Bipolar plate assembly for electrolytic cell

Abstract

Aspects of the present disclosure include bipolar plate assemblies for electrolytic cells (electrolyzers). An exemplary bipolar plate assembly for an electrolyzer includes an anode half-plate having one or more inlet manifolds, an anode side flow field coupled to the one or more inlet manifolds, and one or more outlet manifolds coupled to the anode side flow field. The anode side flow field is a dimple flow field having a series of dimples. The bipolar plate assembly also includes a cathode half-plate coupled to the anode half-plate, the cathode half-plate having one or more outlet manifolds and a cathode side flow field coupled to the one or more outlet manifolds. The cathode side flow field is a base channel flow field having alternating bases and channels.

Description

Technical Field

[0001] This disclosure relates to hydrogen fuel cells and electrolysis, and more particularly to bipolar plate assemblies for electrolyzers. Background Technology

[0002] Hydrogen fuel cells and related technologies have emerged as promising clean energy solutions, offering high efficiency and zero emissions for a wide range of applications, from transportation (e.g., personal and commercial vehicles, ships, aircraft, etc.) to stationary power generation. In a hydrogen fuel cell, hydrogen enters through the anode, where it is split into protons and electrons. Protons pass through the electrolyte membrane, while electrons flow through external circuitry, generating electricity. At the cathode, protons, electrons, and oxygen combine to produce water. Hydrogen fuel cells are typically implemented in fuel cell stacks, which are components of multiple individual hydrogen fuel cells connected in series to increase total voltage and power output.

[0003] Hydrogen fuel cells typically require a supply of hydrogen fuel provided via one or more electrolyzers. An electrolyzer is a device that uses electrical energy to drive a non-spontaneous chemical reaction that separates water (H₂O) into hydrogen (H₂) and oxygen (O₂) gases. An electrolyzer typically includes an anode, a cathode, and an electrolyte. When an electric current is applied between the anode and cathode, water molecules split at the anode to produce oxygen and protons (H₂O). + At the cathode, protons combine with electrons to produce hydrogen gas. Summary of the Invention

[0004] In one exemplary embodiment, a bipolar plate assembly for an electrolyzer includes an anode half-plate having one or more anode-side inlet headers, an anode-side flow field connected to the one or more anode-side inlet headers, and one or more anode-side outlet headers connected to the anode-side flow field. The anode-side flow field is a pit flow field having a series of pits. The bipolar plate assembly also includes a cathode half-plate connected to the anode half-plate, the cathode half-plate having a cathode-side flow field and one or more cathode-side outlet headers connected to the cathode-side flow field. The cathode-side flow field is a substrate-channel flow field having alternating substrates and channels.

[0005] In some embodiments, the anode half-plate and the cathode half-plate are assembled asymmetrically such that the fluid flow in the anode half-plate is rotated 90 degrees relative to the fluid flow in the cathode half-plate.

[0006] In some embodiments, the anode half-plate and the cathode half-plate together define a single separator of the electrolyzer.

[0007] In some embodiments, the anode half-plate and the cathode half-plate have the same thickness.

[0008] In some embodiments, the anode half-plate has a first thickness, and the cathode half-plate has a second thickness less than the first thickness.

[0009] In some embodiments, the inlet and outlet manifolds of the anode half-plate and the outlet manifold of the cathode half-plate are sealed relative to the anode-side flow field and the cathode-side flow field.

[0010] In some embodiments, the anode-side tunnel connects the anode-side inlet manifold and the anode-side outlet manifold to the anode-side flow field, respectively.

[0011] In some embodiments, the cathode-side tunnel connects the cathode-side outlet manifold to the cathode-side flow field.

[0012] In some embodiments, the cathode half-plate and the anode half-plate are connected via a symmetrical metal bead structure.

[0013] In some embodiments, the cathode half-plate includes a first metal bead height, and the anode half-plate includes a second metal bead height that is different from the first metal bead height.

[0014] In some embodiments, the inlet and outlet manifolds of the cathode half-plate and the anode half-plate are sealed with elastomeric beads.

[0015] In yet another exemplary embodiment, a method may include forming an anode half-plate having one or more anode-side inlet manifolds, an anode-side flow field connected to the one or more anode-side inlet manifolds, and one or more anode-side outlet manifolds connected to the anode-side flow field. The anode-side flow field is a pit flow field having a series of pits. The method further includes forming a cathode half-plate connected to the anode half-plate, the cathode half-plate having a cathode-side flow field and one or more cathode-side outlet manifolds connected to the cathode-side flow field. The cathode-side flow field is a substrate-channel flow field having alternating substrates and channels.

[0016] In some embodiments, the anode half-plate and the cathode half-plate are assembled asymmetrically such that the fluid flow in the anode half-plate is rotated 90 degrees relative to the fluid flow in the cathode half-plate.

[0017] In some embodiments, the anode half-plate and the cathode half-plate together define a single separator of the electrolyzer.

[0018] In some embodiments, the anode half-plate and the cathode half-plate have the same thickness.

[0019] In some embodiments, the anode half-plate has a first thickness, and the cathode half-plate has a second thickness less than the first thickness.

[0020] In some embodiments, the inlet and outlet manifolds of the anode half-plate and the outlet manifold of the cathode half-plate are sealed relative to the anode-side flow field and the cathode-side flow field.

[0021] In some embodiments, the anode-side tunnel connects the anode-side inlet manifold and the anode-side outlet manifold to the anode-side flow field, respectively.

[0022] In some embodiments, the cathode-side tunnel connects the cathode-side outlet manifold to the cathode-side flow field.

[0023] In some embodiments, the cathode half-plate and the anode half-plate are connected via a symmetrical metal bead structure.

[0024] In some embodiments, the cathode half-plate includes a first metal bead height, and the anode half-plate includes a second metal bead height that is different from the first metal bead height.

[0025] In some embodiments, the inlet and outlet manifolds of the cathode half-plate and the anode half-plate are sealed with elastomeric beads.

[0026] In some embodiments, the method further includes forming bead-like protrusions around the anode-side inlet manifold and the anode-side outlet manifold to form a seal to restrict fluid flow.

[0027] In some embodiments, the method further includes forming bead-like protrusions around the cathode-side outlet manifold to form a seal to restrict fluid flow.

[0028] In some embodiments, the method further includes applying a thin elastomeric material to the beaded protrusions of the anode half-plate and the cathode half-plate.

[0029] In some embodiments, the method further includes beaded protrusions aligned with the anode half-side plate and the cathode half-side plate to provide a sealing function.

[0030] In some embodiments, the method further includes forming bead shapes at different heights on the anode and cathode sides to form an asymmetric bead seal.

[0031] In some embodiments, the method further includes forming beaded sealing features on the anode and cathode sides using only an elastomeric material.

[0032] The above-described features and advantages, as well as other features and advantages, of this disclosure will become apparent when taken in conjunction with the accompanying drawings and the following detailed description. Attached Figure Description

[0033] Other features, advantages, and details appear as examples only in the following detailed description, with reference to the accompanying drawings.

[0034] Figure 1 A simplified cross-sectional view of the membrane electrode assembly (MEA) layer of an electrolyzer according to one or more embodiments is depicted;

[0035] Figure 2 It is an anode half-plate according to one or more embodiments;

[0036] Figure 3 It is a cathode half-plate according to one or more embodiments;

[0037] Figure 4 An electrolytic cell (e.g., an electrolyzer) according to one or more embodiments is depicted;

[0038] Figure 5A A cross-sectional view of a bipolar plate with a symmetrical metal bead structure according to one or more embodiments is depicted.

[0039] Figure 5B A cross-sectional view of a bipolar plate with an asymmetric metal bead structure according to one or more embodiments is depicted.

[0040] Figure 5C Depicting according to one or more embodiments Figure 2 A cross-sectional view of region AA of the anode half-plate;

[0041] Figure 6 A computer system according to one or more embodiments; and

[0042] Figure 7 It is a flowchart according to one or more embodiments. Detailed Implementation

[0043] The following description is exemplary in nature and is not intended to limit this disclosure, its application or use.

[0044] Understanding and optimizing hydrogen fuel cells and their various supporting systems, such as electrolyzers (also known as electrolyzers), has become essential for the widespread adoption and commercialization of hydrogen fuel cell technology. One of the key components in hydrogen fuel cells and electrolyzers is the bipolar plate (BPP). In a fuel cell stack, the BPP serves multiple functions, such as distributing reactant gases, removing reaction products, conducting current between cells, and providing mechanical support. Similarly, in the case of an electrolyzer, the BPP separates the anode and cathode chambers, distributes water and gas, conducts current, and provides mechanical support for the various manifolds, channels, and flow fields that constitute the electrolyzer.

[0045] As research into hydrogen fuel cell technology progresses, optimizing BPP design will continue to be a driving force for improving overall performance and durability. Unfortunately, improvements in bipolar plate design are somewhat limited. For example, since electrolyzer applications do not require a coolant path, common electrolyzer plates are typically made from a single separator, and the gas path between the inlet header and the flow field (effective region) is primarily fabricated using improved plastic frames and / or overmolded designs. In short, these approaches generally involve adding plastic components to metal separators to form channels and paths for gas flow. The use of different materials (metal and plastic) can lead to issues with thermal expansion and chemical compatibility, potentially causing degradation over time. Furthermore, ensuring a reliable seal between the plastic frame and the metal plate is difficult, and any defects in the seal can lead to gas or fluid leakage, reducing the efficiency and performance of the electrolyzer. Overall, this approach results in complexity in the combined electrode assembly (UEA) design and reduced component life.

[0046] This disclosure describes a bipolar plate assembly for an electrolyzer. The electrolyzer described herein does not rely on a single, individual plate, but is manufactured from separate anode and cathode halves, which are welded together or bonded by conductive adhesive or brazing to form a bipolar plate assembly. Advantageously, the halves in this type of construction can be uniquely designed to support their specific electrochemical functions. In particular, the anolyte flow field (FF) can be configured with a concave flow field structure to achieve an increased or maximum water flow with a relatively low pressure drop. Conversely, the cathode flow field can be configured with a substrate channel pattern. Other advantages are possible. For example, in some embodiments, the manifolds in the corresponding anode and cathode halves can be asymmetrically positioned to provide relatively uncomplicated sealing for the anolyte and cathode flows, respectively. Furthermore, the use of the bipolar plate design enables tunneling for flow from the manifolds to the effective flow field region.

[0047] Figure 1 A simplified cross-sectional view of the membrane electrode assembly (MEA) layer 101 of an electrolyzer 100 according to one or more embodiments is depicted. Figure 1 As shown, the electrolyzer 100 includes a porous transport layer (PTL) 102 and a proton generating electrode 104 (also called an anode or H). + Generative electrode), membrane 106, proton consumption electrode 108 (also known as cathode or H) + The consumable electrode and the gas diffusion layer (GDL) 110 (sometimes referred to as the diffusion medium or DM) are constructed and arranged as shown in the figure. In this construction, protons (H) +The proton-generating electrode 104 is generated at the interface between the proton-generating electrode 104 and the membrane 106, and extends through the proton-consuming electrode 108. In some embodiments, the proton-generating electrode 104 and the proton-consuming electrode 108 are coupled to a power source (not shown separately) that supplies current across the anode and cathode, such that water supplied to the electrolyzer 100 can be decomposed into hydrogen and oxygen. The combination of the proton-generating electrode 104, the membrane 106, and the proton-consuming electrode 108 together defines a membrane electrode assembly (MEA) 109.

[0048] In some embodiments, PTL 102 facilitates the uniform distribution of the reactant stream (typically water) onto membrane 106 on proton generating electrode 104. PTL 102 also facilitates the efficient removal of byproducts, such as oxygen, from electrolyzer 100. In some embodiments, PTL 102 is made of materials that provide a combination of high conductivity, chemical stability, mechanical strength, and porosity, such as, for example, sintered titanium, stainless steel, carbon-based materials (such as carbon paper and carbon cloth), and nickel-based materials (such as nickel foam). It should be understood that while the embodiments herein illustrate PTL 102 as a single component, in other embodiments, PTL 102 may comprise multiple layers or components. The porous structure of PTL 102 allows water to pass through the active region of MEA 109 (reference 109). Figure 2 and Figure 3 The PTL 102 is uniformly distributed on the surface of the electrolyte, thereby enhancing the electrochemical reactions therein. Additionally, the PTL 102 provides electrical and mechanical support to the electrolyzer 100. In some embodiments, the PTL 102 supports the membrane 106 to resist the pressure difference between the anode and cathode sides of the battery. In some embodiments, a first side of the PTL 102 (not shown separately) faces the anode-side flow field 210 (see [link to relevant documentation]). Figure 2 The reactant stream 112 (e.g., water) enters the MEA layer 101, while the fluid 114 (e.g., unconsumed reactant stream and oxygen produced by the electrochemical reaction therein) exits the MEA layer 101.

[0049] In some embodiments, the proton generating electrode 104 is positioned directly below the PTL 102 and between the PTL 102 and the membrane 106. The proton generating electrode 104 is responsible for the oxidation of water molecules during electrolysis, producing oxygen and protons (H+). + Protons generated at the proton-generating electrode 104 pass through the membrane 106 to the proton-consuming electrode 108, while electrons flow through an external circuit (not shown separately). The proton-generating electrode 104 is designed to facilitate efficient electrochemical reactions, ensuring the desired hydrogen production, and can be coupled to the PTL 102 to ensure uniform water distribution and efficient oxygen removal.

[0050] In some embodiments, MEA 109 is located between PTL 102 and GDL 110. MEA 109 is the core functional unit of electrolyzer 100 and represents the active region where the main electrochemical reactions occur (anode-side flow field 210 and cathode-side flow field 310, see...). Figure 2 and Figure 3 This process converts electrical energy into chemical energy by splitting water into hydrogen and oxygen. MEA109 comprises several layers, including a proton exchange membrane (PEM, e.g., membrane 106), an anode catalyst layer (e.g., proton generating electrode 104), and a cathode catalyst layer (e.g., proton consuming electrode 108). The PEM is a solid polymer electrolyte that conducts protons (H+, H+, and H+). + The proton generation electrode 104 is sandwiched between membrane 106 and PTL 102 and contains finely divided catalyst particles, such as iridium (Ir) and / or titanium oxide particles. Conversely, the proton consumption electrode 108 is sandwiched between membrane 106 and GDL 110 and contains finely divided catalyst particles, such as platinum (Pt), supported by carbon particles. These catalyst layers adhere to both sides of the PEM and may contain finely divided catalyst particles supported by carbon particles. The catalyst layer can be coated on membrane 106, coated on PTL 102, coated on GDL 110, and / or decals can be transferred onto any one or all of membrane 106, PTL 102 and GDL 110.

[0051] In some embodiments, the proton consumption electrode 108 is located directly below the membrane 106 and between the membrane 106 and the GDL 110. The proton consumption electrode 108 is responsible for reducing protons (H+) during the electrolysis process. + The proton-consuming electrode 108 facilitates the efficient combination of protons that have already passed from the proton-generating electrode 104 through the membrane 106 with electrons that have already traveled through an external circuit (e.g., a power source, not separately indicated). The proton-consuming electrode 108 is designed to promote efficient electrochemical reactions, ensure desired hydrogen reduction, and can be coupled to the GDL 110 to ensure uniform removal of hydrogen from the electrolyzer 100.

[0052] In some embodiments, GDL 110 is a porous material, such as carbon fiber paper or cloth, that promotes uniform hydrogen discharge from MEA109. In some embodiments, a first side of GDL 110 (not shown separately) faces the cathode-side flow field 310 (see [link to relevant documentation]). Figure 3This facilitates the removal of reactants and byproducts 116 (typically hydrogen). It should be understood that while the illustrated embodiment shows GDL 110 as a single component, in other embodiments, GDL may comprise multiple layers or components.

[0053] Sub-pad 118 encapsulates the periphery of MEA109 and extends into the inactive region of electrolyzer 100 (i.e., respectively in...). Figure 2 , 3 (and various manifolds, seals, etc. of the anode half-plate 200, cathode half-plate 300, and MEA layer 101 in section 4).

[0054] Figure 2 A description is provided for an electrolyzer (e.g., according to one or more embodiments) Figure 1 The anode half-plate 200 of the bipolar plate assembly of the electrolyzer 100. For example... Figure 2 As shown, the anode half-plate 200 includes one or more anode-side inlet manifolds 202, one or more anode-side outlet manifolds 204, and one or more cathode-side outlet manifolds 206, constructed and arranged as shown in the figure (see Figure 200). Figure 3 ) and anode side flow field 210. While not implying any particular limitation, various components of the anode half plate 200 may be formed using techniques such as, for example, hydroforming, stamping, machining and / or chemical and electrochemical etching.

[0055] The anode-side inlet manifold 202 serves as the inlet point for the reactant stream (typically water) of the anode half-plate 200, which is used for the electrochemical reaction occurring within the anode-side flow field 210 (the anode active region). The primary function of the anode-side inlet manifold 202 is to uniformly distribute the incoming reactant stream (water) across the anode-side flow field 210. This ensures that water is supplied evenly to the active region where the electrochemical reaction occurs, resulting in efficient hydrogen production. In some embodiments, the anode-side inlet manifold 202 is arranged symmetrically and / or at uniform intervals (centerline-to-centerline spacing) to uniformly distribute the fluid into the anode-side flow field 210.

[0056] The anode-side outlet manifold 204 serves as an outlet point from the anode half-plate 200 for the reactant stream and any byproducts generated during the electrochemical reaction occurring within the anode-side flow field 210 (anode active region). The primary function of the anode-side outlet manifold 204 is to collect and remove the reactant stream (water) and any byproducts (e.g., oxygen) from the anode-side flow field 210 after the electrochemical reaction has occurred. This ensures that used fluids and gases are efficiently discharged from the active region, thereby reducing or preventing any buildup that could impede the efficiency of the electrolysis process. In some embodiments, the anode-side outlet manifold 204 is arranged symmetrically and / or at uniform intervals (centerline-to-centerline spacing) to uniformly distribute the fluid into the anode-side flow field 210.

[0057] like Figure 2 As further shown, in some embodiments, manifolds (e.g., anode-side inlet manifold 202 and / or anode-side outlet manifold 204) are connected to a series of anode-side fluid passages 212, which connect the anode-side inlet manifold 202 and the anode-side outlet manifold 204 to the anode-side flow field 210, respectively. In some embodiments, manifolds 202, 204 are sealed, and fluids (e.g., hydrogen, water, etc.) cannot flow directly from manifolds 202, 204 to the anode-side flow field 210 on the respective plates or seals. In some embodiments, the anode-side fluid passages 212 on the anode half-plate 200, when facing the cathode-side channel (or plate) of the cathode half-plate 300 (see [reference]...) Figure 3 ) Forming pathways between the various plates (see) Figure 5CIn other words, in some embodiments, fluid from manifolds 202, 204 will enter through corresponding fluid passages 212 and exit through orifices or openings 213 into the anode-side flow field 210. In some embodiments, fluid passages 212 are designed and positioned to reduce or minimize pressure loss and ensure uniform flow distribution. While not implying particular limitation, various techniques can be employed to reduce or minimize pressure loss and ensure uniform flow distribution, such as fluid passage geometry design, fluid passage layout, and fluid passage positioning. Fluid passage geometry design includes selecting the cross-sectional shape and / or aspect ratio of the fluid passage 212. Fluid passages with smooth, circular cross-sectional shapes (e.g., circular or elliptical) tend to have lower pressure loss compared to sharp-edged or rectangular fluid passages because the smooth shape reduces turbulence and friction losses. The aspect ratio (width-to-height ratio) of the fluid passage 212 should be optimized to balance flow resistance and structural integrity. Fluid passages that are too narrow may increase pressure loss, while fluid passages that are too wide may compromise the mechanical strength of the plate. In one embodiment, the fluid passage layout can also be optimized and may include selecting parallel fluid passages and / or branching fluid passages for fluid distribution. Fluid passages 212 can be constructed in parallel to distribute fluid uniformly. In some embodiments, each parallelly arranged fluid passage 212 has the same or similar (within processing constraints) length and cross-sectional area to ensure uniform flow velocity. Conversely or additionally, fluid passages 212 can be arranged in branching patterns, such as tree-like or fractal designs. These patterns divide the flow into smaller flows, ensuring that fluid reaches all areas of the anode-side flow field 210. Fluid passage positioning refers to the relative positioning of the fluid passage 212 with respect to the anode-side flow field 210 and the manifolds (anode-side inlet manifold 202 and anode-side exhaust manifold 204). In some embodiments, fluid passages 212 can be symmetrically positioned about the central axis of the anode-side flow field 210 to ensure uniform distribution. Alternatively, in some embodiments, asymmetric positioning can be utilized to guide the target flow volume to any area within the anode-side flow field 210 (this approach can be helpful based on pressure imbalances found empirically or during simulation, for example, using computational fluid dynamics (CFD) simulations). It should be understood that the geometry, layout, and positioning of fluid pathways will vary depending on the needs of a given application. In some embodiments, CFD simulation tools can be used to improve or optimize these parameters.

[0058] In some embodiments, the manifold seal 214 isolates the manifold (e.g., the anode-side inlet manifold 202, the anode-side outlet manifold 204, and / or the cathode-side outlet manifold 206) from the anode-side flow field 210. In some embodiments, the manifold seal 214 is a metal bead seal (e.g., a symmetrical metal bead configuration of the bipolar plate 500 or an asymmetrical metal bead configuration of the bipolar plate 550, see [link]). Figure 5A and 5BHowever, other configurations, such as elastomeric seals on a metal plate only (i.e., without metal bead seals), are also possible, and all such configurations are within the scope of this disclosure. In some embodiments, manifold seal 214 is formed on the anode-side fluid passage 212, thereby allowing flow between the manifold and the anode-side flow field 210.

[0059] The anode-side flow field 210 is responsible for uniformly distributing the reactant stream (typically water) across the surface of the anode active region, thereby promoting efficient electrochemical reactions. In some embodiments, the anode-side flow field 210 is configured as a pitted flow field for efficient fluid flow. In this pitted flow field configuration, the anode-side flow field 210 includes a series of pits 216 or protrusions arranged in a regular pattern. The pits 216 generate localized turbulence, enhancing mass transfer and reducing pressure loss. This configuration is particularly effective in ensuring uniform distribution of the reactant stream and efficient removal of oxygen.

[0060] Figure 3 A cathode half-plate 300 according to one or more embodiments is depicted. For example... Figure 3 As shown, the cathode half-plate 300 includes one or more anode-side inlet manifolds 202 (see Figure 1). Figure 2 ), one or more anode-side outlet manifolds 204 (see Figure 2 One or more cathode-side outlet manifolds 206 and cathode-side flow fields 310 are constructed and arranged as shown in the figure. While not implying any particular limitation, various components of the cathode half-plate 300 can be formed using techniques such as, for example, hydroforming, stamping, machining and / or chemical and electrochemical etching.

[0061] The cathode-side outlet manifold 206 serves as the outlet point for hydrogen generated during the electrochemical reaction occurring within the cathode-side flow field 310 (cathode active region) of the cathode half-plate 300. The primary function of the cathode-side outlet manifold 206 is to collect and remove hydrogen generated from the cathode-side flow field 310 after the electrochemical reaction has occurred, as well as any anolyte-side reactant fluid transported to the cathode-side flow field 310 via membrane diffusion. This ensures that used fluids and gases are efficiently discharged from the active region, thereby reducing or preventing any buildup that could impede the efficiency of the electrolysis process. In some embodiments, the cathode-side outlet manifold 206 is arranged symmetrically and / or at uniform intervals (centerline-to-centerline pitch) to uniformly distribute fluid to the cathode-side flow field 310.

[0062] like Figure 3Further shown, in some embodiments, a manifold (e.g., cathode-side outlet manifold 206) is connected to a series of cathode-side fluid passages 312 that connect the cathode-side outlet manifold 206 to the cathode-side flow field 310. In some embodiments, the cathode-side outlet manifold 206 is sealed, and fluid (e.g., hydrogen) cannot directly reach the cathode-side flow field 310 from the cathode-side outlet manifold 206 via a corresponding plate or seal. In some embodiments, the cathode-side fluid passages 312 on the cathode half-plate 300, when facing the anode-side channel (or plate) of the anode half-plate 200 (see... Figure 2 ) Forming pathways between the corresponding plates (see Figure 5C In other words, in some embodiments, fluid from the cathode-side outlet manifold 206 will enter through a corresponding fluid passage 312 and exit through a hole or opening 313 into the cathode-side flow field 310. In some embodiments, the fluid passage 312 is designed and positioned in accordance with the previous description of fluid passage 212 (refer to...). Figure 2 The method described is similar to reducing or minimizing pressure loss and ensuring uniform flow distribution.

[0063] Fluid passages 312 can be arranged in parallel configurations to uniformly distribute fluid. In some embodiments, each parallelly arranged fluid passage 312 has the same or similar (within tool limitations) length and cross-sectional area to ensure uniform flow velocity. Conversely or additionally, fluid passages 312 can be arranged in branching patterns, such as tree-like or fractal designs. These patterns divide the flow into smaller streams, ensuring that fluid reaches all areas of the cathode-side flow field 310. In some embodiments, fluid passages 312 can be symmetrically positioned about the central axis of the cathode-side flow field 310 to ensure uniform distribution. Alternatively, in some embodiments, asymmetric positioning can be utilized to direct the target flow rate to any area within the cathode-side flow field 310 (this approach can help with pressure imbalances discovered empirically or during simulation, e.g., using CFD simulation). It should be understood that channel geometry design, channel layout, and channel positioning will vary depending on the needs of a given application. In some embodiments, CFD simulation tools can be used to refine or optimize these parameters.

[0064] In some embodiments, the manifold seal 214 isolates the manifold (e.g., the anode-side inlet manifold 202, the anode-side outlet manifold 204, and / or the cathode-side outlet manifold 206) from the cathode-side flow field 310. In some embodiments, the top cover seal 214 is a metal bead seal (see...). Figure 5A and 5BHowever, other configurations (such as elastomeric seals on metal plates) are also possible, and all such configurations are within the scope of this disclosure. In some embodiments, manifold seal 214 is formed on cathode-side fluid passage 312, thereby allowing flow between manifold and cathode-side flow field 310.

[0065] The cathode-side flow field 310 is responsible for uniformly distributing the reactant and product fluids (hydrogen) on the surface of the cathode active region, thereby promoting efficient electrochemical reactions. In some embodiments, the cathode-side flow field 310 is configured as a substrate channel flow field to reduce or minimize interfacial contact resistance and reduce gas diffusion layer (GDL) intrusion. In the substrate channel configuration, the flow field consists of alternating substrates (raised regions) and channels (recessed regions). The substrates provide direct mechanical support to the GDL (not shown separately), preventing it from sagging or intruding into the channels. This structural support helps maintain the integrity and position of the GDL, reducing the risk of intrusion. In the substrate channel field structure, the cathode-side flow field 310 includes a substrate channel 316, which, as needed, can be arranged as a wavy channel structure, a straight channel structure (such as... Figure 3 (as shown) or cross-channel structure.

[0066] Now for reference Figure 2 and Figure 3 In some embodiments, the manifolds of the anode half-plate 200 (e.g., anode-side inlet manifold 202 and anode-side outlet manifold 204) and the manifolds of the cathode half-plate 300 (e.g., cathode-side outlet manifold 206) are asymmetrically assembled, wherein fluid flow in the anode half-plate 200 is at a 90° angle to fluid flow in the cathode half-plate 300. For example, in Figure 2 In the configuration shown, the anode-side flow direction 218 continuously moves an anode-side fluid, such as water, along a first direction (as shown) between the anode-side inlet manifold 202, the anode-side flow field 210, and the anode-side outlet manifold 204. Conversely, in Figure 3 In the configuration shown, the cathode-side flow direction 318 causes the cathode-side fluid (e.g., hydrogen) to move continuously between the cathode-side flow field 310 and the cathode-side outlet manifold 206 in a second direction orthogonal to the first direction (as shown, from within the cathode-side flow field 310 to the cathode-side outlet manifold 206).

[0067] Figure 4 Views of an electrolyzer 100 (also called an electrolytic cell) according to one or more embodiments are depicted. Figure 4As shown, the electrolyzer 100 includes two anode half-plates 200 and two cathode half-plates 300 arranged in an alternating configuration. The electrolyzer 100 also includes an MEA layer 101 (also referred to as a gasket-type MEA with GDL and PTL). In some embodiments, an anode half-plate 200 and a cathode half-plate 300 are paired on each side of the MEA layer 101. Figure 4 As further shown, the electrolyzer 100 includes multiple inlets 404, multiple outlets 406, and multiple hydrogen outlets 408 and 410 (see [reference]). Figure 2 and Figure 3 It was observed that, advantageously, the flow field of the anode half-plate 200 is a pit flow field structure, while the flow field of the cathode half-plate 300 is a base channel flow field structure.

[0068] Figure 5A A cross-sectional view of a bipolar plate 500 having a symmetrical metal bead structure according to one or more embodiments is depicted. Figure 5B A cross-sectional view of a bipolar plate 550 having an asymmetric metal bead structure according to one or more embodiments is depicted. Figure 5A and 5B As shown, bipolar plates 500 and 550 may include an anode half-plate 200, which is connected to a cathode half-plate 300 using one or more welds 502 in symmetrical and asymmetrical metal bead sealing configurations, respectively. The welds 502 may be supported by or replaced by other sealing mechanisms, such as adhesives and / or brazing. Whether symmetrical or asymmetrical, the metal bead seals typically consist of raised metal ridges or beads (not shown separately) integrated into the surface of the respective bipolar plate (e.g., anode half-plate 200 and / or cathode half-plate 300). In some embodiments, a relatively thin (e.g., less than 150 micrometers, such as 50 to 130 micrometers) elastomeric layer 504 may be attached to the topmost and / or bottommost surfaces 506 of the metal beads (not shown separately) of the respective half-plate. The thin elastomeric layer 504 may be fabricated by screen printing, dispensing, etc.

[0069] Specifically, Figure 5A A symmetrical metal bead structure is depicted, wherein the anode half-plate 200 and the cathode half-plate 300 have metal beads of similar sealing height (within processing or manufacturing limitations). Conversely, Figure 5B An asymmetric metal bead structure is depicted, wherein the anode half-plate 200 and the cathode half-plate 300 have different metal bead heights. In both embodiments, the anode half-plate and the cathode half-plate may have different thicknesses. Advantageously, Figure 5BThe asymmetric metal bead construction shown allows the bipolar plate 550 to be individually modified as needed for the respective anode and cathode subsystems to support their respective functions. For example, in some embodiments, the anode half-plate 200 is relatively thicker than the cathode half-plate 300 (as shown). This type of asymmetric construction allows for deeper anode-side protrusions compared to cathode protrusions, which can better accommodate relatively higher water flows through the anode half-plate 200.

[0070] In any case, the use of two separate half-plates (e.g., anode half-plate 200 and cathode half-plate 300) that can be welded together in this manner or otherwise fixed or glued together greatly simplifies any channel features near the manifold (see [link]). Figure 2 and Figure 3 The fabrication of these features for robust fluid flow and distribution to their respective active regions is possible because these features can be directly formed into the anode half-plate 200 and cathode half-plate 300 by hydroforming, stamping, machining and / or chemical and electrochemical etching of the corresponding halves of the channel features (e.g., top and bottom).

[0071] Figure 5C Depicting according to one or more embodiments Figure 2 A cross-sectional view of region AA of the anode half-plate. (See diagram below.) Figure 5C As shown, the anode half-plate 200 and the cathode half-plate 300 are shaped to jointly define an anode-side fluid passage 212 after joining. Although specifically shown with respect to the anode half-plate 200, the cathode-side fluid passage 312 can be similarly defined, and all such configurations are within the scope of this disclosure.

[0072] Figure 6 Examples of embodiments of a computer system 600 capable of performing various aspects of the embodiments described herein are illustrated. In some embodiments, one or more computer systems 600 may implement an electrolyzer system and / or otherwise incorporate into or combine with an electrolyzer system, such as an electrolyzer system consisting of separate anode and cathode half-plates (see...). Figure 2 and Figure 3 Electrolyzer 100 manufactured by (see) Figure 1 For example, in some embodiments, the computer system 600 may apply or receive signals (e.g., voltage, current, etc.) to cause one or more fluids (e.g., water, hydrogen, etc.) to enter and / or leave the electrolyzer 100.

[0073] Computer system 600 includes at least one processing device 602, which typically includes one or more processors or processing units for performing various functions, such as any and / or all of the functions previously described herein. Components of computer system 600 also include system memory 604 and a bus 606 that connects various system components, including system memory 604, to processing device 602. System memory 604 may include various computer system readable media. Such media can be any available media accessible by processing device 602 and includes volatile and non-volatile media, as well as removable and non-removable media. For example, system memory 604 includes non-volatile memory 608 such as a hard disk drive and may also include volatile memory 610, such as random access memory (RAM) and / or cache memory. Computer system 600 may also include other removable / non-removable, volatile / non-volatile computer system storage media.

[0074] System memory 604 may include at least one program product having a set (e.g., at least one) of program modules configured to perform the functions of the embodiments described herein. For example, system memory 604 stores various program modules that generally perform the functions and / or methods of the embodiments described herein. One or more modules 612, 614 may be included to perform functions associated with any block diagram described herein. Computer system 600 is not limited thereto, as other modules may be included depending on the desired functionality of computer system 600. As used herein, the term "module" refers to processing circuitry that may include application-specific integrated circuits (ASICs), electronic circuitry, processor (shared, dedicated, or group) and memory executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components that provide the described functions.

[0075] The processing device 602 may also be configured to communicate with one or more external devices 616, such as, for example, a keyboard, pointing devices, and / or any device that enables the processing device 602 to communicate with one or more other computing devices (e.g., a network interface card, a modem, etc.). Communication with various devices may occur via input / output (I / O) interfaces 618 and 620.

[0076] Processing device 602 can also communicate with one or more networks 622, such as a local area network (LAN), a general wide area network (WAN), a bus network, and / or a public network (e.g., the Internet), via network adapter 624. In some embodiments, network adapter 624 is or includes an optical network adapter for communication over an optical network. It should be understood that, although not shown, other hardware and / or software components may be used in conjunction with computer system 600. Examples include, but are not limited to, microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, and data archiving storage systems.

[0077] Now for reference Figure 7 A flowchart 700, generally illustrating the use of a bipolar plate assembly for an electrolytic cell, is shown according to an embodiment. (See reference...) Figure 1-6 Describe flowchart 700, and flowchart 700 may include Figure 7 Additional steps not depicted. Although depicted in a specific order, Figure 7 The blocks depicted can be rearranged, subdivided, and / or combined.

[0078] At block 702, the method includes forming an anode half-plate having one or more inlet manifolds, an anode-side flow field connected to the one or more inlet manifolds, and one or more outlet manifolds connected to the anode-side flow field. In some embodiments, the anode-side flow field is a pitted flow field having a series of pits.

[0079] At block 704, the method includes forming a cathode half-plate coupled to the anode half-plate. In some embodiments, the cathode half-plate includes a cathode-side flow field and one or more outlet manifolds coupled to the cathode-side flow field. In some embodiments, the cathode-side flow field includes a base-channel flow field having alternating bases and channels. In some embodiments, the cathode-side flow field is a base-channel flow field having alternating bases and channels.

[0080] At frame 706, the method includes securing an anode half-plate to a cathode half-plate, thereby defining a bipolar plate assembly for an electrolyzer. While not intended to be particularly limiting, in some embodiments, the anode half-plate and cathode half-plate are welded together to form a single bipolar plate assembly.

[0081] In some embodiments, the anode half-plate and the cathode half-plate are assembled asymmetrically such that the fluid flow in the anode half-plate is rotated 90 degrees relative to the fluid flow in the cathode half-plate.

[0082] In some embodiments, the anode half-plate and the cathode half-plate together define a single separator of the electrolyzer.

[0083] In some embodiments, the anode half-plate and the cathode half-plate have the same thickness.

[0084] In some embodiments, the anode half-plate has a first thickness, and the cathode half-plate has a second thickness less than the first thickness.

[0085] In some embodiments, the inlet and outlet manifolds of the anode half-plate and the outlet manifold of the cathode half-plate are sealed and isolated from the anode-side flow field and the cathode-side flow field.

[0086] In some embodiments, the anode-side tunnel connects the anode-side inlet manifold and the anode-side outlet manifold to the anode-side flow field, respectively.

[0087] In some embodiments, the cathode-side tunnel connects the cathode-side outlet manifold to the cathode-side flow field.

[0088] In some embodiments, the cathode half-plate and the anode half-plate are connected via a symmetrical metal bead structure.

[0089] In some embodiments, the cathode half-plate includes a first metal bead height, and the anode half-plate includes a second metal bead height that is different from the first metal bead height.

[0090] In some embodiments, the inlet and outlet manifolds of the cathode half-plate and the anode half-plate are sealed with elastomeric beads.

[0091] In some embodiments, the method includes forming beaded protrusions on a manifold of an anode half-plate. In some embodiments, the method includes forming beaded protrusions on a manifold of a cathode half-plate. In some embodiments, beaded protrusions on the anode half-plate engage with beaded protrusions on the cathode half-plate to form a beaded seal.

[0092] In some embodiments, the anode half-plate has bead-like protrusions surrounding the anode-side inlet manifold and the anode-side outlet manifold, forming a seal to restrict fluid flow. In some embodiments, the cathode half-plate has bead-like protrusions surrounding the cathode-side outlet manifold, forming a seal to restrict fluid flow.

[0093] In some embodiments, an elastomeric material is applied to the beaded protrusions of the anode and cathode halves.

[0094] In some embodiments, bead-like protrusions on the anode and cathode halves are aligned to provide a sealing function.

[0095] In some embodiments, the heights of the beaded protrusions on the anode and cathode halves are asymmetrical. In some embodiments, the height of the beaded protrusions on the anode halves may be greater than the height of the beaded protrusions on the cathode halves. In some embodiments, the beaded seals on both the cathode and anode halves are made solely of elastomer.

[0096] The terms “a” and “an” do not indicate a limitation of quantity, but rather that at least one of the referenced items is present. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Throughout the specification, the reference to “aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in the aspects.

[0097] Furthermore, as used in this disclosure, phrases such as "at least one of A, B, or C" or "at least one of A, B, and C" should be interpreted as selecting at least one from the group including "A, B, and C". Unless explicitly stated otherwise in conjunction with specific examples in this disclosure, this phrasing does not imply "at least one of A, at least one of B, and at least one of C". As used in this disclosure, the example "at least one of A, B, or C" would cover any of the following selections: {A}, {B}, {C}, {A,B}, {A,C}, {B,C}, and {A,B,C}.

[0098] When an element, such as a layer, film, region, or substrate, is referred to as being “on” another element, it can be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being “directly” on another element, there are no intermediate elements present.

[0099] Unless otherwise stated herein, all test standards are the most recent standards in force as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which a test standard appears.

[0100] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0101] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A bipolar plate assembly for an electrolyzer, the bipolar plate assembly comprising: An anode half-plate, the anode half-plate comprising one or more anode-side inlet manifolds, an anode-side flow field connected to the one or more anode-side inlet manifolds, and one or more anode-side outlet manifolds connected to the anode-side flow field, the anode-side flow field comprising a pitted flow field having a series of pits; and A cathode half-plate connected to the anode half-plate, the cathode half-plate including a cathode-side flow field and one or more cathode-side outlet manifolds connected to the cathode-side flow field, the cathode-side flow field including a base-channel flow field having alternating bases and channels.

2. The bipolar plate assembly according to claim 1, wherein, The anode half-plate and the cathode half-plate are assembled asymmetrically such that the fluid flow in the anode half-plate is rotated 90 degrees relative to the fluid flow in the cathode half-plate.

3. The bipolar plate assembly according to claim 1, wherein, The anode half-plate and the cathode half-plate together define a single partition of the electrolyzer.

4. The bipolar plate assembly of claim 3, wherein the anode half-plate and the cathode half-plate have the same thickness.

5. The bipolar plate assembly according to claim 3, wherein, The anode half-plate has a first thickness, and the cathode half-plate has a second thickness less than the first thickness.

6. The bipolar plate assembly according to claim 1, wherein, The one or more anode-side inlet manifolds and the one or more anode-side outlet manifolds of the anode half-plate, and the one or more cathode-side outlet manifolds of the cathode half-plate, are sealed relative to the anode-side flow field and the cathode-side flow field.

7. The bipolar plate assembly of claim 6 further includes an anode-side tunnel, the anode-side tunnel connecting the one or more anode-side inlet manifolds and the one or more anode-side outlet manifolds to the anode-side flow field, respectively.

8. The bipolar plate assembly of claim 6 further includes a cathode-side tunnel connecting the one or more cathode-side outlet manifolds to the cathode-side flow field.

9. The bipolar plate assembly according to claim 1, wherein, The cathode half-plate and the anode half-plate are connected via a symmetrical metal bead structure.

10. The bipolar plate assembly according to claim 1, wherein, The cathode half-plate includes a first metal bead height, and the anode half-plate includes a second metal bead height that is different from the first metal bead height.

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