Electrode plates for liquid and gas transport

Abstract

In one aspect, an electrode sheet (5) is provided that is designed for metallization for liquid and gas transport. The electrode sheet (5) designed for liquid and gas transport includes a polymer substrate (1) having a first facet and a second facet, the first and second facets being designed for metallization to act as current collectors. The first facet and / or the second facet of the polymer substrate (1) includes a structured surface having a channel pattern (3). The polymer substrate (1) further includes a plurality of through-holes (2) through the substrate (1) to connect the channel (3) pattern to opposite facets of the polymer substrate (1).

Description

Technical Field

[0001] This disclosure relates to an electrode sheet for efficiently transporting liquids and gases, a membrane electrode assembly (MEA) including the electrode sheet, an apparatus including the electrode sheet designed for liquid and gas transport, and a method for manufacturing the electrode sheet designed for liquid and gas transport. Background Technology

[0002] Electrode plates designed for liquid and gas transport are commonly found in the hydrogen industry, and more specifically in fuel cells and electrolyzers.

[0003] An electrolyzer is an electrochemical energy converter that uses electrical energy to decompose water (H2O) into hydrogen (H2) and oxygen (O2). Different electrolyzer designs are known in this industry, such as low-temperature proton exchange membrane (PEM) electrolyzers, anodic PEM electrolyzers, alkaline electrolyzers, and various high-temperature solid oxide (SO4) electrolyzers. Typical reactions at the anode and cathode of a PEM electrolyzer are as follows: - Anode: 2H₂O → O₂ + 4H₂O + + 4e - - Cathode: 2H + + 2e - → H2 A fuel cell is an electrochemical cell that converts the chemical reaction energy of a continuously supplied fuel and oxidant into electrical energy. Therefore, a fuel cell is an electrochemical energy converter. Among known fuel cells, hydrogen (H2) and oxygen (O2) are specifically converted into water (H2O), electrical energy, and heat. Different fuel cell designs exist, such as proton exchange membrane (PEM) fuel cells, phosphoric acid fuel cells, solid acid fuel cells, alkaline fuel cells, and several high-temperature fuel cells (such as, for example, solid oxide fuel cells and molten carbonate fuel cells).

[0004] For fuel cells, water can be formed by absorbing electrons from the external circuitry and protons that have traveled through the membrane to the cathode, rather than by decomposing the water into oxygen and hydrogen. Water formed in this way can be discharged from the fuel cell. The net reaction is: - Anode: H2 → 2H + + 2e - - Cathode: O2 + 4H + + 4e - → 2H2O One of the most common types of electrolyzers and fuel cells today is the proton exchange membrane (PEM) electrolyzer or fuel cell. PEMs are easily identifiable because the cathode and anode sides are separated by a polymer electrolyte membrane (such as a polyfluoroalkyl-based polymer). Typically, a PEM electrolyzer or fuel cell includes bipolar plates, electrodes, one or more catalyst layers, an electrolyte membrane, one or more current collectors, and one or more liners. One of the main disadvantages of PEM electrolyzers or fuel cells is their relatively high cost and low durability, which limits their introduction and penetration into various industries.

[0005] A key aspect associated with the high cost of PEM devices is the use of large and heavy bipolar plates (BPPs). BPPs, for example, account for approximately 20% of the component cost of a fuel cell or electrolyzer. Currently, most BPPs are made of metals such as titanium. Therefore, the high cost of BPPs is primarily related to the high cost of raw materials and the manufacturing costs of forming the channels required for high temperatures and pressures. Furthermore, the BPPs are coated with a corrosion-resistant layer. In a PEM device, the BPP is responsible for transporting and distributing reactant gases, can act as a current collector, provides heat and water management, and isolates the individual cells located within a single PEM device.

[0006] Another major cost factor is related to the membrane electrode assembly (MEA), particularly the raw materials used to assemble the membrane. Generally, raw materials are expected to account for 60% of the total cost of a fuel cell / electrolyzer.

[0007] Furthermore, when assembling single cells and / or stacks, the BPP and MEA require separate handling because the BPP currently requires process steps that exceed the limitations of the materials used within the MEA, such as temperature tolerance. This increases the number of production steps and makes device manufacturing more complex, resulting in high costs associated with PEM devices.

[0008] Furthermore, components of PEM devices (such as electrolyzers and fuel cells) are not currently fully optimized for specific applications. Therefore, PEM devices also utilize costly and suboptimal porous transport layers (PTLs). In addition, PEM devices involve the poor use of rare and expensive catalyst materials, poorly optimized surfaces for electrocatalytic activity, and the use of non-environmentally friendly base membrane materials.

[0009] To facilitate the reaction and transport of reactants, protons, or reaction products, various materials typically include poorly optimized pore sizes and / or pore distributions. This, in turn, limits proper movement within electrolyzers or fuel cells. Furthermore, as mentioned earlier, porous transport layers are currently primarily assembled with structured bipolar plates to accommodate the distribution of reactants and products in gaseous or liquid forms.

[0010] This invention aims to simplify and optimize the design and / or assembly of electrode sheets, membrane electrode assemblies, or PEM devices for liquid and gas transport, thereby reducing the cost, weight, or complexity of electrolyzers and / or fuel cells. Furthermore, this invention can be manufactured using a continuous process. Summary of the Invention

[0011] This disclosure relates to an electrode sheet designed for metallization for liquid and gas delivery, addressing one or more bottlenecks encountered in the fabrication of PEM devices, such as unoptimized porous delivery layers (PTLs), unimproved utilization of costly rare catalysts, high weight of bipolar plates, and / or limitations in manufacturing scalability.

[0012] Therefore, electrode sheets designed for metallization for liquid and gas transport have been developed. These electrode sheets, designed for metallization for liquid and gas transport, include a polymer substrate layer comprising a first side and a second side. The electrode sheets designed for metallization for liquid and gas transport can act as current collectors. The first and / or second side of the polymer substrate layer includes structured surfaces with channel patterns. Furthermore, the polymer substrate layer includes a plurality of through-holes to connect the channel patterns to opposite sides of the polymer substrate layer. The structured surfaces facilitate the diffusion and uniform distribution of reagents (e.g., water (H2O)) or gases (such as hydrogen (H2)) and / or reaction products. The multiple through-holes can allow for easy and / or optimized transport from the inlet to the catalyst layer, or facilitate the disposal of various reaction products.

[0013] The polymer substrate, including a structured surface and multiple vias, may further have functional layers and / or metallization layers. Optional functionalization of the polymer substrate can produce improved anchoring between the polymer substrate and the metallization layer. Furthermore, the metallization layer can act as an electrode, a current collector, and / or optionally remove heat generated during the reaction.

[0014] The channel pattern in the gas-permeable sheet may further include multiple interconnecting trenches. The trenches may have a width ranging from 0.1 µm to 100 µm. The trenches increase the electrochemically active area, thus increasing the efficiency of the PEM device and / or facilitating the distribution of reagents and / or products after the anodic or cathodic reaction.

[0015] Furthermore, when selecting applications such as electrolyzers or fuel cells, the design of the electrode sheets for liquid and gas transport according to the present invention can be further optimized by selecting a through-hole diameter in the range of 0.05µm to 100µm.

[0016] In another aspect of the invention, the metallization layer provided on a sheet designed for liquid and gas delivery may have a thickness ranging from 0.01 µm to 150 µm. Furthermore, the metallization layer may be selected from the group consisting of titanium, tantalum, niobium, platinum, gold, or other suitable metals. Reducing the metallization layer can positively impact the weight of the PEM device and optionally reduce the cost of the PEM device because the amount of metal can be reduced. In another aspect of the invention, the metallization layer may completely cover the polymer substrate layer. Therefore, the fully metallized polymer substrate layer may optionally serve as a bipolar plate and / or current collector. The fully metallized layer can further reduce the weight and / or thickness of the PEM device.

[0017] In another aspect of the invention, the anode stack may include electrode sheets designed according to the invention for liquid and gas delivery. The anode stack may be permeable to anolyte reagents and / or reaction products. The anode stack layers further include a first catalyst layer to facilitate anolyte reactions, such as the decomposition of H₂O into H₂ in an electrolyzer. + O2 and e - The channel pattern in the electrode sheet designed for liquid and gas transport, including the first catalyst layer, can point towards the electrolyte layer. The electrolyte layer separates the anode stack from the cathode stack. An anode stack including electrode sheets designed for liquid and gas transport can have the advantage of a thinner stack, which can increase the number of cells per volume.

[0018] In another aspect of the invention, the membrane electrode assembly (MEA) includes an anode stack according to the invention. The MEA further includes an electrolyte, which may optionally include a membrane and / or a cathode stack.

[0019] In another aspect of the invention, the cathode stack includes a second catalyst layer. The cathode stack is permeable to cathode reaction products and / or reactants. The cathode gas-permeable electrode sheet may further include a gas-permeable electrode sheet according to the invention, thereby optionally further optimizing the thickness and weight of the membrane electrode assembly. In another aspect of the invention, the membrane electrode assembly according to the invention may have a thickness in the range of 100 µm to 500 µm.

[0020] In another aspect of the invention, the electrolysis apparatus includes at least one membrane electrode assembly according to the invention. The electrolysis apparatus may further include one or more outlets, one or more inlets, a power source, and optionally one or more bipolar plates, at least one flow field or current collector. Attached Figure Description

[0021] These and other features, aspects, and advantages of the apparatus, systems, and methods of this disclosure will become more readily understood from the following description, the appended claims, and the accompanying drawings, in which: Figure 1A An optical microscope top view of the polymer substrate according to the present invention is shown; Figures 1B to 1D A scanning electron microscopy (SEM) image of the polymer substrate according to the present invention is shown; Figure 2A Showing Figure 1A The polymer substrate layer depicted in the figure further includes a functional layer; Figure 2B Showing Figure 1A The polymer substrate layer depicted in the figure further includes a metallization layer; Figure 2C Showing Figure 2B The polymer substrate layer depicted in the figure further includes a first catalyst layer; Figure 3 Showing Figure 2C A schematic unfolded diagram; Figure 4 An electrolysis device including a single-cell battery is shown; Figure 5 Two were shown Figure 4 The single-cell battery unit depicted in the text; Figure 6 A single-cell electrolysis device is shown. Detailed Implementation

[0022] The terminology used to describe particular embodiments is not intended to limit the invention. As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well. The term “and / or” includes any and all combinations of one or more of the associated listed items. It should be understood that the terms “comprises” and / or “comprising” specify the presence of a stated feature but do not exclude the presence or addition of one or more other features. It should be further understood that, unless otherwise specified, when a particular step of a method is referred to as following another step, that particular step may be performed directly after that other step or may be performed before that particular step by one or more intermediate steps. Similarly, it should be understood that, unless otherwise specified, when describing a connection between structures or components, the connection may be established directly or through intermediate structures or components.

[0023] As used herein, the term "electrode sheet designed for liquid and gas delivery" refers to a sheet capable of permeating and dispensing anodic and / or cathodic reaction reagents and / or anodic and / or cathodic reaction products. The reagents and / or products may be in liquid and / or gaseous form.

[0024] The invention will be described more fully below with reference to the accompanying drawings, in which embodiments of the invention are illustrated. In the drawings, for clarity, the absolute and relative sizes of systems, components, layers, and regions may be enlarged. Embodiments may be described with reference to schematic and / or cross-sectional views of possible idealized embodiments and intermediate structures of the invention. Throughout the description and figures, the same numbers refer to the same elements. Relative terms and their derivatives should be interpreted as referring to orientations as described thereafter or shown in the figures discussed. These relative terms are for ease of description, and unless otherwise indicated, it is not necessary to construct or operate the system in a specific orientation.

[0025] The growing focus on green energy alternatives has led to increased attention on the development of hydrogen-related technologies. By producing hydrogen from water in an electrolyzer, renewable electricity can be stored as chemical energy. The produced hydrogen can be stored and thus used to generate electricity using fuel cells. For example, when H2O is converted to H2O... + O2 and e - When the required energy is supplied by environmental energy systems such as solar panels and windmills, electrolyzers and fuel cells can both be considered green alternatives. Therefore, using renewable energy to produce hydrogen from water electrolysis can be considered an important solution for long-term energy storage. Furthermore, electrolyzers can contribute to the decarbonization of various industries.

[0026] To date, various electrolyzers have been introduced to the market, such as proton exchange membrane (PEM) electrolyzers, anolyte membrane electrolyzers, alkaline electrolyzers, and solid oxide electrolyzers. Currently, PEM stacks are considered the most dynamic and efficient water electrolysis system for producing very high H2 purity. A key bottleneck with PEM stacks is the manufacture of affordable, high-performance PEM stacks, which limits the expansion of PEM-based systems.

[0027] The high cost of PEM stacks related to manufacturing processes is related to the following: 1. High-cost bipolar plates 2. Costly and suboptimal porous transport layer (PTL) 3. Insufficient utilization of valuable and rare catalyst materials. 4. Insufficient surface optimization for electrocatalytic activity. 5. Using non-environmentally friendly membrane materials as electrolyte materials. 6. Manufacturing scalability issues.

[0028] Typically, PTLs may include titanium (Ti) structures. Ti structures can act as current collectors and / or supports for electrochemically active regions within the PEM stack. The Ti layer will be applied primarily using conventional processes such as chemical vapor deposition. Currently, PTLs are not optimized for electrolytic applications. In particular, the bulk geometry, 3D structure, and surface terminations are not fully optimized for use in PEM devices. This adversely affects the cost of the PEM device.

[0029] A conventional single-cell battery comprises a porous transport layer, an active layer, and a current collector. The porous transport layer is used to uniformly distribute incoming gas toward the active layer. The active layer may further include a catalyst layer, which supports and facilitates the reaction mechanism to convert reactants into corresponding ions and electrons. Electrons can be collected by the current collector, while ions or protons can be transported across the entire electrolyte and / or porous membrane. Protons will combine with electrons or with oxygen and electrons, respectively, in the electrolyzer or fuel cell.

[0030] A membrane electrode assembly (MEA) may include a porous anode transport layer, an electrolyte material (such as a polyfluoroalkyl-based polymer membrane), and a porous cathode transport layer. Currently, MEA single cells can be constructed from a hybrid organic / inorganic porous transport layer, a current collector, an electrocatalyst, and a proton-conducting membrane, thereby allowing PEM water electrolysis with high surface area and high material utilization.

[0031] To manufacture an electrolyzer or fuel cell, the MEA may further include bipolar plates and support structures to facilitate the supply and disposal of reactant gases and final products (such as hydrogen or water, respectively, for the electrolyzer or fuel cell).

[0032] One aspect of the present invention is to provide an electrode sheet designed for liquid and gas delivery that is suitable for metallization. The electrode sheet designed for liquid and gas delivery further provides a solution to one or more of the reasons mentioned above related to the high cost of manufacturing PEM stacks. Furthermore, the present invention may be able to replace at least a porous delivery layer.

[0033] Compared to conventional manufacturing methods, the electrode sheet designed for liquid and gas transport according to the present invention can be engineered or designed to achieve high performance, better integration, and reduced material usage. The sheet can be manufactured separately and used as an independent assembly product in the assembly of electrode sheets designed for liquid and gas transport. This product can be produced separately for use in electrode stacks of an electrolysis device, particularly anode or cathode stacks. Therefore, the thickness of the electrode sheet designed for liquid and gas transport can be reduced. In a preferred embodiment, the thickness can be reduced by at least 2 times, more preferably at least 5 times, and most preferably at least 10 times. Therefore, more individual cell units can be integrated into a stack of the same volume. Therefore, more hydrogen can be produced in the same electrolyzer volume.

[0034] The electrode sheet according to the invention, designed for metallization and used for liquid and gas transport, comprises a polymer substrate layer. The polymer substrate layer further comprises a first facet and a second facet, which are adaptable for metallization to act as current collectors. The first and second facets of the polymer substrate layer include structured surfaces with channel patterns. Furthermore, the polymer substrate layer may include a plurality of through-holes extending through the substrate layer. The through-holes facilitate connecting the channel patterns to opposite facets of the polymer substrate layer.

[0035] Examples include a polymer substrate 1 with a structured surface having a channel pattern and multiple through-holes 2. Figure 1A As shown in the image.

[0036] Similarly, Figure 1B The scanning electron microscopy of a gas-permeable sheet 5 including a polymer substrate layer 1 is shown. The substrate layer 1 includes a plurality of through-holes 2 and channel patterns 3. Figure 1C and Figure 1D It shows Figure 1B The unfolded diagram. Figure 1C and Figure 1B It includes through-hole 2, channel 3 pattern and intersection 4 of channels or trenches 3 connecting opposite sides of polymer substrate 1.

[0037] The interconnection at intersection 4 allows for the distribution of incoming reaction reagents and / or outgoing reaction products associated with the anodic and / or cathodic reactions.

[0038] In another aspect of the invention, the channel 3 and / or the interconnecting trench may have a width in the range of 0.1µm to 100µm, preferably in the range of 0.5µm to 20µm, and more preferably in the range of 1µm to 10µm.

[0039] In another aspect of the invention, the through hole 2 may have a diameter in the range of 0.05µm to 100µm, preferably in the range of 0.5µm to 20µm, and more preferably in the range of 1µm to 10µm.

[0040] The wide range of channel 3 and / or trench widths and the wide range of through-hole 2 diameters allow for appropriate optimization of the design of electrode sheets 5 for liquid and gas delivery, and thus allow for improved dispensing of reagents and / or products or enhanced diffusion of reagents and products associated with electrolyzer processes or fuel cell processes.

[0041] like Figure 2A As shown, the electrode sheet 5, designed for metallization and used for liquid and gas delivery according to the invention, may further include a functional layer 8. The functional layer 8 may optionally be applied to the substrate polymer layer 1 to increase the metallization layer 6 (see [reference]). Figure 2B The anchoring of the electrode sheet 5 to the polymer substrate 1 further enhances the quality of the electrode sheet 5, which is designed for metallization and is intended for liquid and gas delivery. Therefore, depending on the polymer substrate 1 and the metallization layer 6, a functional layer may be optionally applied.

[0042] Figure 2B An electrode sheet 5, designed for liquid and gas transport according to the present invention, comprising a polymer substrate layer 1 and a plurality of through holes 2, is shown, the electrode sheet further comprising a metallization layer 6.

[0043] In a preferred embodiment, the metallization layer 6 may be selected from the group consisting of titanium, tantalum, niobium, platinum, or gold. Preferred metals have the advantages of being chemically, thermally, and mechanically stable under harsh conditions (such as temperatures up to 80°C, minimum pressures of 20 bar, and tolerance to acidic environments associated with electrolyzer or fuel cell processes). Furthermore, the metallization layer 6 provides suitable electrical and / or thermal conductivity to remove heat from the stack.

[0044] In another preferred embodiment of the invention, the metallization layer 6 may completely cover the polymer substrate layer 1. The encapsulated polymer substrate layer 1 allows for proper electron transport and provides improved thermal removal.

[0045] In another aspect of the invention, the metallization layer 6 may have a thickness in the range of 0.1µm to 10µm, preferably in the range of 0.1µm to 5µm, and more preferably in the range of 0.5µm to 1µm.

[0046] In another embodiment, an anode stack may be designed. The anode stack includes a gas-permeable electrode sheet 5 according to the invention. The electrode sheet 5, designed for liquid and gas transport, is permeable to the reactants and / or reaction products of the anodic reaction. The anode stack may further include a first catalyst layer 7. Figure 2C As shown, the first catalyst layer 7 can be directly applied to the electrode sheet 5 designed for liquid and gas transport according to the present invention, and thereby also cover the channel pattern and / or interconnecting trenches.

[0047] Especially in Figure 2C Figure 2D shows a side view of an electrode sheet 5 designed for liquid and gas transport according to the present invention. The sheet 5 designed for liquid and gas transport includes a polymer substrate layer 1, a plurality of through-holes 2, a metallization layer 6, and a first catalyst layer 7. The electrode sheet 5 designed for liquid and gas transport shown in Figure 2D can serve as an anode stack.

[0048] Figure 3 Showing Figure 2C A schematic unfolded view, which includes a first catalyst layer 7 on the through hole 2. Figure 3It further includes a polymer substrate layer 1, a functional layer 8, a metallization layer 6, and a first catalyst layer 7.

[0049] Furthermore, the electrode sheet 5 coated with the first catalyst layer 7, designed for liquid and gas transport, can point towards the electrolyte layer 9, see [link / reference]. Figure 4 Electrolyte layer 9 allows for the proper transport of protons associated with the reaction in the electrolyzer or fuel cell.

[0050] In another embodiment of the invention, the thickness of the anode stack can be in the range of 1µm to 200µm, preferably in the range of 10µm to 150µm, and more preferably in the range of 50µm to 150µm.

[0051] Another aspect of the invention relates to a PEM device comprising one or more MEAs according to the invention, such as Figure 4 and Figure 5 As shown in the figure. A membrane electrode assembly including an anode stack according to the invention can be designed. The MEA may further include an electrolyte 9 and / or a cathode stack 11. The MEA according to the invention may have a thickness in the range of 100µm to 500µm, preferably in the range of 100µm to 250µm, and more preferably in the range of 100µm to 150µm.

[0052] The cathode stack may include a second catalyst layer and second electrode plates designed for liquid and gas transport. The second catalyst layer may facilitate cathode reactions, such as H+ in an electrolyzer. + With e - Recombined into H2. The cathode stack is permeable to the cathode reaction products and may further include a second gas-permeable electrode sheet 5 according to the invention.

[0053] More specifically, Figure 4 A PEM electrolyzer 100 is shown, which includes electrode sheets 5 designed for liquid and gas transport according to the present invention. The electrode sheets 5 designed for liquid and gas transport include a first catalyst layer 7. The PEM electrolyzer 100 further includes an electrolyte material 9, a cathode stack 11, a bipolar plate 10, an inlet 12, two outlets 13a and 13b, and a power source 14.

[0054] Figure 5 An electrolysis device 200 comprising two individual cell units is shown. The electrolysis device 100 includes electrode plates 5 designed for liquid and gas transport according to the invention. The electrode plates 5 designed for liquid and gas transport include a first catalyst layer 7 and can serve as an anode stack. The electrolysis device further includes one or more electrolyte materials 9, one or more cathode stacks 11, bipolar plates 10a, one or more end plates 15, one or more outlets 13a, 13b, 13c, one or more inlets 12, and a power source 14.

[0055] In another aspect of the invention, one or more end plates 15 may be designed to contain a polymer substrate layer instead of a metalloid substrate. One or more end plates 15 include a polymer substrate layer, which further includes a third structured surface comprising a third channel pattern. One or more end plates 15 may further include optional functional layers, such that the anchoring of the metallization layer is improved. The end plates 15 further include a metallization layer. The metallization layer 6 may allow one or more end plates 15 to act as a current collector and may facilitate heat removal from the first catalyst layer and / or the second catalyst layer. One or more end plates 15 may further reduce the thickness and / or weight of a single cell.

[0056] The PEM device may optionally include at least one bipolar plate 10, which acts as a current collector and / or distributes the reactants and products of the anodic and cathodic reactions among sequential membrane electrode assemblies. One or more outlets 13a, 13b are used to remove the reactants and / or products of the anodic and cathodic reactions. One or more inlets supply the anodic reaction reagents. Optionally, two or more end plates 15 provide a start and end point for the electrolysis unit 100. One or more gasket materials provide a seal within the electrolysis unit 200, and a power source 14 provides the energy required to carry out the anodic reaction.

[0057] In another aspect of the invention, the number of individual battery cells in a stack of the same volume can be increased by at least 3 times, preferably by at least 5 times, and more preferably by 10 times.

[0058] Using electrode sheets 5 designed according to the invention for liquid and gas transport in anode stacks, cathode stacks, membrane electrode assemblies, or PEM devices can result in improved hydrodynamics, improved material utilization, improved device performance, reduced number of manufacturing steps, energy savings, reduced mechanical stress on the membrane leading to improved stability and safety, scalable manufacturing processes, or optionally, easier recycling of the stack. Therefore, lower costs are expected for the stacks, MEAs, or PEM devices.

[0059] In another aspect of the invention, Figure 6An electrolysis apparatus 300 is shown, wherein a polymer substrate layer 1 is made suitable for metallization, which can serve as a bipolar plate 10b. The bipolar plate 10b according to the invention may include a second structured surface comprising a second channel pattern. The metallization layer 60 may help allow the bipolar plate 10b to act as a current collector and may help remove heat from the first catalyst layer and / or the second catalyst layer. The bipolar plate 10b according to the invention can further reduce the thickness and / or weight of a single cell. Furthermore, having a bipolar plate 10b according to the invention solves the problem of a lack of continuous processes seen in the construction of PEM devices, because the bipolar plate 10b can be processed simultaneously or by at least utilizing the same processing conditions as the active material (yeast) used for the gas-permeable electrode sheet 5 according to the invention.

[0060] In particular, Figure 6 A single-cell electrolysis device is shown, comprising electrode sheets 5 designed for liquid and gas transport according to the invention. The electrode sheets 5 designed for liquid and gas transport further include a first catalyst layer 7. The electrode sheets 5 designed for liquid and gas transport can serve as an anode stack in the electrolysis device. The electrolysis device further includes an end plate 15 supporting 15b. The electrolysis device further includes an electrolyte material 9, a cathode stack, two outlets 13a, 13b, and an inlet 12.

[0061] In another aspect of the invention, the first structured surface, the second structured surface, and the third structured surface, which include a first channel pattern, a second channel pattern, or a third channel pattern, include the same channel pattern.

[0062] In another aspect of the invention, a method for manufacturing an electrode sheet 5 according to the invention, designed for metallization and used for liquid and gas transport, can be described, the method comprising the following steps: 1. A first mask layer is laminated onto the polymer substrate layer 1 to obtain a first masked polymer substrate layer.

[0063] 2. A plurality of through holes 2 or a structured surface with a channel pattern 3 is formed on the first masked polymer substrate layer 1 using photolithography.

[0064] 3. Remove the first mask from the polymer substrate 1 to obtain the first modified polymer substrate 1.

[0065] 4. The second mask is laminated onto the first modified polymer substrate 1 to obtain the masked first modified polymer substrate.

[0066] 5. A second modified polymer substrate layer 1 is obtained by forming multiple through holes 2 or a structured surface with a channel pattern 3 using photolithography.

[0067] 6. Remove the second mask from the second modified polymer substrate layer.

[0068] 7. Optionally, a functional layer 8 may be coated on the second modified polymer substrate 1.

[0069] 8. For example, chemical vapor deposition (CVD), physical vapor deposition (PVD), electroless plating, electroplating, or any physical or chemical deposition method suitable for applying a metal layer is used to coat the metal layer 6 with the optionally coated second modified polymer substrate 1, thereby obtaining a metallized modified polymer substrate.

[0070] 9. Optionally, a first catalyst layer 7 or a second catalyst layer may be coated onto a metallized modified polymer substrate.

[0071] For clarity and brevity, features are described herein as part of the same or separate embodiments; however, it should be understood that the scope of the invention may include embodiments having combinations of all or some of the described features. For example, while an embodiment of PEM electrolysis is shown, those skilled in the art who benefit from this disclosure will envision alternative methods to achieve similar functionality and results. For example, PEM fuel cells, alkaline membrane electrolysis and / or fuel cells, and CO2 electrolysis may be combined or separated into one or more alternative components. The various elements of the embodiments discussed and illustrated offer certain advantages, such as thinner / more compact devices and optimized porous delivery layers. Of course, it should be understood that any of the above embodiments or processes may be combined with one or more other embodiments or processes to provide even further improvements in finding and matching designs and advantages. It should be understood that this disclosure provides specific advantages for electrolyzers and is generally applicable to any application in which porous delivery layers are involved.

[0072] In interpreting the appended claims, it should be understood that, unless specifically stated otherwise, the word "comprising" does not exclude the presence of other elements or actions besides those listed in a given claim; the words "a" or "an" preceding an element do not exclude the presence of a plurality of such elements; any reference numerals in the claims do not limit their scope; several "modes" may be represented by the same or different items or implementation structures or functions; any of the disclosed means or portions thereof may be combined together or divided into other parts. Where one claim refers to another, this may indicate synergistic advantages achieved by a combination of their respective features. However, the mere fact that certain measures are recited in mutually different claims does not indicate that such combinations of measures are not advantageously applicable. Therefore, embodiments of the invention may include all working combinations of the claims, wherein each claim may, in principle, refer to any of the preceding claims unless explicitly excluded by the context.

Claims

1. An electrode sheet for liquid and gas transport, comprising: A polymer substrate layer, including a first side and a second side, the polymer substrate layer including a metallization layer that acts as a current collector; in The first and / or second sides of the polymer substrate layer include structured surfaces with channel patterns, and wherein The polymer substrate includes a plurality of through-holes through the substrate to connect the channel pattern to the opposite sides of the polymer substrate.

2. The electrode sheet for liquid and gas transport according to claim 1, wherein, The polymer substrate layer includes a functional layer and a metallization layer.

3. The electrode sheet for liquid and gas transport according to any one of claims 1 or 2, wherein, The channel pattern includes multiple interconnecting trenches.

4. The electrode sheet for liquid and gas transport according to any one of claims 1 to 3, wherein, The interconnecting trench has a width ranging from 0.1µm to 100µm.

5. The electrode sheet for liquid and gas transport according to any one of the preceding claims, wherein, The plurality of through holes have diameters ranging from 0.05µm to 100µm.

6. The electrode sheet for liquid and gas transport according to any one of the preceding claims, wherein, The metallization layer has a thickness ranging from 0.1 µm to 10 µm.

7. The electrode sheet for liquid and gas transport according to any one of the preceding claims, wherein, The metal of the metallization layer is selected from the group consisting of titanium, tantalum, niobium, platinum, or gold.

8. The electrode sheet for liquid and gas transport according to any one of the preceding claims, wherein, The metallization layer completely covers the polymer substrate layer.

9. An anode stack comprising an electrode sheet according to any one of the preceding claims, said anode stack being permeable to anolyte reagents and / or products, and comprising a first catalyst layer, wherein, The channel pattern in the electrode sheet, which is designed for liquid and gas transport, including the first catalyst layer, points toward the electrolyte layer.

10. A membrane electrode assembly (MEA) comprising an anode stack, an electrolyte, and / or a cathode stack as claimed in claim 9.

11. The membrane electrode assembly according to claim 10, wherein, The cathode stack includes a second catalyst layer and electrode plates for liquid and gas transport.

12. The membrane electrode assembly according to claim 10 or 11, wherein, The electrode sheet for liquid and gas transport is permeable to the cathode reaction products and includes the electrode sheet for liquid and gas transport according to any one of claims 1 to 8.

13. The membrane electrode assembly according to any one of claims 10 to 12, wherein, The thickness of the MEA is in the range of 100 to 500 µm.

14. An electrolysis apparatus comprising at least one membrane electrode assembly according to any one of claims 10 to 13, the electrolysis apparatus further comprising: Optional at least one bipolar plate, said at least one bipolar plate acting as a current collector and / or distributing reaction reagents and products of the anodic and cathodic reactions among sequential membrane electrode assemblies; One or more outlets, said one or more outlets removing reaction reagents and / or products of the anodic and cathodic reactions; One or more inlets supplying the anode reaction reagent; Optional two or more end plates, which provide a start and end point for the electrolysis device; One or more gasket materials, the one or more gasket materials providing a seal in the electrolysis device; A power source that provides the energy required for the anodic reaction.

15. A method for manufacturing an electrode sheet for liquid and gas transport, the method comprising the steps of: A first mask layer is pressed onto a polymer substrate layer to obtain a first masked polymer substrate layer; Multiple vias or structured surfaces with channel patterns are formed on the first masked polymer substrate using photolithography. The first mask is removed from the polymer substrate layer to obtain a first modified polymer substrate layer; A second mask is laminated onto the first modified polymer substrate layer to obtain a masked first modified polymer substrate layer; Multiple through-holes or structured surfaces with channel patterns are formed using photolithography to obtain a second modified polymer substrate layer 1; Remove the second mask from the second modified polymer substrate layer; Optionally, a functional layer is coated on the second modified polymer substrate layer; Metallize the optionally functionalized coated second modified polymer substrate 1; Optionally, a first catalyst layer or a second catalyst layer may be coated onto a metallized modified polymer substrate.

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