrolysis system 110 is typically used as a fuel or energy source for those same power generation systems, such as fuel cell systems. Alternatively, the pure hydrogen produced by the electrolysis system 110 can be stored for later use.

[0053] A typical electrolyzer cell 180 or electrolytic cell comprises a plurality of components that are compressed and bundled to form a single component; a plurality of electrolyzer cells 180 can be stacked on top of each other, together with bipolar plates (BPPs) 184, 185 therebetween, to form an electrolyzer cell stack (e.g., Figure 2B The electrolyzer cell stacks 111, 112 in the electrolysis system 110 may each house a plurality of electrolyzer cells 180 connected in series and / or in parallel. The number of electrolyzer cell stacks 111, 112 in the electrolysis system 110 may vary depending on the amount of power required to meet the power demands of any load (e.g., a fuel cell stack). The number of electrolyzer cells 180 in the electrolyzer cell stacks 111, 112 may vary depending on the amount of power required to operate the electrolysis system 110 (including the electrolyzer cell stacks 111, 112).

[0054] Electrolyzer cell 180 includes a multi-component membrane electrode assembly (MEA) 181 having an electrolyte 181E, an anode 181A, and a cathode 181C. Typically, the anode 181A, cathode 181C, and electrolyte 181E of the membrane electrode assembly (MEA) 181 are configured in a multilayer arrangement to activate an electrochemical reaction through contact of water with one or more gas diffusion layers 182, 183, thereby producing hydrogen and / or oxygen. Gas diffusion layers (GDLs) 182, 183, also known as porous transport layers (PTLs), are typically located on one or both sides of the MEA 181. Bipolar plates (BPPs) 184, 185 are typically located on either side of the GDLs 182, 183 and separate the individual electrolyzer cells 180 of the electrolyzer cell stacks 111, 112. A single bipolar plate 185, along with adjacent gas diffusion layers 182, 183 and MEA 181, forms a repeating unit 188.

[0055] like Figure 2B and Figure 2C As shown, the exemplary electrolysis system 110 may include two electrolysis cell stacks 111, 112 and a fluid circuit 110FC, which includes Figure 2B and 2C Various fluid channels are shown, which are configured to convey, inject, and remove fluids and other components to, from, and from the electrolysis system 110. Those skilled in the art will appreciate that the electrolysis system 110 may utilize one or more of several components within the fluid circuit 110FC, as well as more or fewer than two electrolyzer cell stacks 111, 112. For example, the electrolysis system 110 may include one electrolyzer cell stack 111, while in other examples, the electrolysis system 110 may include three or more electrolyzer cell stacks.

[0056] The electrolysis system 110 may include one or more types of electrolyzer cell stacks 111, 112. In the illustrated embodiment, the cell stacks 111, 112 may utilize polymer electrolyte membrane (PEM) electrolyzer cells 180. The PEM electrolyzer cells 180 typically operate at a temperature of about 4°C to about 150°C, including any specific temperature or temperature range subsumed therein. The PEM electrolyzer cells 180 also typically operate at a pressure of about 100 bar or less, but pressures up to about 1000 bar (including any specific pressure or pressure range subsumed therein) may be used because this reduces the overall energy requirements of the system. The standard electrochemical reaction that produces hydrogen gas in the PEM electrolyzer cells 180 is as follows. Anode: 2H2O→O2+4H + +4e – Cathode: 4H + +4e – →2H2 Overall: 2H2O (liquid) → 2H2 + O2

[0057] Additionally, a solid oxide electrolyzer cell 180 may also be used in the electrolysis system 110. The solid oxide electrolyzer cell 180 will operate at a temperature of about 500° C. to about 1000° C., including any specific temperature or temperature range subsumed therein. The standard electrochemical reaction that produces hydrogen gas in the solid oxide electrolyzer cell 180 is as follows. Anode: 2O 2- →O2+4e – Cathode: 2H2O+4e – →2H2+2O 2- Overall: 2H2O (liquid) → 2H2 + O2

[0058] Additionally, an AEM electrolyzer cell 180 employing an alkaline medium may also be used. An exemplary AEM electrolyzer cell 180 is an alkaline electrolyzer cell 180. An alkaline electrolyzer cell 180 employs an aqueous solution as an electrolyte, such as a potassium hydroxide (KOH) and / or sodium hydroxide (NaOH) solution. An alkaline electrolyzer cell 180 typically operates at an operating temperature of about 0° C. to about 150° C., including any specific temperature or temperature range subsumed therein. An alkaline electrolyzer cell 180 typically operates at a pressure range of about 1 bar to about 100 bar, including any specific pressure or pressure range subsumed therein. Typical electrochemical reactions that produce hydrogen gas in an alkaline electrolyzer cell 180 are as follows. Anode: 4OH - →O2+2H2O+4e – Cathode: 4H2O+4e – →2H2+4OH - Overall: 2H2O→2H2+O2

[0059] like Figure 2B As shown, the electrolyzer cell stacks 111, 112 include one or more electrolyzer cells 180 that use electricity to chemically generate substantially pure hydrogen and oxygen from water. In turn, the pure hydrogen generated by the electrolyzer can be used as a fuel or energy source. Figure 2B As shown, the electrolyzer cell stacks 111 , 112 output the generated hydrogen to a hydrogen separator 116 along a fluid connection line 113 , and also output the generated oxygen to an oxygen separator 114 along a fluid connection line 115 .

[0060] The hydrogen separator 116 can be configured to output pure hydrogen and also discharge an additional output fluid to a hydrogen discharge tank 120, which then outputs the fluid to a deionized water discharge pipe 121. The oxygen separator 114 can output a fluid to an oxygen discharge tank 124, which in turn outputs the fluid to a deionized water discharge pipe 125. It will be understood by those skilled in the art that some of the input and output fluids can be pure water or other fluids, such as coolant or byproducts of the chemical reactions of the electrolyzer cell stacks 111, 112. For example, oxygen and hydrogen can flow from the cell stacks 111, 112 to the respective separators 114, 116. The system 110 can also include a rectifier 132 configured to convert electricity 133 flowing to the cell stacks 111, 112 from alternating current (AC) to direct current (DC).

[0061] The deionized water discharge pipes 121, 125 are respectively output to the deionized water tank 140, which is part of the polishing circuit 136 in the fluid circuit 110FC. Figure 2C When the ionized water interacts with the internal components of the electrolyzer cell stacks 111 , 112 , the water containing the ions may damage the electrolyzer cell stacks 111 , 112 . Figure 2C As shown in more detail, the polishing circuit 136 is configured to deionize the water so that it can be used in the cell stacks 111 , 112 without damaging the cell stacks 111 , 112 .

[0062] In the illustrated embodiment, the deionized water tank 140 outputs fluid, particularly water, to a deionized water polishing pump 144. The deionized water polishing pump 144 in turn outputs the water to a water polishing heat exchanger 146 for polishing and treatment. Subsequently, the water flows to a deionized water resin tank 148.

[0063] The coolant is directed through the electrolysis system 110, particularly through the deionized water heat exchanger 172, which is fluidly connected to the oxygen separator 114. The coolant used to cool the water flow can then be fed into the water polishing heat exchanger 146 via the coolant inlet pipe 127 for polishing. The coolant is then fed back into the deionized water heat exchanger 172 to cool the water therein.

[0064] After the water is output from the deionized water polishing heat exchanger 146 and then enters the deionized water resin tank 148, a portion of the water can be sent to the deionized water high pressure supply pump 160. The other portion of the water can be sent to the deionized water pressure control valve 152, as shown in FIG. Figure 2C The water sent to the deionized water pressure control valve 152 will flow through the recirculation fluid connection pipe 154, which allows the water to flow back to the deionized water tank 140 for continued polishing.

[0065] In some embodiments, the electrolysis system 110 can be equipped with a deionized water skid to polish the water flow and remove ions from the water at a faster rate. The water fed into the deionized water high-pressure supply pump 160 is then output to the deionized water supply pipe 164, where it flows into the oxygen separator 114 for recycling and is ultimately reused in the electrolytic cell stacks 111 and 112. This process can then be repeated.

[0066] The electrolysis system 110 described herein can be used in stationary and / or non-mobile power systems, such as industrial applications and power plants. The electrolysis system 110 can also be implemented in conjunction with other electrolysis systems 110 .

[0067] The present electrolysis system 110 can be included in stationary or mobile applications. The electrolysis system 110 can be located in a vehicle or powertrain 100. The vehicle or powertrain 100 including the electrolysis system 110 can be an automobile, a passenger car, a bus, a truck, a train, a locomotive, an aircraft, a light vehicle, a medium vehicle, or a heavy vehicle.

[0068] The present disclosure provides a frame assembly 210 including an electrochemical cell 212, such as Figure 3A In addition to the electrochemical cell 212, the frame assembly 210 also includes a frame 214 and a reinforcement system 216, as shown. Figure 3A shown.

[0069] The electrochemical cell 212 includes a first catalyst layer 218, a second catalyst layer 220, and / or a membrane 222, such as Figure 3A As described above, the first catalyst layer 218 can be the anode 181A. As described above, the second catalyst layer 220 can be the cathode 181C. As described above, the membrane 222 can be the electrolyte 181E. The electrochemical cell 212 can be a fuel cell, such as the fuel cell 20 described above, or an electrolyzer cell, such as the electrolyzer cell 180 described above.

[0070] The first catalyst layer 218 and the second catalyst layer 220 are spaced apart from each other along the first axis A1. Figure 3A The membrane 222 is disposed between the first catalyst layer 218 and the second catalyst layer 220 relative to the first axis A1.

[0071] The first catalyst layer 218 and the second catalyst layer 220 each have a first length L1, such as Figure 3A The membrane 222 has a second length L2, which is greater than the first length L1 of the first catalyst layer 218 and the second catalyst layer 220. The first catalyst layer 218 and the second catalyst layer 220 each have a first thickness T1, as shown in FIG. Figure 3AIn some embodiments, the membrane 222 has a second thickness T2 that is less than the first thickness T1 of the catalyst layers 218 and 220. In some embodiments, the second thickness T2 of the membrane 222 can be greater than the first thickness T1 of the catalyst layers 218 and 220. In some embodiments, the catalyst layers 218 and 220 can have different thicknesses from each other.

[0072] The membrane 222 is formed to include an active region 224 that is bonded to the catalyst layers 218, 220 and an inactive region 226 that is located on either side of the active region 224 relative to a second axis A2 that is perpendicular to the first axis A1. Figure 3A As shown. In the illustrative embodiment, the first axis A1 and the second axis A2 are perpendicular to each other. In some embodiments, the first axis A1 can be a vertical axis and the second axis A2 can be a horizontal axis. In some embodiments, the second axis A2 can be a vertical axis and the first axis A1 can be a horizontal axis. In other embodiments, the first axis A1 and the second axis A2 can be vertical, horizontal, diagonal and / or in any orientation. The active area 224 of the membrane 222 is the portion of the membrane 222 that overlaps and engages with each of the first catalyst layer 218 and the second catalyst layer 220. The inactive area 226 of the membrane 222 is the portion of the membrane 222 that does not overlap or engage with each of the first catalyst layer 218 and the second catalyst layer 220.

[0073] The frame 214 includes an upper frame 228 disposed above the electrochemical cell 212 relative to the first axis A1 and a lower frame 230 disposed below the electrochemical cell 212. Figure 3A . In other words, the upper frame 228 is disposed on a first side of the electrochemical cell 212 relative to the first axis A1, and the lower frame 230 is disposed on a second side of the electrochemical cell 212 opposite the first side relative to the first axis A1. The upper frame 228 overlaps a portion of the inactive area 226 of the membrane 222. The lower frame 230 overlaps a portion of the inactive area 226 of the membrane 222. The upper frame 228 and the lower frame 230 do not overlap the active area 224 of the membrane 222.

[0074] The upper frame 228 includes a first upper plate 232 and a second upper plate 234. Figure 3A As shown. The first upper plate 232 and the second upper plate 234 are spaced apart from each other relative to the second axis A2. The lower frame 230 includes a first lower plate 236 and a second lower plate 238. The first lower plate 236 and the second lower plate 238 are spaced apart from each other relative to the second axis A2. The first upper plate 232 is aligned with the first lower plate 236 along the second axis A2, and the second upper plate 234 is aligned with the second lower plate 238 along the second axis A2.

[0075] Each of the first upper plate 232, the second upper plate 234, the first lower plate 236, and the second lower plate 238 has the same length, also referred to as a third length L3, as shown in FIG. Figure 3A The third length L3 is greater than the first length L1 of the catalyst layers 218 and 220 and less than the second length L2 of the membrane 222 .

[0076] In some embodiments, the frame 214 is formed of polyethylene naphthalate (PEN). In some embodiments, the frame 214 is formed of polyethylene terephthalate (PET), such as biaxially oriented polyethylene terephthalate (BOPET). The frame 214 is coupled to bipolar plates 215 and 217 disposed above and below the frame 214 relative to the first axis A1, such as Figure 3B As described above, the bipolar plates 215 and 217 can be any of the bipolar plates 28, 30, 184, and 185. The frame 214 is also bonded to the gas diffusion layers 219 and 221. As described above, the gas diffusion layers 219 and 221 can be any of the gas diffusion layers 24, 26, 182, and 183.

[0077] The gas diffusion layer 219 is arranged between the first upper plate 232 and the second upper plate 234 relative to the second axis A2. Figure 3B As shown, the bipolar plate 215 is arranged above the first upper plate 232, the gas diffusion layer 219, and the second upper plate 234. The gas diffusion layer 221 is arranged between the first lower plate 236 and the second lower plate 238 relative to the second axis A2. The bipolar plate 217 is arranged below the first lower plate 236, the gas diffusion layer 221, and the second lower plate 238.

[0078] The reinforcement system 216 includes an outer layer 240 and a core layer 242, such as Figure 3A As shown. For example, outer layer 240 and core layer 242 are formed from adhesive materials (which will be discussed in more detail below) such that outer layer 240 and core layer 242 are bonded and / or adhered to surrounding components. Reinforcement system 216 is configured to increase the mechanical stability of frame assembly 210.

[0079] Typically, the membranes in typical or known cells in the art extend outwardly to the outer edges of the frame (ie, to the outer edges 228E and 230E of the frame 214, as shown in FIG. Figure 3A ). In these typical cells, a large portion of the membrane does not overlap with the catalyst layer, which results in design instability around the large non-overlapping portion of the membrane. Therefore, the reinforcement system 216 provided herein provides structural integrity to the outer portion of the membrane 222 that does not overlap with the catalyst layers 218, 220 (i.e., the inactive region 226 of the membrane 222) in a manner not available in known cell designs.

[0080] Specifically, the present reinforcement system 216 improves the reliability of the electrochemical cell 212 by preventing edge burrs and eliminating the problem of perforation that may cause holes in the membrane 222, thereby causing membrane degradation. Therefore, the reinforcement system 216 increases the mechanical stability of the electrochemical cell 212 and eliminates failure of the membrane 222 near the outer edge of the membrane 222 (i.e., at the inactive area 226 of the membrane 222). In addition, the length of the membrane 222 is reduced compared to typical or known cells because the membrane 222 does not extend to the outer edges 228E, 230E of the frame 214, which reduces the cost and difficulty of manufacturing the electrochemical cell 212.

[0081] The outer layer 240 is disposed between the upper frame 228 and the lower frame 230 relative to the first axis A1, as shown in FIG. Figure 3A As shown. Figure 3A As shown, outer edges 228E of upper frame 228 and outer edges 230E of lower frame 230 are aligned with outer edges 240E of outer layer 240, such that outer edges 228E, 230E, and 240E are flush with one another. Outer layer 240 is positioned on each side of electrochemical cell 212 relative to second axis A2. In some embodiments, outer layer 240 is formed from an adhesive material including an acrylic adhesive, epoxy resin, polyamide, silicone adhesive, combinations thereof, or other suitable alternatives.

[0082] The outer layer 240 has a first outer portion 244 and a second outer portion 246, as shown in FIG. Figure 3A As shown, the first outer portion 244 is disposed between the first upper plate 232 of the upper frame 228 and the first lower plate 236 of the lower frame 230. The second outer portion 246 is disposed between the second upper plate 234 of the upper frame 228 and the second lower plate 238 of the lower frame 230. The second outer portion 246 of the outer layer 240 is spaced apart from the first outer portion 244 of the outer layer 240 along the second axis A2 such that the electrochemical cell 212 is disposed therebetween.

[0083] In some embodiments, the first outer portion 244 is formed to include a first sheet 244A coupled and / or adhered to the first upper plate 232 and a second sheet 244B coupled and / or adhered to the first lower plate 236, as shown in FIG. Figure 3A In some embodiments, the second outer portion 246 is formed to include a first sheet 246A coupled and / or adhered to the second upper plate 234 and a second sheet 246B coupled and / or adhered to the second lower plate 238 .

[0084] The fourth length L4 of each of the sheets 244A, 244B, 246A, 246B of the outer layer 240 is less than the third length L3 of the first upper plate 232, the second upper plate 234, the first lower plate 236, and the second lower plate 238. Figure 3AThe sheets 244A, 244B, 246A, 246B of the outer layer 240 each have the same thickness, also referred to as a third thickness T3 . The third thickness T3 is greater than the first thickness T1 of the catalyst layers 218 , 220 and the second thickness T2 of the membrane 222 .

[0085] In some embodiments, the outer layer 240 is formed to include a first fill portion 248, a second fill portion 250, a third fill portion 252, and / or a fourth fill portion 254, as shown in FIG. Figure 3A As shown in FIG. 1 , a first filling portion 248 extends along the second axis A2 from the first sheet 244A of the first outer portion 244 to the first sheet 246A of the second outer portion 246. A second filling portion 250 extends along the second axis A2 from the first sheet 246A of the second outer portion 246 to the first sheet 244A of the first outer portion 244. A third filling portion 252 extends along the second axis A2 from the second sheet 244B of the first outer portion 244 to the second sheet 246B of the second outer portion 246. A fourth filling portion 254 extends along the second axis A2 from the second sheet 246B of the second outer portion 246 to the second sheet 244B of the first outer portion 244.

[0086] The fifth thickness T5 of each of the filling portions 248, 250, 252, 254 is the same, as shown in FIG. Figure 3A The fifth thickness T5 is less than the first thickness T1 of the catalyst layers 218 , 220 , the second thickness T2 of the membrane 222 , and the third thickness T3 of each of the sheets 244A, 244B, 246A, 246B of the outer layer 240 .

[0087] Each of the filling portions 248, 250, 252, 254 has the same length, referred to as the sixth length L6. Figure 3A The sixth length L6 is smaller than the first length L1 of the catalyst layers 218 and 220 , the second length L2 of the membrane 222 , the third length L3 of the upper and lower plates 232 and 234 and 236 and 238 , and the fourth length L4 of the sheets 244A, 244B, 246A, and 246B of the outer layer 240 .

[0088] As previously mentioned, in addition to the outer layer 240, the reinforcement system 216 also includes a core layer 242, such as Figure 3A In some embodiments, core layer 242 is formed from an adhesive material including a polyimide film. In some embodiments, core layer 242 is formed from other polyimide-based adhesive materials or polyimide films having particularly advantageous properties, such as, but not limited to, Upilex or Kaptrex. In some embodiments, core layer 242 is formed from other adhesive materials, such as aliphatic polyamides, including, but not limited to, nylon.

[0089] The core layer 242 is arranged on each side of the first catalyst layer 218 and the second catalyst layer 220 relative to the second axis A2. Figure 3A The core layer 242 is arranged between the upper frame 228 and the lower frame 230 relative to the first axis A1. The core layer 242 includes a first core sheet 242A, a second core sheet 242B, a third core sheet 242C and a fourth core sheet 242D. Figure 3A shown.

[0090] The first core sheet 242A is disposed adjacent to the first catalyst layer 218 relative to the first axis A1 and between the first upper plate 232 and the inactive region 226 of the membrane 222. The second core sheet 242B is disposed adjacent to the first catalyst layer 218 on a side of the first catalyst layer 218 opposite the first core sheet 242A. The second core sheet 242B is disposed between the second upper plate 234 and the inactive region 226 of the membrane 222 relative to the first axis A1. The second core sheet 242B is spaced apart from the first core sheet 242A relative to the second axis A2 to position the first catalyst layer 218 therebetween.

[0091] The third core sheet 242C is disposed adjacent to the second catalyst layer 220 relative to the first axis A1 and is disposed between the inactive region 226 of the membrane 222 and the first lower plate 236, as shown in FIG. Figure 3A As shown. A fourth core sheet 242D is positioned adjacent to the second catalyst layer 220 on a side of the second catalyst layer 220 opposite the third core sheet 242C. The fourth core sheet 242D is positioned between the inactive region 226 of the membrane 222 and the second lower plate 238 relative to the first axis A1. The fourth core sheet 242D is spaced apart from the third core sheet 242C relative to the second axis A2 to position the second catalyst layer 220 therebetween.

[0092] The first core sheet 242A contacts and / or adheres to each of the first fill portion 248, the first sheet 244A of the outer layer 240, the inactive region 226 of the membrane 222, and the first catalyst layer 218, as shown. Figure 3A The entire first core sheet 242A overlaps the inactive area 226 of the membrane 222. The first filler portion 248 and the first upper plate 232 overlap only a portion of the first core sheet 242A.

[0093] The second core sheet 242B contacts and / or adheres to each of the second fill portion 250, the first sheet 246A of the outer layer 240, the inactive region 226 of the membrane 222, and the first catalyst layer 218, as shown. Figure 3AThe entirety of the second core sheet 242B overlaps the inactive area 226 of the membrane 222. The second filler portion 250 and the second upper plate 234 overlap only a portion of the second core sheet 242B.

[0094] The third core sheet 242C contacts and / or adheres to each of the third fill portion 252, the second sheet 244B of the outer layer 240, the inactive region 226 of the membrane 222, and the second catalyst layer 220, as shown. Figure 3A The entirety of the third core sheet 242C overlaps the inactive area 226 of the membrane 222. The third filler portion 252 and the first lower plate 236 overlap only a portion of the third core sheet 242C.

[0095] The fourth core sheet 242D contacts and / or adheres to each of the fourth fill portion 254, the second sheet 246B of the outer layer 240, the inactive region 226 of the membrane 222, and the second catalyst layer 220, as shown. Figure 3A The entirety of the fourth core sheet 242D overlaps the inactive area 226 of the membrane 222. The fourth filler portion 254 and the second lower plate 238 overlap only a portion of the fourth core sheet 242D.

[0096] The first outer portion 244 of the outer layer 240 contacts and / or adheres to each of the first upper plate 232, the first fill portion 248, the first core sheet 242A, the inactive area 226 of the membrane 222, the third core sheet 242C, the third fill portion 252, and the first lower plate 236, as shown. Figure 3A The second outer portion 246 of the outer layer 240 contacts and / or adheres to each of the second upper plate 234, the second fill portion 250, the second core sheet 242B, the inactive area 226 of the membrane 222, the fourth core sheet 242D, the fourth fill portion 254, and the second lower plate 238.

[0097] The outer edge 242E of each of the core sheets 242A, 242B, 242C, 242D is aligned with the outer edge 222E of the membrane 222, as shown in FIG. Figure 3A In other words, the outer edge 242E of each of the core sheets 242A, 242B, 242C, 242D is flush with the outer edge 222E of the membrane 222 .

[0098] Each of the core sheets 242A, 242B, 242C, 242D has the same thickness, referred to as the fourth thickness T4, as shown in FIG. Figure 3AAs shown. Fourth thickness T4 is equal to first thickness T1 of first catalyst layer 218 and second catalyst layer 220. Fourth thickness T4 is greater than second thickness T2 of membrane 222. Fourth thickness T4 of each of core sheets 242A, 242B, 242C, 242D is less than third thickness T3 of each of sheets 244A, 244B, 246A, 246B of outer layer 240. Fourth thickness T4 is greater than fifth thickness T5 of each of filler portions 248, 250, 252, 254.

[0099] Each of the core sheets 242A, 242B, 242C, 242D has the same length, referred to as the fifth length L5. Figure 3A The fifth length L5 is less than the first length L1 of the catalyst layers 218 and 220, the second length L2 of the membrane 222, the third length L3 of the upper plates 232, 234 and the lower plates 236, 238, and the fourth length L4 of the sheets 244A, 244B, 246A, 246B of the outer layer 240. The fifth length L5 is greater than the sixth length L6 of each of the filling portions 248, 250, 252, 254.

[0100] The sum of the fifth length L5 of the first core sheet 242A, the first length L1 of the first catalyst layer 218, and the fifth length L5 of the second core sheet 242B is equal to the second length L2 of the membrane 222. Figure 3A Because the inactive area 226 of the membrane 222 is located on each side of the active area 224 of the membrane 222 relative to the second axis A2, the length of the inactive area 226 of the membrane 222 is equal to twice the fifth length L5 (i.e., the length of the first core sheet 242A plus the length of the second core sheet 242B).

[0101] In some embodiments, the first filler portion 248, the second filler portion 250, the third filler portion 252, and / or the fourth filler portion 254 are omitted. In such embodiments, a gap is formed between the corresponding upper frame 228 / lower frame 230 and the core layer 242 relative to the first axis A1.

[0102] To manufacture the frame assembly 210, the core sheets 242A, 242B, 242C, 242D are adhered to the membrane 222 and catalyst layers 218, 220, as shown. Figure 4 For example, each of the core sheets 242A, 242B, 242C, 242D is adhered to the inactive areas 226 of the membrane 222 at opposite corners of the membrane 222. The core sheets 242A, 242B, 242C, 242D can be adhered to the membrane 222 by pressing the core sheets 242A, 242B, 242C, 242D onto the membrane 222 using a force F.

[0103] In some embodiments, the core sheets 242A, 242B, 242C, 242D can be pressed onto the film 222 via a hot press. In some embodiments, the core sheets 242A, 242B, 242C, 242D can be pressed onto the film 222 via a cold press. In some embodiments, the core sheets 242A, 242B, 242C, 242D can be mechanically pressed onto the film 222 (i.e., by machine or manual pressing). In some embodiments, the core sheets 242A, 242B, 242C, 242D can be rolled onto the film 222 via a hot roller, a cold roller, or a room temperature roller. The core sheets 242A, 242B, 242C, 242D can be applied to the film 222 in the form of a tape, a film, a glue, a paste, a liquid, a granular form, an atomized form, a spray form, or any other suitable form.

[0104] The outer layer 240 is adhered to the frame 214, as Figure 5 For example, the first sheet 244A of the first outer portion 244 of the outer layer 240 is adhered to the first upper plate 232. The second sheet 244B of the first outer portion 244 of the outer layer 240 is adhered to the first lower plate 236, as shown. Figure 5 The first sheet 246A of the second outer portion 246 of the outer layer 240 is adhered to the second upper plate 234. The second sheet 246B of the second outer portion 246 of the outer layer 240 is adhered to the second lower plate 238, as shown. Figure 5 shown.

[0105] The outer layer 240 can be adhered to the corresponding plate 232, 234, 236, 238 by pressing the outer layer 240 onto the corresponding plate 232, 234, 236, 238 using a force F. In some embodiments, the outer layer 240 can be pressed onto the corresponding plate 232, 234, 236, 238 using a hot press. In some embodiments, the outer layer 240 can be pressed onto the corresponding plate 232, 234, 236, 238 using a cold press. In some embodiments, the outer layer 240 can be mechanically pressed onto the corresponding plate 232, 234, 236, 238 (i.e., by machine or manual pressing). In some embodiments, the outer layer 240 can be rolled onto the corresponding plate 232, 234, 236, 238 using a hot roller, a cold roller, or a room temperature roller. The outer layer 240 may be applied to the frame 214 in the form of a tape, a film, a glue, a paste, a liquid, a granular form, an atomized form, a spray form, or any other suitable form.

[0106] The combined outer layer 240 and frame 214 are then adhered to the combined cells 212 and core layer 242 as shown. Figure 6As shown. For example, first sheet 244A of first outer portion 244 of outer layer 240 is adhered to core sheet 242A, film 222, and second sheet 244B of first outer portion 244 of outer layer 240. Second sheet 244B of first outer portion 244 of outer layer 240 is adhered to core sheet 242C, film 222, and first sheet 244A. First sheet 246A of second outer portion 246 of outer layer 240 is adhered to core sheet 242B, film 222, and second sheet 246B of second outer portion 246 of outer layer 240. Second sheet 246B of second outer portion 246 of outer layer 240 is adhered to core sheet 242D, film 222, and first sheet 246A of second outer portion 246 of outer layer 240.

[0107] The combined outer layer 240 and frame 214 may be adhered to the combined battery 212 and core layer 242 by pressing the two components together using a force F, such as Figure 6 As shown. In some embodiments, the combined outer layer 240 and frame 214 can be pressed onto the combined battery 212 and core layer 242 via a hot press. In some embodiments, the combined outer layer 240 and frame 214 can be pressed onto the combined battery 212 and core layer 242 via a cold press. In some embodiments, the combined outer layer 240 and frame 214 can be mechanically pressed onto the combined battery 212 and core layer 242 (i.e., by machine or manual pressing). In some embodiments, the combined outer layer 240 and frame 214 can be rolled onto the combined battery 212 and core layer 242 via a hot roller, a cold roller, or a room temperature roller.

[0108] When the combined outer layer 240 and frame 214 are pressed onto the combined battery 212 and core layer 242, portions of the outer layer 240 can be forced to move along the second axis A2 to fill the gaps formed between the core sheets 242A, 242B, 242C, 242D and the corresponding upper frame 228 or the corresponding lower frame 230. In this way, filled portions 248, 250, 252, 254 of the outer layer 240 are formed, as shown in FIG. Figure 3A shown.

[0109] The present disclosure provides an alternative reinforcement system 316 for use with the electrochemical cell 212 and frame 214, as described above. Figure 7 Another embodiment of a frame assembly 310 is illustrated that is substantially similar to frame assembly 210. However, frame assembly 310 includes a different reinforcement system 316. The features and components of frame assembly 210 are applicable and present in frame assembly 310 unless disclosed to the contrary.

[0110] The reinforcement system 316 includes an outer layer 340, a core layer 342, and / or a filler layer 356, such as Figure 7The outer layer 340 is arranged between the upper frame 228 and the lower frame 230 relative to the first axis A1. Figure 7 As shown, outer edges 228E of upper frame 228 and 230E of lower frame 230 are aligned with outer edges 340E of outer layer 340, such that outer edges 228E, 230E, and 340E are flush with one another. Outer layer 340 is positioned on each side of electrochemical cell 212 relative to second axis A2. In some embodiments, outer layer 340 is formed from an acrylic adhesive, epoxy resin, polyamide, silicone adhesive, or other suitable alternatives.

[0111] The outer layer 340 has a first outer portion 344 and a second outer portion 346, as shown Figure 7 As shown, the first outer portion 344 is disposed between the first upper plate 232 of the upper frame 228 and the first lower plate 236 of the lower frame 230. The second outer portion 346 is disposed vertically between the second upper plate 234 of the upper frame 228 and the second lower plate 238 of the lower frame 230. The second outer portion 346 of the outer layer 340 is spaced apart from the first outer portion 344 of the outer layer 340 relative to the second axis A2 to position the electrochemical cell 212 therebetween.

[0112] In some embodiments, the first outer portion 344 is formed to include a first sheet 344A coupled and / or adhered to the first upper plate 232 and a second sheet 344B coupled and / or adhered to the first lower plate 236, as shown in FIG. Figure 7 In some embodiments, the second outer portion 346 is formed to include a first sheet 346A coupled and / or adhered to the second upper plate 234 and a second sheet 346B coupled and / or adhered to the second lower plate 238 .

[0113] The fourth length L4 of each of the sheets 344A, 344B, 346A, 346B is less than the third length L3 of the first upper plate 232, the second upper plate 234, the first lower plate 236, and the second lower plate 238. Figure 7 As shown, the sheets 344A, 344B, 346A, and 346B each have the same third thickness T3. The third thickness T3 is greater than the first thickness T1 of the catalyst layers 218 and 220 and the second thickness T2 of the membrane 222.

[0114] The core layer 342 is arranged on each side of the first catalyst layer 218 and the second catalyst layer 220 relative to the second axis A2. Figure 7 The core layer 342 is disposed between the upper frame 228 and the lower frame 230 relative to the first axis A1.

[0115] The core layer 342 includes a first core sheet 342A, a second core sheet 342B, a third core sheet 342C and a fourth core sheet 342D. Figure 7As shown. The first core sheet 342A is positioned adjacent to the first catalyst layer 218 relative to the first axis A1 and between the first upper plate 232 and the inactive region 226 of the membrane 222. The second core sheet 342B is positioned adjacent to the first catalyst layer 218 on a side of the first catalyst layer 218 opposite the first core sheet 342A. The second core sheet 342B is positioned between the second upper plate 234 and the inactive region 226 of the membrane 222 relative to the first axis A1. The second core sheet 342B is spaced apart from the first core sheet 342A relative to the second axis A2 to position the first catalyst layer 218 therebetween.

[0116] The third core sheet 342C is disposed adjacent to the second catalyst layer 220 relative to the first axis A1 and between the inactive region 226 of the membrane 222 and the first lower plate 236, as shown in FIG. Figure 7 As shown. A fourth core sheet 342D is positioned adjacent to the second catalyst layer 220 on a side of the second catalyst layer 220 opposite the third core sheet 342C. The fourth core sheet 342D is positioned between the inactive region 226 of the membrane 222 and the second lower plate 238 relative to the first axis A1. The fourth core sheet 342D is spaced apart from the third core sheet 342C relative to the second axis A2 to position the second catalyst layer 220 therebetween.

[0117] The outer edge 342E of each of the core sheets 342A, 342B, 342C, 342D is aligned with the outer edge 222E of the membrane 222, as shown in FIG. Figure 7 In other words, the outer edge 342E of each of the core sheets 342A, 342B, 342C, 342D is flush with the outer edge 222E of the membrane 222 .

[0118] Each of the core sheets 342A, 342B, 342C, 342D has the same fourth thickness T4, such as Figure 7 As shown. Fourth thickness T4 is equal to first thickness T1 of first catalyst layer 218 and second catalyst layer 220. Fourth thickness T4 is greater than second thickness T2 of membrane 222. Fourth thickness T4 of each of core sheets 342A, 342B, 342C, and 342D is less than third thickness T3 of each of first sheet 344A, second sheet 344B, first sheet 346A, and second sheet 346B.

[0119] Each of the core sheets 342A, 342B, 342C, 342D has the same length, also referred to as the fifth length L5, as shown in FIG. Figure 7The fifth length L5 is smaller than the first length L1 of the catalyst layers 218 and 220, the second length L2 of the membrane 222, the third length L3 of the upper and lower plates 232 and 234, and the fourth length L4 of the sheets 344A, 344B, 346A, and 346B.

[0120] The sum of the fifth length L5 of the first core sheet 342A, the first length L1 of the first catalyst layer 218, and the fifth length L5 of the second core sheet 342B is equal to the second length L2 of the membrane 222. Figure 7 Because the inactive area 226 of the membrane 222 is located on each side of the active area 224 of the membrane 222 relative to the second axis A2, the length of the inactive area 226 of the membrane 222 is equal to twice the fifth length L5 (i.e., the length of the first core sheet 342A plus the length of the second core sheet 342B).

[0121] In some embodiments, core layer 342 is formed from a polyimide film. In some embodiments, core layer 342 is formed from other polyimide-based materials such as, but not limited to, Upilex or Kaptrex. In some embodiments, core layer 342 is formed from an aliphatic polyamide such as, but not limited to, nylon.

[0122] The filler layer 356 of the reinforcement system 316 is arranged between the core layer 342 and the upper frame 228 or the lower frame 230 relative to the first axis A1, as shown in FIG. Figure 7 The filling layer 356 includes a first filling sheet 356A, a second filling sheet 356B, a third filling sheet 356C, and a fourth filling sheet 356D. In some embodiments, the filling layer 356 is formed of polyethylene naphthalate (PEN).

[0123] The first filling sheet 356A is positioned between the first upper plate 232 and the first core sheet 342A of the core layer 342 relative to the first axis A1. Figure 7 As shown. The second filler sheet 356B is positioned between the second upper plate 234 and the second core sheet 342B of the core layer 342 relative to the first axis A1. The third filler sheet 356C is positioned between the third core sheet 342C of the core layer 342 and the first lower plate 236 relative to the first axis A1. The fourth filler sheet 356D is positioned between the fourth core sheet 342D of the core layer 342 and the second lower plate 238 relative to the first axis A1.

[0124] The fifth thickness T5 of each of the filling sheets 356A, 356B, 356C, 356D is the same, as shown in FIG. Figure 7The fifth thickness T5 is less than the first thickness T1 of the catalyst layers 218, 220, the second thickness T2 of the membrane 222, the third thickness T3 of each of the sheets 344A, 344B, 346A, 346B, and the fourth thickness T4 of the core sheets 342A, 342B, 342C, 342D.

[0125] Each of the filling sheets 356A, 356B, 356C, 356D has the same length, referred to as the sixth length L6. Figure 7 The sixth length L6 is less than the first length L1 of the catalyst layers 218 and 220, the second length L2 of the membrane 222, the third length L3 of the upper and lower plates 232 and 234, and 236 and 238, the fourth length L4 of the sheets 344A, 344B, 346A, and 346B, and the fifth length L5 of the core sheets 342A, 342B, 342C, and 342D.

[0126] like Figure 7 As shown, first core sheet 342A contacts and / or adheres to each of first filler sheet 356A, first sheet 344A of outer layer 340, inactive region 226 of membrane 222, and first catalyst layer 218. The entirety of first core sheet 342A overlaps inactive region 226 of membrane 222. First filler sheet 356A and first upper plate 232 overlap only a portion of first core sheet 342A.

[0127] The second core sheet 342B contacts and / or adheres to each of the second filler sheet 356B, the first sheet 346A of the outer layer 340, the inactive region 226 of the membrane 222, and the first catalyst layer 218, as shown. Figure 7 The entirety of the second core sheet 342B overlaps the inactive region 226 of the membrane 222. The second filler sheet 356B and the second upper plate 234 overlap only a portion of the second core sheet 342B.

[0128] The third core sheet 342C contacts and / or adheres to each of the third filler sheet 356C, the second sheet 344B of the outer layer 340, the inactive region 226 of the membrane 222, and the second catalyst layer 220, as shown. Figure 7 The entirety of the third core sheet 342C overlaps the inactive area 226 of the membrane 222. The third filler sheet 356C and the first lower plate 236 overlap only a portion of the third core sheet 342C.

[0129] The fourth core sheet 342D contacts and / or adheres to each of the fourth filler sheet 356D, the second sheet 346B of the outer layer 340, the inactive region 226 of the membrane 222, and the second catalyst layer 220, as shown. Figure 7The entirety of the fourth core sheet 342D overlaps the inactive area 226 of the membrane 222. The fourth filler sheet 356D and the second lower plate 238 overlap only a portion of the fourth core sheet 342D.

[0130] To make the frame assembly 310, the core sheets 342A, 342B, 342C, 342D are adhered to the membrane 222 and catalyst layers 218, 220, as shown. Figure 8 As shown. For example, each of the core sheets 342A, 342B, 342C, 342D is adhered to the inactive area 226 of the film 222 at opposite corners of the film 222. The core sheets 342A, 342B, 342C, 342D can be adhered to the film 222 by pressing the core sheets 342A, 342B, 342C, 342D onto the film 222 using a force F. In some embodiments, the core sheets 342A, 342B, 342C, 342D can be pressed onto the film 222 via a hot press. In some embodiments, the core sheets 342A, 342B, 342C, 342D can be pressed onto the film 222 via a cold press. In some embodiments, the core sheets 342A, 342B, 342C, 342D can be mechanically pressed onto the film 222 (i.e., by machine or manual pressing). In some embodiments, the core sheets 342A, 342B, 342C, 342D can be rolled onto the film 222 via hot rollers, cold rollers, or room temperature rollers. The core sheets 342A, 342B, 342C, 342D can be applied to the film 222 in the form of a tape, a film, a glue, a paste, a liquid, a granular form, an atomized form, a spray form, or any other suitable form.

[0131] For example, the filler layer 356 is formed as part of the frame 214, such as Figure 9 The outer layer 340 is adhered to the frame 214, as shown. Figure 9 For example, the first sheet 344A of the first outer portion 344 of the outer layer 340 is adhered to the first upper panel 232 such that the first sheet 344A is positioned adjacent to the first filler sheet 356A, as shown. Figure 9 The second sheet 344B of the first outer portion 344 of the outer layer 340 is adhered to the first lower panel 236 so that the second sheet 344B is positioned adjacent to the third filler sheet 356C, as shown. Figure 9 As shown. The first sheet 346A of the second outer portion 346 of the outer layer 340 is adhered to the second upper panel 234 so that the first sheet 346A is positioned adjacent to the second filling sheet 356B. The second sheet 346B of the second outer portion 346 of the outer layer 340 is adhered to the second lower panel 238 so that the second sheet 346B is positioned adjacent to the fourth filling sheet 356D, as shown. Figure 9 shown.

[0132] The outer layer 340 may be adhered to the corresponding plate 232, 234, 236, 238 by pressing the outer layer 340 onto the corresponding plate 232, 234, 236, 238 using a force F, such as Figure 9 As shown. In some embodiments, the outer layer 340 can be pressed onto the corresponding plate 232, 234, 236, 238 via a hot press. In some embodiments, the outer layer 340 can be pressed onto the corresponding plate 232, 234, 236, 238 via a cold press. In some embodiments, the outer layer 340 can be mechanically pressed onto the corresponding plate 232, 234, 236, 238 (i.e., by machine or manual pressing). In some embodiments, the outer layer 340 can be rolled onto the corresponding plate 232, 234, 236, 238 via a hot roller, a cold roller, or a room temperature roller. The outer layer 340 can be applied to the frame 214 in the form of a tape, a film, a glue, a paste, a liquid, a granular form, an atomized form, a spray form, or any other suitable form.

[0133] The combined outer layer 340, filler layer 356, and frame 214 are then adhered to the combined cells 212 and core layer 342, as shown. Figure 10 For example, first sheet 344A of outer layer 340 is adhered to core sheet 342A, film 222, and second sheet 344B of outer layer 340, while first filler sheet 356A is adhered to core sheet 342A. Second sheet 344B of outer layer 340 is adhered to core sheet 342C, film 222, and first sheet 344A, while third filler sheet 356C is adhered to core sheet 342C.

[0134] The first sheet 346A of the outer layer 340 is adhered to the core sheet 342B, the membrane 222, and the second sheet 346B of the outer layer 340, while the second filler sheet 356B is adhered to the core sheet 342B, as shown. Figure 10 The second sheet 346B of the outer layer 340 is adhered to the core sheet 342D, the membrane 222, and the first sheet 346A of the outer layer 340, while the fourth filler sheet 356D is adhered to the core sheet 342D.

[0135] The combined outer layer 340, filler layer 356, and frame 214 may be adhered to the combined battery 212 and core layer 342 by pressing the two components together using a force F, such as Figure 10As shown. In some embodiments, the combined outer layer 340, filler layer 356, and frame 214 can be pressed onto the combined battery 212 and core layer 342 via a hot press. In some embodiments, the combined outer layer 340, filler layer 356, and frame 214 can be pressed onto the combined battery 212 and core layer 342 via a cold press. In some embodiments, the combined outer layer 340, filler layer 356, and frame 214 can be mechanically pressed onto the combined battery 212 and core layer 342 (i.e., by machine or manual pressing). In some embodiments, the combined outer layer 340, filler layer 356, and frame 214 can be rolled onto the combined battery 212 and core layer 342 via a hot roller, a cold roller, or a room temperature roller.

[0136] The present disclosure provides an alternative reinforcement system 416 for use with the electrochemical cell 212 and frame 214, as described above. Figure 11 Another embodiment of a frame assembly 410 is illustrated that is substantially similar to frame assembly 210. However, frame assembly 410 includes a different reinforcement system 416. The features and components of frame assembly 210 are applicable and present in frame assembly 410 unless disclosed to the contrary.

[0137] The present disclosure provides a frame assembly 410 including an electrochemical cell 212, a frame 214, and a reinforcement system 416, such as Figure 11 As shown. The reinforcement system 416 includes an outer layer 440 and a core layer 442, as shown Figure 11 As previously mentioned, core layer 442 is identical to core layer 242 .

[0138] The outer layer 440 is disposed between the upper frame 228 and the lower frame 230 relative to the first axis A1, as shown in FIG. Figure 11 As shown. Figure 11 As shown, outer edges 228E of upper frame 228 and lower frame 230 are aligned with outer edges 440E of outer layer 440 such that outer edges 228E, 230E, 440E are flush with one another. Outer layer 440 is located on each side of electrochemical cell 212 relative to second axis A2.

[0139] The outer layer 440 has a first outer portion 444 and a second outer portion 446, as shown Figure 11 As shown, the first outer portion 444 is disposed between the first upper plate 232 of the upper frame 228 and the first lower plate 236 of the lower frame 230 relative to the first axis A1. The second outer portion 446 is disposed between the second upper plate 234 of the upper frame 228 and the second lower plate 238 of the lower frame 230 relative to the first axis A1. The second outer portion 446 of the outer layer 440 is spaced apart from the first outer portion 444 of the outer layer 440 relative to the second axis A2 such that the electrochemical cell 212 is disposed therebetween.

[0140] The fourth length L4 of each of the first outer portion 444 and the second outer portion 446 is less than the third length L3 of the first upper plate 232, the second upper plate 234, the first lower plate 236, and the second lower plate 238. Figure 11 In some embodiments, outer layer 440 is formed from polyimide, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), or other suitable alternatives.

[0141] The core layer 442 is arranged on each side of the first catalyst layer 218 and the second catalyst layer 220 relative to the second axis A2. Figure 11 The core layer 442 is disposed between the upper frame 228 and the lower frame 230 relative to the first axis A1.

[0142] The first outer portion 444 of the outer layer 440 contacts and / or adheres to each of the first upper plate 232, the first core sheet 442A, the inactive area 226 of the membrane 222, the third core sheet 442C, and the first lower plate 236, as shown in FIG. Figure 11 A second outer portion 446 of the outer layer 440 contacts and / or adheres to each of the second upper plate 234 , the second core sheet 442B, the inactive area 226 of the membrane 222 , the fourth core sheet 442D, and the second lower plate 238 .

[0143] To make the frame assembly 410, the core sheets 442A, 442B, 442C, 442D are adhered to the membrane 222 and catalyst layers 218, 220, as shown. Figure 12 As shown. For example, each of the core sheets 442A, 442B, 442C, 442D is adhered to the inactive area 226 of the film 222 at opposite corners of the film 222. The core sheets 442A, 442B, 442C, 442D can be adhered to the film 222 by pressing the core sheets 442A, 442B, 442C, 442D onto the film 222 using a force F. In some embodiments, the core sheets 442A, 442B, 442C, 442D can be pressed onto the film 222 via a hot press. In some embodiments, the core sheets 442A, 442B, 442C, 442D can be pressed onto the film 222 via a cold press. In some embodiments, the core sheets 442A, 442B, 442C, 442D can be mechanically pressed onto the film 222 (i.e., by machine or manual pressing). In some embodiments, the core sheets 442A, 442B, 442C, 442D can be rolled onto the film 222 via hot rollers, cold rollers, or room temperature rollers. The core sheets 442A, 442B, 442C, 442D can be applied to the film 222 in the form of a tape, a film, a glue, a paste, a liquid, a granular form, an atomized form, a spray form, or any other suitable form.

[0144] The outer layer 440, electrochemical cell 212, and core layer 442 are then adhered to the frame 214 by pressing the components together using a force F, as shown. Figure 13 As shown. In some embodiments, the frame 214 can be pressed onto the outer layer 440, the electrochemical cell 212, and the core layer 442 via a hot press. In some embodiments, the frame 214 can be pressed onto the outer layer 440, the electrochemical cell 212, and the core layer 442 via a cold press. In some embodiments, the frame 214 can be mechanically pressed onto the outer layer 440, the electrochemical cell 212, and the core layer 442 (i.e., by machine or manual pressing). In some embodiments, the frame 214 can be rolled onto the outer layer 440, the electrochemical cell 212, and the core layer 442 via a hot roller, a cold roller, or a room temperature roller.

[0145] The following described aspects of the invention are contemplated and are non-limiting:

[0146] A first aspect of the present invention relates to a frame assembly. The frame assembly includes an electrochemical cell, a frame, and a reinforcement system. The electrochemical cell includes a first catalyst layer, a second catalyst layer spaced apart from the first catalyst layer along a first axis, and a membrane located between the first catalyst layer and the second catalyst layer. The membrane is formed to include an active area and an inactive area, the inactive area being located on each side of the active area of ​​the membrane along a second axis perpendicular to the first axis. The frame includes an upper frame arranged above the inactive area of ​​the membrane relative to the first axis and a lower frame arranged below the inactive area of ​​the membrane relative to the first axis. The reinforcement system is configured to increase the mechanical stability of the electrochemical cell. The reinforcement system includes an outer layer and a core layer. The outer layer is arranged between the upper frame and the lower frame relative to the first axis and is located on each side of the electrochemical cell relative to the second axis. The core layer is arranged on each side of the first catalyst layer and the second catalyst layer relative to the second axis, and the core layer is arranged between the upper frame and the lower frame relative to the first axis.

[0147] A second aspect of the present invention relates to a frame assembly. The frame assembly includes an electrochemical cell, a frame, and a reinforcement system. The electrochemical cell includes a first catalyst layer, a second catalyst layer spaced apart from the first catalyst layer along a first axis, and a membrane located between the first catalyst layer and the second catalyst layer. The membrane is formed to include an active region and an inactive region, the inactive region being located on each side of the active region along a second axis perpendicular to the first axis. The frame includes an upper frame arranged above the membrane relative to the first axis and a lower frame arranged below the membrane relative to the first axis. The reinforcement system is configured to increase the mechanical stability of the electrochemical cell. The reinforcement system includes an outer layer, a core layer, and a filling layer. The outer layer is completely arranged between the upper frame and the lower frame relative to the first axis. The outer layer is located on each side of the electrochemical cell, the core layer, and the filling layer relative to the second axis. The core layer is arranged on each side of the first catalyst layer and the second catalyst layer relative to the second axis, and the core layer is arranged between the upper frame and the lower frame relative to the first axis. The filling layer is completely arranged between the upper frame and the lower frame relative to the first axis.

[0148] In the first aspect of the present invention, the electrochemical cell may be a fuel cell. In the first aspect of the present invention, the electrochemical cell may be an electrolyzer cell. In the first aspect of the present invention, the upper frame may include a first upper plate and a second upper plate spaced apart from the first upper plate relative to the second axis. In the first aspect of the present invention, the first upper plate and the second upper plate may not overlap the active area of ​​the membrane.

[0149] In a first aspect of the invention, the lower frame may include a first lower plate and a second lower plate spaced apart from the first lower plate relative to a second axis. In the first aspect of the invention, the first lower plate and the second lower plate may not overlap with the active area of ​​the membrane. In the first aspect of the invention, the first upper plate may be spaced apart from the first lower plate relative to the first axis to position a portion of the outer layer and a portion of the core layer therebetween. In the first aspect of the invention, the second upper plate may be spaced apart from the second lower plate relative to the first axis to position another portion of the outer layer and another portion of the core layer therebetween.

[0150] In a first aspect of the invention, the core layer may include (i) a first core sheet disposed adjacent to the first catalyst layer relative to the second axis and disposed between the first upper plate and the inactive region of the membrane relative to the first axis, (ii) a second core sheet disposed adjacent to the first catalyst layer relative to the second axis and disposed between the second upper plate and the inactive region of the membrane relative to the first axis, (iii) a third core sheet disposed adjacent to the second catalyst layer relative to the second axis and disposed between the inactive region of the membrane and the first lower plate relative to the first axis, and (iv) a fourth core sheet disposed adjacent to the second catalyst layer relative to the second axis and disposed between the inactive region of the membrane and the second lower plate relative to the first axis. In the first aspect of the invention, the first core sheet, the second core sheet, the third core sheet, and the fourth core sheet may each have a first thickness. In the first aspect of the invention, the first thickness may be equal to the second thickness of the first catalyst layer and the second catalyst layer.

[0151] In the first aspect of the present invention, the first core sheet, the second core sheet, the third core sheet, and the fourth core sheet can each have a first length. In the first aspect of the present invention, each of the first catalyst layer and the second catalyst layer has a second length. In the first aspect of the present invention, the first length and the second length can each be less than the third length of the membrane.

[0152] In the first aspect of the invention, the sum of the first length of the first core sheet, the second length of the first catalyst layer, and the first length of the second core sheet may be equal to the third length of the membrane. In the first aspect of the invention, the frame assembly may further include a filling layer. In the first aspect of the invention, the filling layer may include (i) a first filling sheet, the first filling sheet being arranged between the first upper plate and the first core sheet of the core layer relative to the first axis, (ii) a second filling sheet, the second filling sheet being arranged between the second upper plate and the second core sheet of the core layer relative to the first axis, (iii) a third filling sheet, the third filling sheet being arranged between the third core sheet of the core layer and the first lower plate relative to the first axis, and (iv) a fourth filling sheet, the fourth filling sheet being arranged between the fourth core sheet and the second lower plate of the core layer relative to the first axis.

[0153] In the first aspect of the present invention, the first thickness of the first filling sheet may be smaller than the second thickness of the first core sheet. In the first aspect of the present invention, the first length of the first filling sheet may be smaller than the second length of the first core sheet.

[0154] In a second aspect of the present invention, the upper frame may include a first upper plate and a second upper plate spaced apart from the first upper plate relative to a second axis. In the second aspect of the present invention, the first upper plate and the second upper plate may not overlap with the active area of ​​the membrane. In the second aspect of the present invention, the lower frame may include a first lower plate and a second lower plate spaced apart from the first lower plate relative to the second axis. In the second aspect of the present invention, the first lower plate and the second lower plate may not overlap with the active area of ​​the membrane.

[0155] In a second aspect of the present invention, the core layer may include (i) a first core sheet arranged adjacent to the first catalyst layer relative to the second axis and arranged between the first upper plate and the inactive area of ​​the membrane relative to the first axis, (ii) a second core sheet arranged between the second upper plate and the inactive area of ​​the membrane relative to the first axis and spaced apart from the first core sheet relative to the second axis to position the first catalyst layer therebetween, (iii) a third core sheet arranged adjacent to the second catalyst layer relative to the second axis and arranged between the inactive area of ​​the membrane and the first lower plate relative to the first axis, and (iv) a fourth core sheet arranged between the inactive area of ​​the membrane and the second lower plate relative to the first axis and spaced apart from the third core sheet relative to the second axis to position the second catalyst layer therebetween.

[0156] In a second aspect of the invention, the filler layer may include (i) a first filler sheet arranged between the first upper plate and the first core sheet of the core layer relative to a first axis, (ii) a second filler sheet arranged between the second upper plate and the second core sheet of the core layer relative to the first axis, (iii) a third filler sheet arranged between the third core sheet of the core layer and the first lower plate relative to the first axis, and (iv) a fourth filler sheet arranged between the fourth core sheet and the second lower plate of the core layer relative to the first axis. In the second aspect of the invention, the first filler sheet may be adhered to each of the first upper plate, the outer layer and the first core sheet. In the second aspect of the invention, the first core sheet may be adhered to each of the first filler sheet, the outer layer and the inactive area of ​​the membrane.

[0157] In a second aspect of the invention, the first filling sheet may have a first thickness and a first length, and the first core sheet may have a second thickness and a second length. In the second aspect of the invention, the first thickness may be less than the second thickness, and the first length may be less than the second length. In the second aspect of the invention, the outer layer may include (i) a first outer sheet, the first outer sheet being arranged adjacent to the first filling sheet, the first core sheet, and the membrane, (ii) a second outer sheet, the second outer sheet being arranged between the first outer sheet and the first lower plate relative to a first axis, and being arranged adjacent to the membrane, the third core sheet, and the third filling sheet, (iii) a third outer sheet, the third outer sheet being arranged adjacent to the second filling sheet, the second core sheet, and the membrane, and (iv) a fourth outer sheet, the fourth outer sheet being arranged between the third outer sheet and the second lower plate relative to the first axis, and being arranged adjacent to the membrane, the fourth core sheet, and the fourth filling sheet.

[0158] The features illustrated or described in conjunction with an exemplary embodiment may be combined with any other features or elements of any other embodiment described herein. Such modifications and variations are intended to be included within the scope of this disclosure. In addition, those skilled in the art will recognize that terms known to those skilled in the art may be used interchangeably herein.

[0159] The above embodiments are described in sufficient detail to enable those skilled in the art to practice what is claimed, and it should be understood that logical, mechanical, and electrical changes may be made without departing from the spirit and scope of the claims. Therefore, the detailed description should not be construed in a limiting sense.

[0160] As used herein, elements or steps listed in the singular and beginning with the word "a" or "an" (a / an) should be understood as not excluding the plural form of the elements or steps, unless such exclusion is explicitly stated. In addition, reference to "one embodiment" of the subject matter described herein is not intended to be interpreted as excluding the existence of additional embodiments that also include the enumerated features. The specified numerical range of units, measurements and / or values ​​includes, is essentially composed of, or is composed of all numerical values, units, measurements and / or ranges including these ranges and / or endpoints or within these ranges and / or endpoints, regardless of whether these numerical values, units, measurements and / or ranges are explicitly specified in the present disclosure.

[0161] Unless otherwise defined, the technical and scientific terms used herein have the same meanings as those generally understood by those of ordinary skill in the art to which this disclosure belongs. As used herein, the terms "first," "second," "third," etc. do not indicate any order or importance, but are used to distinguish one element from another. The term "or" is intended to include and refer to any one or all of the listed items. In addition, the terms "connect" and "couple" are not limited to physical or mechanical connections or couplings, but may also include direct or indirect electrical connections or couplings.

[0162] Furthermore, unless expressly stated to the contrary, embodiments that “comprise,” “include,” or “have” an element or elements having a particular property may include additional such elements that do not have that property. The terms “comprise” or “comprising” refer to compositions, compounds, formulations, or methods that include, but do not exclude, additional elements, components, and / or method steps. The term “comprising” also refers to compositions, compounds, formulations, or method embodiments of the present disclosure that include, but do not exclude, additional elements, components, and / or method steps.

[0163] The phrases "consisting of" or "consists of" refer to mixtures, compositions, formulations, or methods that exclude the presence of any additional elements, components, or method steps. The phrase "consisting of" refers to compounds, compositions, formulations, or methods disclosed herein that exclude the presence of any additional elements, components, or method steps.

[0164] The phrases “consisting essentially of” or “consists essentially of” refer to compositions, compounds, formulations, or methods that include additional elements, components, or method steps that have no material effect on the properties of the composition, compound, formulation, or method. The phrase “consisting essentially of” also refers to compositions, compounds, formulations, or methods of the present disclosure that include additional elements, components, or method steps that have no material effect on the properties of the composition, compound, formulation, or method.

[0165] Approximating language, as used throughout the specification and claims, may be used to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, a value modified by one or more terms, such as "about" and "substantially," is not limited to the precise value specified. In some cases, approximating language may correspond to the precision of an instrument used to measure a value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged. Unless context or language indicates otherwise, such ranges are identified and include all subranges contained therein.

[0166] As used herein, the terms "may" and "may be" indicate the possibility of something occurring under a set of circumstances; possessing a particular property, characteristic, or function; and / or qualifying another verb by expressing one or more capabilities or possibilities associated with the qualifying verb. Thus, the use of "may" and "may be" indicates that the modified term is clearly appropriate, capable, or suitable for the indicated capability, function, or usage, while taking into account that in some circumstances, the modified term may sometimes be inappropriate, unable, or unsuitable.

[0167] It should be understood that the above description is illustrative and not restrictive. For example, the above embodiments (and / or aspects thereof) can be used alone, together, or in combination with each other. In addition, many modifications can be made to adapt specific situations or materials to the teachings of the subject matter described herein without departing from the scope thereof. Although the sizes and types of materials described herein are intended to limit the parameters of the disclosed subject matter, they are by no means restrictive, but rather exemplary embodiments. After reviewing the above description, many other embodiments will be apparent to those skilled in the art. Therefore, the scope of the subject matter described herein should be determined with reference to the appended claims and the full range of equivalents to which such claims are entitled.

[0168] This written description uses examples to disclose several embodiments of the subject matter described herein, including the best mode, and also to enable one of ordinary skill in the art to practice the embodiments of the disclosed subject matter, including making and using the devices or systems and performing the methods. The patentable scope of the subject matter described herein is defined by the claims and may include other examples that occur to one of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

[0169] While only certain features of the invention have been illustrated and described herein, numerous modifications and changes will occur to those skilled in the art, and it is to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

Claims

1. A frame assembly comprising: An electrochemical cell comprising a first catalyst layer, a second catalyst layer spaced apart from the first catalyst layer along a first axis, and a membrane positioned between the first catalyst layer and the second catalyst layer, the membrane being formed to include an active region and an inactive region positioned on each side of the active region of the membrane along a second axis perpendicular to the first axis, a frame including an upper frame arranged above the inactive area of ​​the membrane relative to the first axis and a lower frame arranged below the inactive area of ​​the membrane relative to the first axis, and a reinforcement system configured to increase the mechanical stability of the electrochemical cell, the reinforcement system comprising an outer layer and a core layer, wherein the outer layer is arranged between the upper frame and the lower frame relative to the first axis and is located on each side of the electrochemical cell relative to the second axis, The core layer is disposed on each side of the first catalyst layer and the second catalyst layer relative to the second axis, and the core layer is disposed between the upper frame and the lower frame relative to the first axis.

2. The frame assembly of claim 1 , wherein the upper frame comprises a first upper plate and a second upper plate spaced apart from the first upper plate relative to the second axis, and wherein the first upper plate and the second upper plate do not overlap with the active area of ​​the membrane, and wherein the lower frame comprises a first lower plate and a second lower plate spaced apart from the first lower plate relative to the second axis, and wherein the first lower plate and the second lower plate do not overlap with the active area of ​​the membrane.

3. The frame assembly of claim 2 , wherein the first upper plate is spaced apart from the first lower plate relative to the first axis to position a portion of the outer layer and a portion of the core layer therebetween, and the second upper plate is spaced apart from the second lower plate relative to the first axis to position another portion of the outer layer and another portion of the core layer therebetween.

4. A frame assembly according to claim 2, wherein the core layer includes (i) a first core sheet, which is arranged adjacent to the first catalyst layer relative to the second axis and arranged between the first upper plate and the inactive area of ​​the membrane relative to the first axis, (ii) a second core sheet, which is arranged adjacent to the first catalyst layer relative to the second axis and arranged between the second upper plate and the inactive area of ​​the membrane relative to the first axis, (iii) a third core sheet, which is arranged adjacent to the second catalyst layer relative to the second axis and arranged between the inactive area of ​​the membrane and the first lower plate relative to the first axis, and (iv) a fourth core sheet, which is arranged adjacent to the second catalyst layer relative to the second axis and arranged between the inactive area of ​​the membrane and the second lower plate relative to the first axis. 5 . The frame assembly of claim 4 , wherein the first core sheet, the second core sheet, the third core sheet, and the fourth core sheet each have a first thickness, and the first thickness is equal to a second thickness of the first catalyst layer and the second catalyst layer.

6. The frame assembly of claim 4 , wherein the first core sheet, the second core sheet, the third core sheet, and the fourth core sheet each have a first length, and wherein each of the first catalyst layer and the second catalyst layer has a second length, and the first length and the second length are each less than the third length of the membrane. 7 . The frame assembly of claim 6 , wherein a sum of the first length of the first core sheet, the second length of the first catalyst layer, and the first length of the second core sheet is equal to the third length of the membrane.

8. The frame assembly according to claim 4 further includes a filling layer, the filling layer including (i) a first filling sheet, the first filling sheet being arranged between the first upper plate and the first core sheet of the core layer relative to the first axis, (ii) a second filling sheet, the second filling sheet being arranged between the second upper plate and the second core sheet of the core layer relative to the first axis, (iii) a third filling sheet, the third filling sheet being arranged between the third core sheet of the core layer and the first lower plate relative to the first axis, and (iv) a fourth filling sheet, the fourth filling sheet being arranged between the fourth core sheet of the core layer and the second lower plate relative to the first axis.

9. The frame assembly of claim 8, wherein the first filler sheet has a first thickness less than the second thickness of the first core sheet, and wherein the first filler sheet has a first length less than the second length of the first core sheet.

10. A frame assembly comprising: An electrochemical cell comprising a first catalyst layer, a second catalyst layer spaced apart from the first catalyst layer along a first axis, and a membrane positioned between the first catalyst layer and the second catalyst layer, the membrane being formed to include an active region and an inactive region positioned on each side of the active region along a second axis perpendicular to the first axis, a frame including an upper frame arranged above the membrane relative to the first axis and a lower frame arranged below the membrane relative to the first axis, and a reinforcement system configured to increase the mechanical stability of the electrochemical cell, the reinforcement system comprising an outer layer, a core layer, and a filler layer, wherein the outer layer is completely arranged between the upper frame and the lower frame relative to the first axis, and the outer layer is located on each side of the electrochemical cell, the core layer and the filling layer relative to the second axis, wherein the core layer is arranged on each side of the first catalyst layer and the second catalyst layer relative to the second axis, and the core layer is arranged between the upper frame and the lower frame relative to the first axis, wherein the filling layer is completely arranged between the upper frame and the lower frame relative to the first axis.

11. The frame assembly of claim 10 , wherein the upper frame comprises a first upper plate and a second upper plate spaced apart from the first upper plate relative to the second axis, and the first upper plate and the second upper plate do not overlap with the active area of ​​the membrane, and wherein the lower frame comprises a first lower plate and a second lower plate spaced apart from the first lower plate relative to the second axis, and the first lower plate and the second lower plate do not overlap with the active area of ​​the membrane.

12. A frame assembly according to claim 11, wherein the core layer includes (i) a first core sheet, which is arranged adjacent to the first catalyst layer relative to the second axis and arranged between the first upper plate and the inactive area of ​​the membrane relative to the first axis, (ii) a second core sheet, which is arranged between the second upper plate and the inactive area of ​​the membrane relative to the first axis and is spaced apart from the first core sheet relative to the second axis to position the first catalyst layer therebetween, (iii) a third core sheet, which is arranged adjacent to the second catalyst layer relative to the second axis and arranged between the inactive area of ​​the membrane and the first lower plate relative to the first axis, and (iv) a fourth core sheet, which is arranged between the inactive area of ​​the membrane and the second lower plate relative to the first axis and is spaced apart from the third core sheet relative to the second axis to position the second catalyst layer therebetween.

13. A frame assembly according to claim 12, wherein the filling layer includes (i) a first filling sheet, which is arranged between the first upper plate and the first core sheet of the core layer relative to the first axis, (ii) a second filling sheet, which is arranged between the second upper plate and the second core sheet of the core layer relative to the first axis, (iii) a third filling sheet, which is arranged between the third core sheet of the core layer and the first lower plate relative to the first axis, and (iv) a fourth filling sheet, which is arranged between the fourth core sheet of the core layer and the second lower plate relative to the first axis.

14. The frame assembly of claim 13, wherein the first filler sheet is adhered to each of the first upper panel, the outer layer, and the first core sheet, and wherein the first core sheet is adhered to each of the first filler sheet, the outer layer, and the inactive area of ​​the membrane.

15. A frame assembly according to claim 13, wherein the outer layer includes (i) a first outer sheet, which is arranged adjacent to the first filling sheet, the first core sheet and the membrane, (ii) a second outer sheet, which is arranged between the first outer sheet and the first lower plate relative to the first axis and adjacent to the membrane, the third core sheet and the third filling sheet, (iii) a third outer sheet, which is arranged adjacent to the second filling sheet, the second core sheet and the membrane, and (iv) a fourth outer sheet, which is arranged between the third outer sheet and the second lower plate relative to the first axis and adjacent to the membrane, the fourth core sheet and the fourth filling sheet.

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